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长城内燃机 GREAT WALL ENGINES

GW4D20/GW4D20B 型增压柴油发动机维修手册 MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

保定长城内燃机制造有限公司

编

Edited by Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Introduction This maintenance manual describes the primary technical data, troubleshooting, maintenance, disassembly and assembly, adjustment, repair and other related information of the GW4D20/GW4D20B turbocharged diesel engines so as to provide reference for the related maintenance personnel and repairman.

GW4D20/GW4D20B 型增压柴油发动机维修手册 WAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Edited by Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited *

CAAMS-1098-138/G·438-QC-09~10-580.00

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Foreword The GW4D20/GW4D20B turbocharged diesel engine is 4-cylinder in line, 4-stroke, 16-air valve, double overhead camshaft (DOHC), turbocharged (VGT, WGT), air intake intercooled vehicle engine, and adopts advanced technologies such as the electric control high-pressure common-rail system, electric control EGR system, etc; it features good power performance, high economical efficiency, high reliability, excellent performance at both high and low speeds, quick low-temperature startup, etc., and its emission conforms to China IV Vehicle Exhaust Emission Standard. The GW4D20/GW4D20B diesel engine is mainly carried various kinds of LCV, SUV/MPV, compact cars, high-grade pickups produced by Great Wall Motor Company Limited and similar models from other auto manufacturers. AS a kind of power machinery reaching the modern advanced level, the GW4D20/GW4D20B turbocharged diesel engine has complicated structures, and has strict requirements for the material, technology and cooperation between parts, and correspondingly requires high levels of application, maintenance and repair. Maintenance Manual of GW4D20/GW4D20B Turbocharged Diesel Engines is a comprehensive manual for engine maintenance; it consists of the primary technical data, disassembly and assembly, adjustment, examination and troubleshooting, etc of the GW4D20/GW4D20B turbocharged diesel engine; you should carefully read and strictly follow the regulations in the manual and master malfunction diagnosis, elimination and maintenance of the diesel engine so as to ensure the best working condition of the engine after maintenance and make the engine reach the desirable power performance and economical index. As for the vehicle and mechanical chassis parts concerned in maintenance, repair and troubleshooting of the diesel engine or the parts supplied by auto and machinery manufacturers, please refer to the maintenance manual of the vehicle or machinery carrying the engine. For your life and property security, please use and operate the engine in strict accordance with the safety information described in this manual. The instructions to important issues should be complied strictly, otherwise it may cause serious injury or machine, vehicle damage and even danger. The warning in this manual refers to possible personal danger; caution refers to possible damage to the diesel engine and attention is used for important information without danger. Please note that the GW4D20/GW4D20B turbocharged diesel engine will be continuously improved according to market demands and changes, and information on maintenance and repair of improved parts will be amended or supplemented when the manual is reprinted. Contents and technical information from this manual are effective as long as the printing is approved. But the Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited (called our company for short thereafter) reserves the right to suspend using and change technical information and the design at any time without previous notice, and the right to change the supply scope, equipment and technology. Therefore, users cannot have any claim on the basis of the data, illustrations and explanations described in this manual. Changes in the range of the product structure, equipment and technology will not be noticed to users, and our company will not assume any relevant responsibility or obligation. We hope to get feedbacks concerning advices on the qualities, performances and structures, experiences in operation, maintenance and repair of GW4D20/GW4D20B turbocharged diesel engines from users and readers so as to help us improve our products and technologies of operation, maintenance and repair. Please send your letter to: Sales and Services Department, Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited, Dingxing County Development Zone, Hebei Province, China, Postal Code: 072650.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Since this manual covers wide information and is edited in short time, careless omission and even errors may be detected, and we would greatly appreciate being informed of them. This manual only provides reference for users in work, and we will not be responsible for any loss or damage caused by using this manual. Our company has its authorized repair stations in various regions, users can get consultation and after-sale service from the nearest authorized repair station on issues concerning use, technical maintenance, troubleshooting, repair or parts replacement of the diesel engine. This maintenance manual should not be reprinted or published without the permission from our company. Our company reserves all copyrights that described in law, and reserves the rights of modification and explanation.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited Dec. 18, 2009

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Table of Contents

Table of Contents Chapter I Introduction .............................................................................................................................. 1 Section I How to Use This Manual ............................................................................................................. 1 Section II Main Contents of Civilized Production for Maintenance ............................................................ 4 Section III Fire Control Measures for Maintenance Workshop .................................................................. 4 Section IV Dress Security Requirements for Maintenance Personnel ...................................................... 5 Section V Main Contents of Maintenance Process Regulation ................................................................. 5 Section VI Identification Marks ................................................................................................................... 5 Section VII General Repair Instructions ..................................................................................................... 6 Section VIII Precautions for Maintenance Operation ................................................................................. 8 Chapter II Technical Information of Engine ........................................................................................... 9 Section I Structure of Engine...................................................................................................................... 9 1.

Cylinder head and cylinder body ................................................................................................. 9

2.

Crank and Connecting Rod Mechanism ...................................................................................... 9

3.

Valve Actuating Mechanism and Intake/Exhaust System ........................................................... 9

4.

Turbocharging System ............................................................................................................... 10

5.

Fuel Supply System ................................................................................................................... 10

6.

Lubrication System ..................................................................................................................... 11

7.

Cooling System ........................................................................................................................... 11

8.

Startup Device............................................................................................................................. 11

Section II View of Engine ......................................................................................................................... 12 1.

Front View of Engine ................................................................................................................. 12

2.

Rear View of Engine .................................................................................................................. 13

3.

Left View of Engine .................................................................................................................... 14

4.

Right View of Engine ................................................................................................................. 15

5.

Vertical View of Engine .............................................................................................................. 16

Section III Main Performance Indexes of Engine..................................................................................... 17 1.

Power Performance Index ......................................................................................................... 17

2.

Economical Efficiency Index ...................................................................................................... 17

3.

Reliability and Durability Index .................................................................................................. 18

4.

Low Public Hazard Index ........................................................................................................... 18

Section IV Engine Property Curves.......................................................................................................... 19 Section V Technical Data and Specifications of Engine........................................................................... 21 1.

Technical Parameters of Engine ................................................................................................ 21

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 2.

Various Temperature and Pressure Ranges of Engine ............................................................. 23

3.

Specifications of Main Engine Accessories ............................................................................... 24

4.

Specifications of Main Parts of Fuel Supply System ................................................................. 25

Section VI Maintenance Standard for Engine .......................................................................................... 26 1.

Tightening Torque of Main Fasteners of Engine ........................................................................ 26

2.

Fit Clearance of Main Parts of Engine ....................................................................................... 28

Section VII Running-in of Engine ............................................................................................................. 32 1.

Preparation Before Running-in .................................................................................................. 32

2.

Running-in.................................................................................................................................. 32

3.

Precautions for Running-in ........................................................................................................ 33

4.

Technical Maintenance After Running-in ................................................................................... 33

5.

Precautions for Usage of New Vehicles .................................................................................... 33

Section VIII Technical Maintenance for Engine........................................................................................ 34 1.

Technical Maintenance Cycle .................................................................................................... 34

2.

Technical Maintenance Contents............................................................................................... 37

3.

Technical Maintenance for Air cleaner ....................................................................................... 40

4.

Technical Maintenance for Oil Supply System .......................................................................... 41

5.

Technical Maintenance for Fuel Lubrication System ................................................................. 43

6.

Technical Maintenance for Cooling System .............................................................................. 46

7.

Additional Maintenance in Severe Driving Conditions .............................................................. 48

8.

Technical Maintenance During Storage ..................................................................................... 48

9.

Precautions in Technical Maintenance ...................................................................................... 48

Section IX Repair Process for Diesel Engine........................................................................................... 48 1.

Repair Process for Diesel Engine .............................................................................................. 48

2.

Engine Handover and Repair Class Identification ..................................................................... 49

3.

Exterior Washing for the Engine ................................................................................................ 50

Section X Technical Requirements for Engine Removal and Reinstallation ........................................... 51 1.

General Technical Requirements for Assembling...................................................................... 51

2.

General Technical Requirements for Removal .......................................................................... 53

Section XI Special Tools and Instruments for Repair ............................................................................... 54 Section XII Repair Operation for Engine .................................................................................................. 56

VI

1.

Model Mark ................................................................................................................................ 56

2.

Air Cleaner ................................................................................................................................. 56

3.

Lubrication System .................................................................................................................... 57

4.

Fuel System ............................................................................................................................... 58

5.

Cooling System .......................................................................................................................... 59

6.

Engine Control ........................................................................................................................... 61 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Table of Contents 7.

Quick start-up system ................................................................................................................ 62

Section XIII Engine Parts and Tightening Torques................................................................................... 63 1.

Engine Bracket Mounting Assembly .......................................................................................... 63

2.

Cylinder Body Mounting Assembly ............................................................................................ 64

3.

Cylinder Body Component ......................................................................................................... 65

4.

Cylinder Head Mounting Assembly ——1 ................................................................................. 66

5.

Cylinder Head Mounting Assembly ——2 ................................................................................. 67

6.

Cylinder Head Mounting Assembly ——3 ................................................................................. 68

7.

Piston Connecting Rod Mounting Assembly ............................................................................. 69

8.

Crankshaft Flywheel and Clutch Mounting Assembly ............................................................... 70

9.

Air Intake and Exhaust Systems Mounting Assembly ——1 ..................................................... 71

10. Air Intake and Exhaust Systems Mounting Assembly ——2 ..................................................... 72 11. Oil Pan and Engine Oil Collector Mounting Assembly .............................................................. 73 12. Engine Oil Pump Mounting Assembly ....................................................................................... 74 13. Engine Oil Cooler and Cooling Pipelines Mounting Assembly .................................................. 75 14. Timing Mechanism Mounting Assembly ——1 .......................................................................... 76 15. Timing Mechanism Mounting Assembly ——2 .......................................................................... 77 16. Fuel Supply System Mounting Assembly ——1① .................................................................... 78 17. Fuel Supply System Mounting Assembly ——2① .................................................................... 79 18. Fuel Supply System Mounting Assembly ——3① .................................................................... 80 19. Turbocharger Mounting Assembly ——1① ............................................................................... 81 20. Turbocharger Mounting Assembly ——2① ............................................................................... 82 21. EGR System Mounting Assembly.............................................................................................. 83 22. Electronic Control System Sensor ............................................................................................. 84 23. Generator Mounting Assembly .................................................................................................. 85 24. Throttle Mounting Assembly ...................................................................................................... 86 25. Thermostat and Water Pump Mounting Assembly .................................................................... 87 26. Engine and Compressor Mounting Assembly ........................................................................... 88 27. Vacuum Pump and Steering Pump Mounting Assembly ........................................................... 89 Chapter III Malfunction Diagnosis and Troubleshooting ................................................................... 90 Section I Troubleshooting ......................................................................................................................... 90 1.

Failure to Start the Diesel Engine .............................................................................................. 91

2.

Difficulty in Starting the Diesel Engine at a Low Temperature................................................... 91

3.

Insufficient Power in the Diesel Engine ..................................................................................... 92

4.

Excessive Fuel Consumption of Diesel Engine ......................................................................... 93

5.

Abnormal Noise During the Diesel Engine Running ................................................................. 93

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

VII

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 6.

Abnormal Noise from Diesel Engine.......................................................................................... 95

7.

Abnormal Smoke from Diesel Engine........................................................................................ 95

8.

Heavy Oil Consumption and Low pressure of the Diesel Engine Lubrication System ............. 96

9.

Abnormal Coolant Temperature, Lack of Coolant in the Diesel Engine Cooling System ......... 98

10. Malfunction of the Diesel Engine Turbocharging System ......................................................... 99 11. Malfunction of the Diesel Engine Oil Supply System .............................................................. 100 12. Diesel Engine Wobble During Idling ........................................................................................ 103 13. Diesel Engine Running at a High Idle Speed .......................................................................... 104 14. Starter not Working, Lacking Power, and Making noise .......................................................... 104 15. Working Starter but Non-working Diesel Engine ..................................................................... 105 16. Diesel Engine Rotating but Unable to be Started .................................................................... 106 17. Difficulty in Starting Due to Malfunction in the Quick Start-up System .................................... 107 18. No Power Generation, Undercharge or Overhigh Charging Current of Generator................. 108 19. Insufficient Capacity, Difficulty in Starting or Overhigh Self Discharge of the Storage Battery 109 Section II Malfunction Diagnosis ............................................................................................................ 110 1.

Start-up system malfunction diagnosis .....................................................................................110

2.

Turbocharging System Malfunction Diagnosis .........................................................................114

Chapter IV Mechanical System ........................................................................................................... 119 Section I Cylinder Head.......................................................................................................................... 119 Section II Camshaft ................................................................................................................................ 137 Section III Valve, Valve Spring, Valve Oil Seal, Rocker Arm and Hydraulic Clearance Adjuster ........... 148 Section IV Crankshaft............................................................................................................................. 157 Section V Piston and connecting rod assembly ..................................................................................... 178 Section VI Engine oil pump assembly.................................................................................................... 196 Section VII Cylinder body assembly ...................................................................................................... 201 Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine........................................................ 215 Section I General .................................................................................................................................... 215 Section II Engine Assembly .................................................................................................................... 216 Section III Engine Brackets .................................................................................................................... 225 Section IV Air Intake Manifold Pipe ........................................................................................................ 235 Section V Exhaust Manifold Pipe ........................................................................................................... 240 Section VI Cylinder Cover ...................................................................................................................... 246 Section VII Camshaft .............................................................................................................................. 253 Section VIII Rocker Arms and Hydraulic Clearance Adjusters .............................................................. 263 Section IX Valve Oil Seal and Valve Spring ........................................................................................... 273 Section X Cylinder Head Assembly and Cylinder Head Gasket ............................................................ 286 Section XI Timing Pulley......................................................................................................................... 298

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Table of Contents Section XII Oil Filter and Oil Cooler ....................................................................................................... 303 Section XIII Primary shaft front bearing of the flywheel and transmission ............................................ 306 Section XIV Oil pump assembly ............................................................................................................. 310 Section XV Oil pan assembly ................................................................................................................. 318 Section XVI Piston and connecting rod assembly ................................................................................. 323 Section XVII Front oil seal of crankshaft ................................................................................................ 337 Section XVIII Rear Oil Seal of Crankshaft ............................................................................................. 342 Section XIX Crankshaft .......................................................................................................................... 346 Section XX Cylinder Body Assembly...................................................................................................... 364 Chapter VI Fuel System ....................................................................................................................... 384 Section I General .................................................................................................................................... 384 1.

Components of Fuel Supply System ....................................................................................... 384

2.

Components of High Pressure Common Rail System ............................................................ 386

Section II On-Board Maintenance .......................................................................................................... 400 1.

Fuel Filter Assembly ................................................................................................................ 400

2.

Fuel Injector Assembly............................................................................................................. 403

3.

High-Pressure Fuel Pump Assembly ....................................................................................... 407

Chapter VII Cooling System ................................................................................................................ 411 Section I General .................................................................................................................................... 411 1.

Water pump............................................................................................................................... 411

2.

Thermostat ............................................................................................................................... 412

3.

Radiator ................................................................................................................................... 412

4.

Antifreeze fluid ......................................................................................................................... 412

Section II On-Board Maintenance .......................................................................................................... 414 1.

Water Pump Assembly............................................................................................................. 414

2.

Thermostat ............................................................................................................................... 420

3.

Radiator ................................................................................................................................... 424

Chapter VIII Lubrication System ......................................................................................................... 428 Section I General .................................................................................................................................... 428 Section II On-board Repair..................................................................................................................... 429 1.

Oil Filter .................................................................................................................................... 429

2.

Engine Oil Pump ...................................................................................................................... 432

3.

Oil Collector ............................................................................................................................. 439

4.

Oil Pan ..................................................................................................................................... 442

Chapter IX Turbocharging System ..................................................................................................... 446 Section I General .................................................................................................................................... 446 1.

Turbocharging system composition ......................................................................................... 446 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 2.

Turbocharger structure ............................................................................................................ 446

Section II On-board Maintenance .......................................................................................................... 449 Section III Inspection and Repair ........................................................................................................... 454 1.

Checking the working condition of the exhaust outlet ............................................................. 454

2.

Checking the working condition of the turbocharger ............................................................... 455

3.

Checking the axial clearance of the impeller shaft. ................................................................. 455

4.

Checking the axial clearance of the rotor ................................................................................ 455

5.

Checking the clearance between the impeller shaft and the bearing ..................................... 456

6.

Checking the radial clearance of the rotor............................................................................... 456

Chapter X Electronic Control EGR System ....................................................................................... 457 Section I General .................................................................................................................................... 457 Section II On-board Maintenance .......................................................................................................... 458 Chapter XI Electrical System .............................................................................................................. 462 Section I Storage Battery ....................................................................................................................... 462 1.

Storage Battery Performance Parameters .............................................................................. 462

2.

Preparing Electrolyte ............................................................................................................... 463

3.

Charging the Storage Battery .................................................................................................. 464

4.

Checking the Storage Battery Remaining Capacity ................................................................ 466

Section II Starting System ...................................................................................................................... 468 1.

General .................................................................................................................................... 468

2.

On-board Maintenance ............................................................................................................ 470

Section III Charging System ................................................................................................................... 473 1.

Generator ................................................................................................................................. 473

2.

Diagnosis ................................................................................................................................. 475

3.

On-board Maintenance ............................................................................................................ 477

Chapter XII Exhaust System ............................................................................................................... 481 Section I General .................................................................................................................................... 481 Section II On-board Maintenance .......................................................................................................... 481 Section III Front Exhaust Pipe ................................................................................................................ 482 Appendix ............................................................................................................................................... 486 Appendix I Engine Malfunction Code ..................................................................................................... 486 Appendix II Conversion Table of Common Measurement Units for Engines......................................... 499

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter I Introduction

Chapter I Introduction Section I How to Use This Manual 1. Index The content (index) of this manual will guide you to the item to be repaired. For the convenience of finding information, the title of each chapter is given at the header of the singular page.

2. Preparations Preparations list the special service tools, special service materials, sealant and lubricating oil that should be prepared before operation and their functions.

3. Repair Procedures Most repair processes begin with an overview illustration which identifies all parts and how they are disassembled and assembled (refitted) in sequence. For example, see Fig. 1-1-1 for the disassembly / assembly schematic diagram for the oil pump parts.

Cylinder body

Outer rotor Oil pump mounting Rubber seal assembly ring

Front oil seal assembly of crankshaft

Removing sequence ① Oil pump ② Rubber seal ring ③ Outer rotor Assembly sequence Assembly in the sequence reverse to disassembly.

Fig. 1-1-1 Disassembly / Assembly Schematic Diagram for Oil Pump Parts The repair procedure is introduced in the following sequence:

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

1

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (1) The schematic diagram shows what to do and where to do it, see Fig. 1-1-2. (2) The title of the work task shows the content of repair. (3) Explain in detail how to carry out the work content and provide other technical information, such as specification and attention, note, etc., and the quantity and dimensions of fasteners. For example: Title of work task: the content of repair Mounting the clutch assembly Using special service tools to mount the clutch assembly. Front bearing installer: 5-8522-0024-0 Schematic diagram What to do and where to do it

Tool No. Detailed explanation: how to carry out the work.

Torque: 23 N·m ± 3 N·m

Specification

Check the assembly quality. Fig. 1-1-2 Mounting the Clutch Assembly This form provides a shortcut for the experienced technical personnel to obtain the data required. The work task title on the top makes the content of repair clear at a glance, while the content below it provides the detailed explanation. Important specification, attention, warning and caution always stand out  in  “boldface”.

4. References To improve lookup and work efficiency, this manual adopts references as few as possible; however, the Section No. and Page No. are given when necessary.

5. Specifications Specifications are listed separately when necessary. There is no need to leave your work for looking up specifications. The specifications are listed at the end of every section for quick reference.

6. Warning, Attention, Caution, Prompt: “Warning!”  is  shown  in  “boldface”  to  remind  the  possibility  of  personnel  injury  to  you  or  others. “Attention!”  is  shown  in  “boldface”  to  remind  the  possibility  of  damage  to  parts  being  repaired.. “Caution!”  is  shown  with  “boldface”  to  remind  the  possibility  of  damage  to  diesel  engine.

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter I Introduction “Prompt”  is  separated  from  the  text  and  is  shown  in  “boldface”;;  it  provides additional information to help you carry out the repair more effectively.

7. Marks Disassembling: separate the integrity (the whole engine) into constituent parts. Removing: separate the engine (the components) and detach the parts. Assemble (refitting, assembling): assembling parts or components into the integrity (the whole engine). Mounting: fix parts at the specified positions (of the engine) according to certain technical requirements. Checking, testing: make careful checking, examination and determination in order to find (the engine) problems (or malfunctions). Washing, cleaning: clean up; without dust, oil stain, etc. Tightening, fastening: make an object rotate to fix or secure it; the object is fixed or secured by outer force. Remind the need to use special tools while performing disassembling or assembling. Remind the need to apply engine oil for lubrication (see Table 2-6-7 for lubrication positions before assembling the engine). Remind the need to apply sealant (see Table 2-6-8 for sealant-applied positions while assembling the engine).

8. Measurement Units The measurement units adopted in this manual are mainly SI units (the standard international unit). For example: Torque: N·m; Force: N; Power: W, kW; Length:  μm,  mm,  m,  km;; Rotating speed: r/min; Pressure, pressure strength: Pa, kPa, MPa; Temperature: °C Volume: mL, L; Mass: g, kg; Electric current: A; Electric  resistance:  Ω,  kΩ;;   Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

3

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Voltage: V; Plane angle: °; Noise: dB/A; Time: s, min, h.

Section II Main Contents of Civilized Production for Maintenance Civilized production is aimed at creating a good producing condition and working environment to improve maintenance quality, ensure personnel and device security, and improve labor efficiency. The main contents are as follows: (1) Design and decorate the workshop according to requirements for maintenance and labor protection, such as ventilation, lighting, fire control, noise control, etc. (2) Keep the workshop and work place clean. (3) Equipping special maintenance and examination tools and avoiding forced disassembly and assembly. (4) Store the components and parts of the engine assembly at the specified rack in the specified storeroom in order, and prevent fire and theft. (5) Keeping all kinds of maintenance facilities, tools, fixtures, and measuring instruments in good condition. (6) Proving mature maintenance process regulations, technical documents and standards, and performing work according to the procedures and specifications. (7) Keep maintenance records, and comply with the handover procedures. The repair records contain: ① Main problems (serious wear or accidental damage) detected after the engine is disassembled; ② Records and conclusions of technical appraisal for major parts; ③ Registration of replacing with new pieces and repaired pieces; ④ Results of quality tests during and after repair; ⑤ Records of test data. Vehicle takeover records contain the following filled items: ① Who and when to send the vehicle for repair; ② Last repair and replacement conditions; ③ The working condition of vehicle after the last repair; ④ The maintenance condition of the engine, and malfunctions that ever happened; ⑤ The damage condition of the engine and the name of the exterior missing parts; ⑥ The item to be repaired and the deadline required by the sender and agreements concerning fee. (8) The maintenance personnel should keep clean and tidy appearances, behave in good manner, work in solidarity and cooperation, observe disciplines and service with enthusiasm.

Section III Fire Control Measures for Maintenance Workshop (1) Flammable materials such as vehicles, diesel, ethyl alcohol, oil paint and refrigerant should be kept away from fire and heat sources. (2) Used cleaning cloth, waste cotton fabric, oil stained gloves, packaging cartons of parts and plastic packaging bags should be collected and placed in the safe place or metallic container. (3) No smoking, no eating in the workshop. (4) The workshop should be equipped with fire fighting equipment and tools, and special persons should be assigned to manage them. Fire control education should be implemented regularly, and a fire control supervisor should be specified.

4

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter I Introduction

Section IV Dress Security Requirements for Maintenance Personnel (1) The maintenance personnel should wear work wear during working. (2) The personnel with long hair or a long braid should wear a working hat, and the braid should be wrapped into the hat to prevent from being involved into the rotating machine. (3) Do not open your clothes or loosen the cuff when carrying out repair; do not wear gloves when operating the rotating machine. (4) When there are strong light, or metal debris splashing in the work area, and when working on the place in contact with strong acid, refrigerant and other chemicals, wear safety goggles.

Section V Main Contents of Maintenance Process Regulation The contents of the maintenance process regulation for the engine are as follows: (1) The procedure sequence and detailed operation contents to accomplish the maintenance work. (2) The tools, equipment and correct operating methods that should be adopted to ensure the maintenance quality and operation security. (3) Quality test items and test facilities that should be used during maintenance. (4) Quality requirements that should be met in the process of maintenance. (5) Norm of the working hour to accomplish the maintenance work.

Section VI Identification Marks Serial number of the engine The serial number of GW4D20/GW4D20B turbocharged diesel engine is stamped on the left cylinder body, as shown in Fig. 1-6-1.

Machine code

Position of identification mark Asterisk

Year

Month

Serial number

Asterisk

Fig. 1-6-1 Serial Number Identification of Diesel Engine

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Section VII General Repair Instructions 1. When carrying out repair, use the baffle, seat and floor mat to keep the vehicle clean and intact and prevent damage. 2. During disassembly, keep parts in a proper order so as to facilitate reassembly. 3. The rules that should be observed during repair. 3.1 Before performing electrical repair, disconnect the negative (-) cable from the storage battery, as shown in Fig. 1-7-1.

Fig. 1-7-1 Removing the Negative (-) Cable of Battery

3.2 If it is necessary to disconnect the storage battery during check and repair, the negative (-) cable of the storage battery should be disconnected first, as it connects to the vehicle body and constitutes the earth wire. 3.3 To prevent damage to the battery terminal, loosen the fixed nut of the cable connection terminal and raise the cable connection terminal without twisting or prying it. 3.4 Clean the battery terminal and the cable connection terminal with special cleaning cloth; do not scrape them with a file or other abrasive objects.

Sealant

Fig. 1-7-2 Precoating Sealant on Parts

3.5 Unscrew the nut when connecting the cable terminal to the battery terminal, and screw it after installation. Do not use a hammer to tap the cable terminal onto the battery terminal. 3.6 Be sure to properly cover the positive pole (+) of the storage battery. 4. Check the hose and conductor connector to ensure secure and correct connections. 5. Non-reusable parts: as for splint pins, gaskets, O rings, oil seals, etc., replace them with new parts.

Indicating torque spanner

Scale indication torque spanner

Fig. 1-7-3 Torque Spanner

6

6. Precoated parts: refer to parts that are coated with sealant in the factory, bolts and nuts, etc., as shown in Fig. 1-7-2.See Fig. 2-6-8 for positions to coat sealant on engine parts,. 6.1 If a precoated part is re-tightened, loose or loosened in any way, it must be recoated with the specified sealant. 6.2 When reusing a precoated part, clear the old sealant away from the part surface or the threaded hole, and clean the surface or the hole with compressed air. Then apply the specified sealant to the specified position, as shown in Fig. 1-7-2.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter I Introduction 7. When necessary, apply sealant to gaskets to prevent leakage. 8. Strictly observe all specifications for bolt tightening torques (see Table 2-6-1, 2-6-2), and use the torque spanner according to technical requirements, as shown in Fig. 1-7-3.

Hydraulic jack

9. Special repair tools, instruments (see Table 2-11-1) and special repair materials (see Table 2-6-8, 2-6-9) may be used, depending on the repair. Be sure to use special repair tools and special repair materials as required according to situations, and strictly observe correct operation specifications. A list of special repair tools and special repair materials can be found in "Chapter II Technical   Information   of   Engine”   in   this   manual.

Scissor jack

Fig. 1-7-4 Jack

Incorrect

10. Be sure to take care when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

Correct Correct

10.1 If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. 10.2 Be sure to hold the vehicle with a support after it is jacked up. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Fig. 1-7-5 Pull Apart Fuel Return Hose and Vacuum Hose

11. Observe the following precautions to prevent damage to parts: 11.1 Non-specialized personnel should not open the cover or housing of the electric control unit (ECU).

Incorrect

11.2 When disconnecting the fuel return hose component and the vacuum hose of the fuel injector, hold the end but not the middle of the hose, as shown in Fig. 1-7-5.

Correct

11.3 To pull apart the circuit connectors, pull the connector itself but not the wires, as shown in Fig. 1-7-6.

Fig. 1-7-6 Checking the Conductor Connector

11.4 Be careful not to drop precision parts, EFI system elements (such as the oil injector, sensor, ECU, etc.) off, as shown in Fig. 1-7-7.If they are dropped, they should be replaced with new parts. 11.5 Never use an impact spanner to disassemble or mount a temperature sensor or other sensors which has specific torque requirements.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Section VIII Precautions for Maintenance Operation If the vehicle is equipped with the mobile communication system, such as the two-way wireless communication equipment and cellular phone, the following precautions should be observed: (1) Install the communication antenna away from the ECU and sensors of automotive electronic system as far as possible. Fig. 1-7-7 Electric Control System Elements of Engine

8

(2) The antenna feeder should be installed more than 20 cm away from the ECU and sensors of automotive electronic system. For the positions of the ECU and sensors, please refer to the related sections.

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Chapter II Technical Information of Engine

Chapter II Technical Information of Engine Section I Structure of Engine The diesel engine is a kind of complex machinery that transforms the thermal energy of fuel into mechanical power. Although there are various types of diesel engine with different structures, they all contain the following mechanisms and systems: Cylinder head

1. Cylinder head and cylinder body For cylinder head and cylinder body, see Fig. 2-1-1.

Cylinder body

Fig. 2-1-1 Cylinder Head and Cylinder Body

Connecting rod

The function of the cylinder head is to seal the upper part of the cylinder and make the upper part of the cylinder and piston crown constitute the combustion chamber. The cylinder head is mounted with the intake valve, exhaust valve, rocker arm, hydraulic lash adjuster, intake/exhaust camshaft assembly, oil injector, etc., and is laid with intake and exhaust pipelines, and cooling water jackets. The cylinder body constitutes the cylinder and is used to mount and support all mechanisms and systems of the diesel engine; it is the foundation and framework of the diesel engine.

2. Crank and Connecting Rod Mechanism Crankshaft

For the crank and connecting rod mechanism of engine, see Fig. 2-1-2.

Connecting rod cap

Fig. 2-1-2 Crank and Connecting Rod Mechanism

The crank and connecting rod mechanism can accomplish the interconversion between the linear reciprocating motion of piston (in cylinder) and the rotation motion of crankshaft, and thereby output the propulsion produced by gas combustion through the crankshaft as the output power, and ensure the fulfillment of working cycles of the diesel engine. The crank and connecting rod mechanism mainly consists of the piston, connecting rod, crankshaft, flywheel, etc.

3. Valve Actuating Mechanism and Intake/Exhaust System Camshaft assembly

Intake/exhaust valve component

Fig. 2-1-3 Valve Actuating Mechanism

The valve actuating mechanism, intake and exhaust systems are as shown in Fig. 2-1-3, 2-1-4. The functions of the valve actuating mechanism and intake and exhaust systems are opening and closing the intake valve and exhaust valve in time to ensure the cylinder to intake flesh and clean air as much as possible and discharge exhaust gas as clear as possible timely. It mainly consists of the valve components (the intake and exhaust valve, valve pin/clip, valve spring, spring seat, valve oil seal, etc.), transmission mechanism (the belt, pulley, intake/exhaust camshaft assembly, rocker arm, Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES hydraulic lash adjuster, etc.), air filter, intake/exhaust pipelines, intake/exhaust manifolds, etc. The electric control EGR valve and EGR cooler contained in the intake/exhaust systems carry out the exhaust gas recirculation process, and effectively limit the Nox constituent in emissions.

Cylinder head

Air intake manifold Cylinder head installation assembly

Exhaust manifold

Fig. 2-1-4 Intake/Exhaust System

4. Turbocharging System

Cylinder head installation assembly

The turbocharging system of engine is as shown in Fig. 2-1-5.

Cylinder body Turbocharger assembly

The function of the turbocharging system is to compress the air from the air filter through the turbocharger and then sent the compressed air into cylinder by use of the exhaust gas energy. Although the working volume of the cylinder does not change, the air density increases after compression, and therefore the volume of the actual intake air increases. In this way, the fuel injected into the cylinder increases and the fuel burns more fully, and therefore the power per liter and output power of the diesel engine are improved.

Fig. 2-1-5 Turbocharging System Oil inlet pipe component

Oil return hose component

High pressure Oil oil rail injector assembly assembly High pressure oil pump assembly

Fig. 2-1-6 Fuel Supply System

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5. Fuel Supply System The fuel supply system of engine is as shown in Fig. 2-1-6. According to the work requirements of the diesel engine, the fuel supply system regularly injects diesel into the combustion chamber at a specified quantity and pressure to provide necessary conditions for sufficient combustion of diesel; at the same time, it adjusts the oil supply quantity according to the loading condition of the diesel engine, and ensures a steady output power. The fuel supply system mainly consists of the fuel tank, fuel filter, fuel delivery pump, high pressure fuel pump, high pressure fuel rail, fuel injector, high/low pressure fuel pipe, and all kinds of sensors, etc.

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Chapter II Technical Information of Engine

6. Lubrication System The lubrication system of engine is as shown in Fig. 2-1-7.

Cylinder body

The lubrication system is mainly used to transport lubricating oil to friction surfaces of all moving parts of the diesel engine to ensure the lubrication of kinematic pairs of all engine parts, and reduce friction resistance and wear of machine elements; it also has other functions such as cooling, cleaning, sealing and rust prevention. The lubrication system is mainly composed of the oil collector, oil pump, oil filter, oil cooler, oil pressure alarm, lubricating oil pipeline, etc.

Engine oil filter

Fig. 2-1-7 Lubrication System

7. Cooling System Cylinder body

The cooling system of engine is as shown in Fig. 2-1-8.

Water pump installation assembly

When the diesel engine is working, the cooling system radiates excessive heat from the heated parts to keep the normal working temperature of the diesel engine. The major components of the cooling system include: the water tank (radiator), liquid storage tank (overflow tank), water pump, thermostat, fan, etc.

8. Startup Device The startup device of engine is as shown in Fig. 2-1-9.

Thermostat assembly

Fig. 2-1-8 Cooling System

Starting motor

Fig. 2-1-9 Startup Device

With the action of external force, the startup device makes the stationary diesel engine begin to rotate before it can rotate independently. The startup device is constituted of the starting motor, storage battery, heater plug and other devices. In conclusion, the cylinder body, cylinder head, crank and connecting rod mechanism, valve actuating mechanism, intake/exhaust systems and fuel supply system work in coordination with each other and fulfill the working cycle of the diesel engine directly to accomplish the transformation of energies. During operation, the technical conditions of these components and whether they coordinate with each other correctly have  decisive  influences  on  the  engine’s  performance.   The lubrication system and cooling system do not accomplish the working cycle directly; however, they are indispensable conditions for the long-term and steady working of the diesel engine. While the startup device provides an initial condition for the stationary diesel engine to rotate, therefore sufficient attention should be given to their working conditions. Otherwise, the normal work of the diesel engine can not be ensured or serious damage to engine parts may be caused.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Section II View of Engine 1. Front View of Engine For the front view of GW4D20 turbocharged diesel engine assembly, see Fig. 2-2-1.

Fig. 2-2-1 Front View of GW4D20 Turbocharged Diesel Engine Assembly (Equipped with Delphi Common Rail System) 1-Accessory Tension Pulley Assembly; 2-Generator Assembly; 3-Generator Belt; 4-Power Steering Fuel Pump Assembly; 5-Air Intake of Gas Compressor; 6-Water outlet Pipe Mouthpiece; 7-Timing Hood; 8-EGR Valve Assembly; 9-Engine Oil Dipstick Assembly; 10-Accessory Wedge Idle Wheel Assembly; 11-Accessory Flat Idle wheel Assembly; 12-Refrigeration Compressor Assembly; 13-Damping Pulley Assembly

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Chapter II Technical Information of Engine

2. Rear View of Engine For the rear view of GW4D20 turbocharged diesel engine assembly, see Fig. 2-2-2.

Fig. 2-2-2 Rear View of GW4D20 Turbocharged Diesel Engine Assembly (Equipped with Delphi Common Rail System) 1-Clutch Assembly; 2-Starting Motor Assembly; 3-EGR Condenser Assembly; 4-EGR Valve Assembly; 5-Fuel Inlet of High Pressure Fuel Pump; 6-Coolant Temperature Sensor; 7-Vacuum Pump Assembly; 8-Heater Water Return Outlet; 9-Heater Water Inlet; 10-Water Outlet Pipe Assembly; 11-Hex Head Screw Plug (Oil Drain Screw Plug); 12-Lower Shell Assembly of Fuel Pan

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

3. Left View of Engine For the left view of GW4D20 turbocharged diesel engine assembly, see Fig. 2-3-3.

Fig. 2-2-3 Left View of GW4D20 Turbocharged Diesel Engine Assembly (Equipped with Delphi Common Rail System) 1-Refrigeration Compressor Assembly; 2-Water Inlet; 3-High Pressure Fuel Pump Assembly; 4-Knock Sensor; 5-Air Intake Manifold; 6-Air Inlet; 7-Turbocharged Pressure Sensor; 8-EGR Valve Assembly; 9-Flywheel Gear Ring Assembly; 10-Starting Motor Assembly; 11-Left Bracket of Engine

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Chapter II Technical Information of Engine

4. Right View of Engine For the right view of GW4D20 turbocharged diesel engine assembly, see Fig. 2-2-4.

Fig. 2-2-3 Right View of GW4D20 Turbocharged Diesel Engine Assembly (Equipped with Delphi Common Rail System) 1-Engine Lifting Hook; 2-Turbocharger Assembly; 3-Air Outlet of Air Compressor; 4-Oil Filter Assembly; 5-Timing CoverⅠ; 6-Upper Shell Assembly of Oil Pan; 7-Lower Shell Assembly of Fuel Pan; 8-Right Bracket of Engine; 9-Oil Pressure Alarm; 10-Crankshaft Position Sensor

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

5. Vertical View of Engine For the vertical view of GW4D20 turbocharged diesel engine assembly, see Fig. 2-2-5.

Fig. 2-2-3 Vertical View of GW4D20 Turbocharged Diesel Engine Assembly (Equipped with Delphi Common Rail System) 1-Fuel Injector Assembly; 2-Suppercharger Assembly; 3-Water outlet Pipe Component; 4-Heater Water Return Pipe Component; 5-High Pressure Fuel Rail Pressure Sensor; 6-High Pressure Fuel Rail; 7-EGR Valve Assembly; 8-Turbocharged Pressure Sensor; 9-Fuel Filler Cap Assembly; 10-Fuel Inlet Pipe Component of Fuel Rail; 11-Engine Oil Dipstick Assembly; 12-Generator Belt; 13-Fuel Inlet Pipe Component of Fuel Injector; 14-Fuel Injector Ballast; 15-Upper Shell Assembly of Fuel Pan; 16-Generator Assembly

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Chapter II Technical Information of Engine

Section III Main Performance Indexes of Engine The indexes used to evaluate and analyze the engine performance mainly include the power performance, economical efficiency, applicability, low public hazard, etc.; every index contains several items, and here we only introduce the indexes that are commonly used:

1. Power Performance Index (1) Effective torque: refers to the torque that is output through the engine flywheel; it is balanced to the external resistance moment which is exerted on the power output end of engine. It is represented by Me, and  the  unit  is  N•m. (2) Effective power: refers to the power output by the engine. It is represented by P e, and the unit is kW. It is calculated by multiplying the effective torque by the crankshaft rotation speed:

Where, Me ——Effective torque (N·m). n ——Crankshaft rotation speed (r/min). The effective torque and the crankshaft rotation speed are usually measured with a hydraulic or electric dynamometer directly; the effective power is calculated by Pe=Me·n/9550 (kW), which indicates the effective power under the tested working condition. The effective power and corresponding rotation speed under the calibrated working condition indicated on the engine nameplate are called the calibrated power and calibrated rotation speed. Presently, the calibrated power of engine is divided into four grades according to the national standards: (1) 15min power: the Max. effective power of engine when the engine constantly rotates for 15 minutes under the standard environmental condition. (2) 1h power: the Max. effective power of engine when the engine constantly rotates for 1 hour under the standard environmental condition. (3) 12h power: the Max. effective power of engine when the engine constantly rotates for 12 hours under the standard environmental condition. (4) Continuous power: the Max. effective power of engine when the engine continuously rotates at the calibrated rotation speed under the standard environmental condition,. Generally speaking, the 15min power is applied to the power calibration of vehicle, motorcycle, motorboat, etc.; 1h power is applied to the industrial tractor, engineering machinery, diesel locomotive, etc.; 12h power is applied to the agricultural tractor, agricultural irrigation and drainage machinery, and river vessel, etc.; continuous power is applied to the power station, vessel, and agricultural irrigation and drainage machinery, etc.

2. Economical Efficiency Index Currently, the frequently used comparative evaluation index is the fuel consumption rate which refers to the fuel mass consumed by the engine in an hour. It is represented by ge, and the unit is g/kW·h: ge=G/P.·103(g/kW·h) Where, G ——Fuel consumption per hour (kz/h) obtained by testing. P ——Effective power of engine (kW). Attention has always been taking for the reduction of fuel consumption since it has great significance for decreasing engine application costs, promoting rational use of resources, improving the ecological environment, etc., and the fuel consumption is decreasing year by year. Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

3. Reliability and Durability Index 3.1 Reliability Reliability of the engine means the engine can work continuously and its normal working ability is not influenced by malfunctions under the designed working condition. In China, the reliability of engine is normally represented by non-stop malfunction times, stop malfunction times and number of major parts and minor parts replaced during the warranty period (or insurance period). The major parts include: the cylinder head, piston, piston ring, piston pin, connecting rod, connecting rod bearing bush, connecting rod bolt, crankshaft, engine body, camshaft, intake and exhaust valves, valve spring, rocker arm, high pressure fuel pump, oil pump gear, driving gear, turbocharger, etc. The rest are minor parts. 3.2 Durability The durability index refers to the total operation hours of the engine or the driving kilometers of the vehicle from the initial use of engine to the first overhaul. It is the index that represents the service life of engine. Now, the durability of the domestic small-sized high-speed diesel engine is 2000 ~ 3000 h, and the high-speed internal combustion engine for vehicle is 100000 ~ 200000 km.

4. Low Public Hazard Index The poisonous emissions and noises from engine are harmful to human health and have negative influences on working efficiency, so China and other counties have established more and more strict controlling standards to protect the normal ecological environment for human beings. The poisonous gases produced by the engine during working mainly come from the exhaust gas, blowby from the crankcase, and vaporized gases from the fuel tank, fuel pipe connector, etc. The exhaust gas from engine contains many compositions, including CO2, steam, surplus oxygen, residual nitrogen, CO, HC, Nox, S02 and particles such as aluminide, black smoke, oil mist, etc.. and stinking gases such as formaldehyde, acrolein, etc. The blowby from the crankcase mainly includes HC, CO and so on, and the main vaporized gas from the oil tank is HC. The total amount of the above exhaust pollutants takes up about 1％ of the exhaust gas from the engine. Most of them are poisonous and harmful, with strong pungency, a stinking odor and carcinogenesis. There is no uniform international emission regulation at present, China and other countries have established their own emission control standards to control the emission of poisonous CO, HC, NOx and the smoke density. China  promulgated  “Law  on  Prevention  of  Air  Pollution”  in  1987  and  then  promulgated  the  GB  engine   exhaust standard to limit the poisonous emissions from the engine. Compared with those of the developed countries, the domestic controlling standards for poisonous engine emissions are looser, but they will get stricter and stricter and will joint with the international standards gradually from the perspective of its developing trend. China promulgated Regulation on Prevention and Control of Environment Noise Pollution in 1988.The engine is widely used as the power source, and its exhaust gases and noises have the largest environmental pollution area, and therefore attracting more and more attention from the public.

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Chapter II Technical Information of Engine

Section IV Engine Property Curves For the power, torque property curves of the GW4D20 turbocharged diesel engine, see Fig. 2-4-1.

Rotation speed (r/min)

Fig. 2-4-1 Power, Torque Property Curves of GW4D20 Turbocharged Diesel Engine ge ——Fuel consumption rate (g/kW·h); G ——Fuel consumption volume (kg/h); P ——Effective power (kW); Me ——Effective torque (N·m) For the power, torque property curves of the GW4D20B turbocharged diesel engine, see Fig. 2-4-2. Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Rotation speed (r/min)

Fig. 2-4-2 Power, Torque Property Curves of GW4D20B Turbocharged Diesel Engine ge ——Fuel consumption rate (g/kW·h); G ——Fuel consumption volume (kg/h); P ——Effective power (kW); Me ——Effective torque (N·m)

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Chapter II Technical Information of Engine

Section V Technical Data and Specifications of Engine 1. Technical Parameters of Engine For the main technical parameters of the GW4D20/GW4D20B turbocharged diesel engine, see Table 2-5-1. Table 2-5-1 Main Technical Parameters of GW4D20/GW4D20B Turbocharged Diesel Engine Item

Unit

Model No. Type

Number of Cylinders Cylinder Diameter X Stroke Total Displacement Compression Ratio Rated Power and Corresponding Rotation Speed

cylinder mm L

Max. Torque and Corresponding Rotation Speed Min. Fuel Consumption Rate Max. No-load Rotation Speed Idle Rotation Speed Fuel Fuel Grade

N·m/ (r/min) g/kW·h r/min r/min

Air Valve Clearance Fuel Injection Sequence Rotation Direction (viewing from the flywheel end) Max. Fuel Injection Pressure Oil Injection Control Intake valve opened (before the piston arrives at the top dead center (TDC)) Intake valve closed (after the piston arrives Valve Actuating at the bottom dead center (BDC)) Phase (℃A) Exhaust valve open (before piston arrives at BDC) Exhaust valve closed (after the piston arrives at the TDC)

r/min

Bar

Technical Parameter GW4D20/GW4D20B Cylinders   in   line,   four   strokes,   forced   cooling,   ω   combustion chamber, 16 valves, DOHC, electric control high-pressure common rail, turbocharged (VGT, WGT), air intake intercooled 4 83.1×92 1.996 16.7:1 110/4000 GW4D20 100/4000 GW4D20B 310/1800~2800 210 4400 750±50 China IV diesel without nitro additives 0# vehicle fuel (-10# or -20#, -35# diesel can be used in winter according to temperatures) (GB19147-2009) 0 (hydraulic tappet) 1—3—4—2 Anticlockwise

℃A

1600 Electric control 24°

℃A

50°

℃A

86°

℃A

16°

Note. ①1 bar = 105 Pa.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (Continued) Item

Unit

Lubrication Mode

Technical Parameter Pressure and splash combination type

Fuel Grade

API CI-4

Engine Oil Capacity

L

6

Oil/fuel Consumption Ratio

%

≤  0.3%  (rated  power  point)

Cooling Mode

Forced circulating water cooling

Coolant

High quality ethylene glycol coolant

Diesel Engine Coolant Capacity

L

Normal, Max. working water temperatures of the diesel engine, opening temperature of large and small cycles, and water circulation direction

3 Normal water temperature: 80 ℃ ~ 90 ℃; Max. water temperature: 110 ℃; thermostat full opening temperature: 80 ℃ (the thermostat is located at the water inlet)

Net mass of diesel engine (including the air condition compressor, power steering oil pump, cooling water)

kg

215 GW4D20 210 GW4D20B

Contour Dimensions (L x W x H), transmission excluded

mm

694×625×829 GW4D20 694×615×829 GW4D20B

Max. rotation speed

r/min

Turbocharger

℃

210000

Noise Acoustic Power Limits

dB/A

760 VGT/750 WGT

Exhaust Pollutants Limits

g/km

≤  110  (complying  with  GB  14097-1999)

Max. durative working temperature

Complying with GB 18352.3-2005 For the technical parameters of the main parts of GBWD20/GW4D20B turbocharged diesel engine electric system, see Table 2-5-2.

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Chapter II Technical Information of Engine

Table 2-5-2 Technical Parameters of Main Parts of GBWD20/GW4D20B Turbocharged Diesel Engine Electric System Item

Unit

Technical Parameter

Nominal voltage

V

12

Rated rotation speed

r/min

5000

Service speed

r/min

900~11000

Generator

Rotation direction

Clockwise (viewing from the direction of pulley)

Polarity

Cathode earthing

Working mode

Continuous rated type

High speed voltage of regulator

V

14.5±0.3

Voltage

V

12

Output power

kW

2

Starting Motor

Clockwise (viewing from the direction of driving gear)

Rotation direction

(Continued) Item

Unit

Technical Parameter

Storage Battery

Rated voltage

V

14

Heater Plug

Heating time

s

Heated to 800 ℃ in 8 s

2. Various Temperature and Pressure Ranges of Engine For various temperature and pressure ranges of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-5-3. Table 2-5-3 Various Temperature and Pressure Ranges of GW4D20/GW4D20B Turbocharged Diesel Engine Item

Temperature Range

Item

Pressure Range

Water Outlet of Cooling System

80℃~90℃

Idle engine oil pressure

≥0.3Mpa

Engine Oil of Lubrication System

≤120℃

Engine oil pressure at the calibrated rotation speed

≥0.4Mpa

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

3. Specifications of Main Engine Accessories For the specifications of main accessories of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-5-4. Table 2-5-4 Specifications of Main Accessories of GW4D20/GW4D20B Turbocharged Diesel Engine Accessory System and Name Oil pump

Specification

Accessory System and Name

Specification

VGT

Cross-section variable type turbocharger

WGT

Turbocharger with bypass valve

Rotor type

Lubrication System

Air intake Turbocharger system Engine oil filter

DELPHI

Rotary type Integral type: equipped with fuel-water separator

Rotary installation type: equipped Fuel filter BOSCH with fuel-water separator Rotary installation type: equipped Xin Feng with fuel-water separator

Cooling system

Double plungers, DELPHI equipped with fan blade pump, IMV

High Oil Supply pressure BOSCH System fuel pump

Xin Feng

High pressure fuel rail

Double plunger pump

DELPHI

Max. oil supply pressure 1600 bar

BOSCH

Max. fuel supply pressure 1600bar

DELPHI

7-hole

BOSCH

6-hole

Xin Feng

Vacuum pump

6-hole

Note. ①1 bar=105 Pa.

24

Centrifugal type

Pumping lift (4500 r/min)

16m

Thermostat type

Wax-type thermostat

Working mode

Continuous rated type

Max. rotation speed

2800

Max. vacuum degree

90

Time for achieving the vacuum degree

Time for achieving 50 kPa ＜ 5 (400r/min）

Triplex plunger pump

Max. fuel supply Xin Feng pressure 1600 bar Fuel injector type

Water pump type

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Chapter II Technical Information of Engine

4. Specifications of Main Parts of Fuel Supply System For the specifications of main parts of GW4D20/GW4D20B turbocharged diesel engine fuel supply system, see Table 2-5-5. Table 2-5-5 Specifications of Main Parts of GW4D20/GW4D20B Turbocharged Diesel Engine Fuel Supply System Parts Name

High Pressure Fuel Pump

Fuel injector

High pressure fuel rail

Installation Position

Rear end face of water pump housing

Top surface of cylinder head

Left side of cylinder body

Specification DELPHI

Double plunger, equipped with fan blade pump, IMV

BOSCH

Triplex plunger pump

Xin Feng

Double plunger pump

DELPHI

7-hole

BOSCH

6-hole

Xin Feng

6-hole

DELPHI

Max. fuel supply pressure 1600 bar

BOSCH

Max. fuel supply pressure 1600 bar

Xin Feng

Max. fuel supply pressure 1600 bar

Electronic Control Unit (ECU)

Inside the engine hood

Working voltage 12 V

Rotation Speed Sensor

Upper cylinder body

Working clearance 0.5 ~ 1.5 mm

Camshaft Phase Sensor

Cylinder head cover

Working clearance 0.5~1.5mm

Water Temperature Sensor

Cylinder head

Rated voltage: 5 V ± 0.15 V, NTC-type, rated resistance:  2.5  kΩ  ±  0.6%  at  20  ℃ and  0.186  kΩ  ±   2% at 100 ℃

Air Intake Pressure Sensor

Air intake manifold

DS-S3

Heater Plug

Lateral surface of cylinder head

Heated to 800 ℃ in 8 s

EGR Valve

Rear end of air intake manifold

Vacuum type

Frame

Equipped with manual fuel delivery pump, fuel-water separator, diesel heater (flow rate: 125 L/h), particle filterability of paper filter core: ＞15 μm100%,  3~5  μm  94.5%,  replacement  period  of   filter core: every 25000 ~ 30000 km of driving range

Fuel filter

Note. ①1 bar=105 Pa.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Section VI Maintenance Standard for Engine The normal operation of engine usually means: the consumption rates of fuel and lubricating oil conform with the design specifications, and the engine is capable of producing its designed power and running smoothly without abnormal noise. Any abnormal phenomenon has a relation with the fitting condition of the kinematic pair of engine. There are strict technical requirements for the assembly of kinematic pairs of engine; the geometric shape, fit clearance, surface roughness and cleanliness of parts should conform with the requirements. When the matching parts are installed, certain precisions should be applied, and the fit clearances are especially important. If the clearance is too small, the engine can not run smoothly, which accompanied with friction increasing, overheat, galling, even blockage if serious; if the clearance is too big, it may create impact and noise shortly after the parts are used, and result in difficulty in forming lubricating oil film, thus decreases the service life of parts. For the diesel engine that is put into service after strict assembly and running-in, its service life lies on proper maintenance.

1. Tightening Torque of Main Fasteners of Engine For the tightening torque of main fasteners of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-6-1. Table 2-6-1 Tightening Torque of Main Fasteners of GW4D20/GW4D20B Turbocharged Diesel Engine Sequence No.

Parts Code

Parts Name and Specification

Installation Position

Tightening Torque Value (N·m)

1

1004303—ED01

Connecting rod bolt

Connecting rod ——connecting rod cap

25 ± 3, rotation angle 90° ± 5°

1003700—ED01

Bolt and washer component of cylinder head

Cylinder body ——cylinder head gasket ——cylinder head

50 ± 3, rotation angle 90°, rotating an additional 120°

3

1021800—ED01

Bolt and washer component of camshaft timing pulley

Camshaft pulley ——camshaft

110±5

4

1005011—ED01

Flywheel bolt

Flywheel ——camshaft

75±5

5

1002116—ED01

Main bearing cap bolt

Cylinder body ——main bearing cap

40 ± 3, rotation angle 90°, rotating an additional 90°

6

1021014 一 ED01

Bolt of crankshaft timing pulley

Crankshaft timing pulley ——crankshaft

185~195

7

Q1840820F32

Hexagonal flange face bolt

Damping pulley of crankshaft ——crankshaft

23±3

8

1009106—ED01A

Fuel drain bolt (hex

Fuel pan assembly

40±5

2

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Chapter II Technical Information of Engine Sequence No.

Parts Code

Parts Name and Specification

Installation Position

Tightening Torque Value (N·m)

head screw plug) 101701l—ED01

Filter pipe connector

Cylinder body ——filter

50~60

10

3611070—ED01

Coolant temperature sensor (water temperature sensor)

Cylinder head

18~22

11

1021031 一 ED01

Fastening bolt of timing idle wheel

Timing idle wheel ——oil pump

43±4

12

1002800—ED01

Oil pressure alarm

Upper cylinder body

13~17

13

1021032 一 ED01

Fastening combination bolt of timing tension pulley

Timing tension pulley ——cylinder head

22~26

14

3701014 一 ED01

Fastening bolt of accessory idle wheel

Oil pump ——timing hood

22~26

15

3701016 一 ED01

Fastening bolt of accessory tension pulley

Compressor support

53~57

16

3770100—ED01

Heater plug assembly

Cylinder head

9~12

Q33014T13F2

All-metal hexagonal flange-face locknut (M14X1.5)

High pressure oil pump pulley ——high pressure fuel pump

65±3

9

17

18

1118013 一 ED01 1118013 一 ED01B

Fuel intake bolt of turbocharger

Fuel intake pipe ——turbocharger Fuel intake pipe ——cylinder block

22±3

19

Q618B02F32

Hex head tapered screw plug (water drain screw plug)

Upper cylinder body

25±3

20

Q32008F32

Hexagonal flange face nut

Exhaust manifold ——cylinder head

30±3

For the tightening torque standards for general fasteners of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-6-2. Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Table 2-6-2 Tightening Torque Standards for General Fasteners of GW4D20/GW4D20B Turbocharged Diesel Engine Sequence Fastener No. Specification

Torque Limit (N·m)

1

M6 x1

9±3

2

M8 x1

25±3

3

M8 x1.25

23±3

Remarks Performance grade 8.8, please refer to QC／T 518-1999

Sequence Fastener No. Specification 4

M10 x1

5

M10 x1.25

6

M12 x1.75

Torque Limit (N·m)

Remarks

45±3

Performance grade 8.8, 45±3 please refer to QC／T 95±10 518-1999

2. Fit Clearance of Main Parts of Engine For the fit clearances of main parts of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-6-3. Table 2-6-3 Fit Clearances of Main Parts of GW4D20/GW4D20B Turbocharged Diesel Engine. Sequence No.

Name of Fit Clearance of Parts

Fit Clearance Value (mm)

Remarks

1

Camshaft axial clearance

0.060~0.115

See Page 153, 210, 220, 230, 293

2

Crankshaft axial clearance

0.10~0.28

See Page 131, 165, 275, 288

Side clearance between piston ring and piston ring groove

0.055 ~ 0.100 (the first compression ring) 0.035 ~ 0.080 (the second compression ring) 0.030 ~ 0.070 (oil ring component)

See Page 147, 150, 257

4

Opening clearance of piston ring

0.20 ~ 0.40 (the first compression ring) 0.65~0.85 (the second compression ring) 0.25 ~ 0.50 (oil ring component)

See Page 146, 150, 257

5

Clearance between big end of connecting rod and crankshaft crank

0.22~0.37

See Page 151, 258, 276, 290

6

Piston cylinder clearance

0.07~0.09

See Page 150, 258, 276, 290

7

Clearance between piston pin and piston pin hole

0.005~0.012

See Page 147, 149

8

Clearance between piston pin and connecting rod small end hole

0.010~0.024

See Page 147, 149

3

For the matching selection by group for the main shaft bearing shell of the turbocharged diesel engine GW4D20/GW4D20B , see Table 2-6-4.

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Chapter II Technical Information of Engine Table 2-6-4 Matching Selection by Group for the Main Shaft Bearing Shell of the Turbocharged Diesel Engine GW4D20/GW4D20B Unit: mm Main bearing journal of crankshaft 1

2

3

φ60.015~φ60.020

φ60.009~φ60.014

φ60.002~φ60.008

Color of Main Bearing Shell

1

Main Bearing Aperture of Cylinder Body

2

3

φ64.000~φ64.006

φ64.007~φ64.012

φ64.013~φ64.018

Yellow

Yellow

N/A

Thickness of shell: 1.976 ~ 1.980 Clearance: 0.020 ~ 0.040 Thickness of shell: 1.976 ~ 1.980 Clearance: 0.026 ~ 0.046 Thickness of shell: 1.980 ~ 1.984 Clearance: 0.024 ~ 0.044

Yellow

N/A

Blue

Thickness of shell: 1.976 ~ 1.980 Clearance: 0.026 ~ 0.046 Thickness of shell: 1.980 ~ 1.984 Clearance: 0.024 ~ 0.044 Thickness of shell: 1.984 ~ 1.988 Clearance: 0.022 ~ 0.042

N/A

Blue

Blue

Thickness of shell: 1.980 ~ 1.984 Clearance: 0.024 ~ 0.044 Thickness of shell: 1.984 ~ 1.988 Clearance: 0.022 ~ 0.042 Thickness of shell: 1.984~1.988 Clearance: 0.022 ~ 0.042

For the matching selection for the main shaft bearing shell of the turbocharged diesel engine GW4D20/GW4D20B, see Table 2-6-5. Table 2-6-5 Matching selection for the Main Shaft Bearing Shell of the Turbocharged Diesel Engine GW4D20/GW4D20B Group No. of Main Bearing Hole of Cylinder Body (1, 2, 3)

Main shaft bearing shell color code (number)

Fit Clearance

=1-3

Yellow (1)

0.020~0.046 mm

=4

None (2)

0.024~0.044 mm

=5-6

Blue (3)

0.022~0.048 mm

Group No. of Main Crankshaft Journal (1, 2, 3)

For the matching selection by group of cylinder Bores and pistons, see table 2-6-6.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Table 2-6-6 Matching Selection by Group of Cylinder Bores and Pistons cylinder Bore Dimension (φ)

Mark

Piston Dimension by Group

Mark

Fit Clearance

83.09~83.10 mm

1

83.1 0.081 0.090 -0.090mm

1

0.071~0.090 mm

83.10~83.11 mm

2

83.1 0.071 0.080 -0.090mm

2

0.071~0.090 mm

83.11~83.12 mm

3

83.1 0.061 0.070 -0.090mm

3

0.071~0.090 mm

For positions for daubing or injecting lubricating oil on assembly parts of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-6-7. Table 2-6-7 Positions for Daubing or Injecting Lubricating oil on Engine Assembly Parts (Mobil Oil Corp., API CI-4 Plus diesel engine oil) Sequence No.

Position for Daubing or Injecting Lubrication Oil on Assembly Parts

Remarks

1

Working surface of main bearing shell

See Page 133, 165, 274, 288

2

Main journal and oil hole

See Page 134, 165, 274, 288

3

Between crankshaft thrust plate and crank arm thrust face

See Page 135, 165, 275, 289

4

Cylinder bore wall

See Page 135, 150, 166, 257, 276, 289

5

Internal surface of connecting rod bearing shell and surface of crankshaft crank pin

See Page 136, 150, 166, 257, 276, 289

6

Surface of piston pin hole, piston ring groove, piston pin surface, connecting rod small end hole

See Page 136, 149, 257, 276, 290

7

Internal surface of bearing hole of the intake/exhaust camshaft of cylinder head, surface of camshaft journal

See Page 107, 117, 139, 203, 210, 220, 230, 259, 279

8

Camshaft

See Page 107, 117, 139, 203, 210, 220, 230, 259, 279

9

Mounting hole of hydraulic tappet, and the surface of tappet

See Page 106, 127, 139, 152, 210, 229, 279, 259, 293

10

Valve guide hole and valve stem

See Page 105, 127, 219

11

Oil pump shaft and outer and inner rotors

See Page 137, 245, 336

12

Oil seal lip

See Page 135, 158, 166, 245, 336

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Chapter II Technical Information of Engine Table 2-6-8 Position for Coating Sealant on Engine Assembly Parts Sequence No.

Position for Coating Sealant

Name of the Coated Sealant

Specification and Model

1

Joint surface between oil pump and cylinder body/fuel pan

Silicon rubber flat sealant

LOCTITE 587 flat sealant

2

Joint surface between fuel pan and lower cylinder body

Silicon rubber flat sealant

LOCTITE 587 flat sealant

3

Joint surface between upper fuel pan and lower fuel pan

Silicon rubber flat sealant

LOCTITE 587 flat sealant

4

Joint surface between upper cylinder body and lower cylinder body

Anaerobic flat sealant

LOCTITE 510 anaerobic flat sealant

5

Joint surface between cylinder head and camshaft bearing cap

Anaerobic flag sealant

LOCTITE 510 anaerobic flat sealant

6

Threaded section of water drain screw plug

Anaerobic thread fixing sealant

LOCTITE 243 thread fixative

7

Threaded section of oil pressure alarm assembly

Anaerobic thread fixing sealant

LOCTITE 243 thread fixative

8

Threaded section of water temperature sensor

Anaerobic thread fixing sealant

LOCTITE 243 thread fixative

9

Water outlet pipe component, heater water return pipe connector, and all pipe connectors on cylinder body

Anaerobic fixative for cylindrical parts

TONSAN 1608 sealing fixative for bowl-shaped plugs

10

bowl-shaped plugs on cylinder body and cylinder head

Anaerobic fixative for cylindrical parts

TONSAN 1608 sealing fixative for bowl-shaped plugs

For the oil filling capacity of GW4D20/GW4D20B turbocharged diesel engine, see Table 2-6-9. Table 2-6-9 Lubricating oil Capacity of Engine Item Total Engine Oil Amount Replace Oil Filter Replace the Compete Machine Oil

Capacity

Recommended Lubricating oil Grades

6.0 L Refill 0.5 L

Mobil Oil Corp., API CI-4 Plus diesel engine oil (choose according to the ambient temperature)

5.0 L

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Section VII Running-in of Engine The new diesel engine or diesel engine just overhauled (including replacements of the piston, piston ring or main bearing shell, connecting rod bearing shell) should go through a running-in period during which the engine should start from a low load to a high load gradually before normal use, and the initial check, adjustment and maintenance should be carried out during the running-in. Try to make all kinematic pairs run-in well and prevent abnormal wear and damage. The experiences have testified that the service life, working reliability and economical efficiency of the diesel engine, to a large extent, lie on the running-in condition of the diesel engine in the initial stage of use.

1. Preparation Before Running-in 1.1 Operators should read the Use and Maintenance Manual for GW4D20/GW4D20B Turbocharged Diesel Engine carefully to be familiar with the structure, performance, operation and maintenance methods of the engine. 1.2 Clear up the external surface of diesel engine. 1.3 Check the oil level, and refill oil to the specified oil level if the oil is not enough. 1.4 Check and refill fuel (vehicle diesel), coolant (anti-freezing, anti-rust liquid). 1.5 Check the electrolyte level of the storage battery, and refill to the specified level if the electrolyte is not sufficient. 1.6 Check if the timing belt is installed properly and if the timing mark is correct. 1.7 Check if the electric line, ECU and harness assembly are correctly and securely connected. 1.8 Set the operating handle of gear box to Neutral.

2. Running-in Before engaged in work with normal load, the new diesel engine should run-in on the vehicle for 2500 km according to the running-in specification, see Table 2-7-1) or on the test rack for 50 h according to the running-in specification. The diesel engine whose piston, piston ring, main bearing shell, connecting rod bearing shell, etc. have been replaced during the overhaul should run-in on the vehicle for 500 km (according to Table 2-7-2) or on the test rack for 10 h according to the running-in specification. During the running-in period, you can carry out further inspection for the assembly quality of all engine parts and implement adjustment when necessary. Table 2-7-1 Specification  for  New  Diesel  Engine’s  Running-in on Vehicle Vehicle Traveling Distance (km)

Vehicle Load

Rotation Speed of Diesel Engine (r/min)

0~300

No-load

Not over 50% the rated rotation speed of the corresponding diesel engine

＞301~1000

Not over 50% of the rated load

Not over 50% the rated rotation speed of the corresponding diesel engine

＞1001~1500

Not over 50% of the rated load

Not over 75% of the rated rotation speed of the corresponding diesel engine

＞1501~2500

Full load

Not over the rated Max. rotation speed of diesel engine

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Chapter II Technical Information of Engine

Table 2-7-2  Specification  for  Diesel  Engine’s  Running-in on Vehicle (for the main parts replaced during the overhaul) Vehicle Traveling Distance (km)

Vehicle Load

Rotation Speed of Diesel Engine (r/min)

0~100

No-load

Not over 50% of the rated rotation speed of the corresponding diesel engine

＞101~250

Not over 50% of the rated load

Not over 50% of the rated rotation speed of the corresponding diesel engine

＞251~450

Not over 75% of the rated load

Not over 75% of the rated rotation speed of the corresponding diesel engine

＞451~500

Full load

Not over the rated Max. rotation speed of diesel engine.

3. Precautions for Running-in 3.1 You should observe, listen to the working condition of all systems of the diesel engine: check if there is any oil, water, gas, or electric leakage; if the oil pressure, coolant temperature are normal; if the rotation speed is steady; if the exhaust gas has a normal color; check the operation condition of turbocharger, and make sure the rotor rotate flexibly, without block, clearance, etc. Any detected fault or abnormal phenomena should be eliminated at first, and then proceed with running-in. 3.2 During running-in period, the vehicle should be driven at first or second level of road surface, it should not be driving on road surface in bad condition, full speed and overspeed driving are absolutely not permitted. 3.3 The max. allowed rotation speed of diesel engine during running-in period is 3000r/min.

4. Technical Maintenance After Running-in A thorough inspection, clean-up and adjustment should be carried out after the completion of running-in of the diesel engine, so as to eliminate the metal powder deposited in the lubricating oil and adjust the improper clearance, the main contents are as follows: 4.1 After driving the vehicle for the first 2500 km (including the running-in period), discharge the engine oil in the lubrication system and replace the oil filter, and replace the engine oil in accordance with specified grades. 4.2 Check the fastening conditions of bolts, nuts of all parts; check the connection conditions of all electrical connectors. Attention: The diesel engine can only be put into service after running-in and maintenance according to technical requirements. Or else it may shorten the service life of the diesel engine.

5. Precautions for Usage of New Vehicles Driving a new vehicle in accordance with the following rules will not only elongate the service life of the vehicle, but also reduce the diesel consumption. 5.1 Keep a normal coolant temperature (80 ℃ ~ 90 ℃; the temperature can be 105 ℃ when a pressure water  tank  is  used)  and  a  normal  oil  pressure  (≥  0.4  MPa). 5.2 Keep the vehicle at a normal driving speed and prevent high speed driving.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 5.3 In the first 300 km of driving range, sudden stop should be avoided. 5.4 When the gear box is set at the high-speed gear, you should not drive the vehicle at a low speed. 5.5 Do not drive the vehicle at the high-speed gear or low-speed gear for a long time, you should shift gears according to the driving condition at the right time. 5.6 When the driving range of a new vehicle reaches to 2500 km, besides daily maintenance, technical maintenance should also be carried out according to the requirements of first-grade technical maintenance; the engine oil and the oil filter should be replaced at the same time.

Section VIII Technical Maintenance for Engine During the service of engines, due to wear of the parts, looseness of tightening parts, looseness of the electrical connectors, change of clearance, oil deterioration, etc., the technical conditions of diesel engine will degrade, a variety of abnormal phenomena such as hard starting, power loss, increase of oil consumption will result, and even the engine can not operate normally. It is important to clean, check, lubricate and adjust the various parts of the engine regularly and change some of the parts according to the  engine’s  technical  status  and  operating  time  or  driving  distance. Attention: with the purpose of keeping a good technical condition, preventing or reducing malfunctions and extending the service life of the engine, the technical maintenance must be carried out seriously according to the specification.

1. Technical Maintenance Cycle Various kinds of required regular maintenance operation are divided into 4 levels according to the degrading degree of the parts of diesel engine: 1.1 Daily technical maintenance: usually at the end of each 8~10 h work shift. 1.2 First level technical maintenance: after the diesel engine operating time adds up to 100 h or the vehicle driving distance adds up to 4000~5000 km. 1.3 Second level technical maintenance: after the diesel engine operating time adds up to 250 h or the vehicle driving distance adds up to 10000 ~ 12500 km. 1.4 Third level technical maintenance: after the diesel engine operating time adds up to 1000 h or the vehicle  driving  distance  adds  up  to  50000  ~  100000  km,  or  upon  user’s  own  decision  in  accordance  with   the working condition of diesel engine. For the maintenance cycle of the GW4D20／GW4D20B turbocharged diesel engine, please refer to Table 2-8-1. According to technical maintenance requirements, the maintenance may be carried out in the procedure of filling, cleaning, washing, adjusting, lubricating, repairing or replacing after check-up.

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Chapter II Technical Information of Engine Table 2-8-1 Maintenance Cycle for GW4D20／GW4D20B Turbocharged Diesel Engine Maintenance cycle Maintenance Items

Diesel engine oil

Daily technical maintenance

First level maintenance

Second level maintenance

Third level maintenance

4000 ～ 5000 km

4000 ～ 12,500 km

4000 ～ 100,000 km

Check the oil level (recommended to check it per 500 ~ 1000 km)

Replace the oil (normally per 8000 ~ 10000 km)

Oil filter

Replace the oil filter (normally per 8000~10000km)

Fuel (diesel) filter

Replace the diesel filter (normally per 20000 ~ 25000 km for GW4D20 turbocharged diesel engine) Replace the diesel filter(normally per 8000 ~ 10000 km for GW4D20B turbocharged diesel engine)

coolant

Check the fluid level

Air cleaner

clean

Normally, replace the filter core per 30000 km.

Parts and various electrical connectors loosed and damaged

Check, tighten, repair

Working condition of diesel engine

Check if it operates normally

Four leakages

Check and remove oil leakage, water leakage, air leakage and electricity leakage.

Appearance of diesel engine

Keep clean

Belt of generator Connecting parts of fuel pipes loosed and damaged

Inspect, adjust, replace Check, tighten, repair

Radiator Connection of turbocharger Fuel injector Timing driving belt

Remarks

clean Check, maintain Check or replace it when malfunction displays Check the appearance of driving belt

Replace the belt (normally per 80000 ~ 100000

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To check it in a professional service station To repair it in a professional service station

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES km)

Tension pulley, accessory wedge idle wheel and flat idle wheel

when replacing the belt, replace the tension pulley subassembly, accessory wedge idle wheel and flat idle wheel depending on the their conditions

Check, maintain

Water pump

Check the water leakage of overflow

Electrical appliance

Check wiring, engine and starter

Crankcase vent system (including intake pipeline)

Check, wash

Replace the tension pulley after changing the belt twice

Note: ① When the vehicle travels in a severe condition, traveling distance and time for replacing the oil filter are: per 5000 km or per 100 h. ② If the diesel used contains impurities, the cycle for replacing the fuel filter should be shortened. If the fuel filter is blocked by impurities, the fuel filter should be replaced in time. (continued) Maintenance cycle Maintenance Items

Daily technical maintenance

First level maintenance

Second level maintenance

Third level maintenance

4000 ～ 5000 km

10000 ～ 12500 km

50000 ～ 100000 km

Washing the cooling system

Wash the cooling system

Washing the engine

Wash the carbon deposit, oil stains, incrustation, oil duct, oil pipe.

Piston ring

Inspect for wear

Cylinder inner wall

Inspect for wear

Connecting rod bearing shell

Inspect for wear

Main shaft bearing shell

Inspect for wear

Camshaft timing driving gear

Inspect for wear

Thrust plate

Inspect for wear

Intake/exhaust valve

Inspect for wear

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Remarks

Depending on the working condition of engine

Chapter II Technical Information of Engine

2. Technical Maintenance Contents In order to ensure the engine operates properly, technical maintenance should be carried out in the following procedure:

Fluid reservoir

2.1 Daily technical maintenance (1) Inspect for the diesel fuel, coolant and oil level (see Fig. 2-8-2), and add oil in accordance with technical requirements if necessary.

Fig. 2-8-1 Checking the coolant level（for reference only）

Diesel specification: use the diesel which complies with CBl9147-2009 provision, for south areas in winter (warm zone) ——10# or 20#, for north areas (cold zone) ——35#.

GB 19147-2009 vehicle diesel ——– diesel

35# ————20# diesel ——– diesel

Attention: correct inspection for various fluid levels can only be carried out when the diesel engine is stopped.

For the areas with environment requirements, use the diesel complying with environmental regulations.

10#

Choose fuel in accordance with the season and local temperature. See Fig. 2-8-2.

——0# diesel

Ambient temperature for diesel engine operation

Fig. 2-8-2 Choosing fuel (vehicle diesel) in accordance with the ambient temperature

Attention: Never fill the fuel tank when the diesel engine is running. If the vehicle is running in the hot climate, the fuel tank should not be fully filled, or else the fuel will overflow due to fuel extension; wipe the fuel as soon as it overflows. Inspect, add coolant. Inspect the oil level. (2) Remove ash and electrolyte spilled on the battery to make sure the vent hole unblocked. In normal conditions, the battery almost needs no maintenance, but it needs to be inspected regularly in high temperature conditions. The fluid level should be between the Min. and Max. marks on the side surface. The storage battery should be filled with distilled water when the electrolyte is not enough.

Fig. 2-8-3 Checking the battery electrolyte level

Caution: Never fill the battery with additional fluid and other impure water optionally, or else it will cause insufficient charging and affect usage. If the fluid level drops fast, the storage battery should be sent to the service station for repair. Warning: the electrolyte is corrosive and must not be splashed in eyes, on skin and clothes; clean it with fresh water immediately if it is splashed on above mentioned places.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES turbocharger

(3) Check if there is oil, water, air or electricity leakage, remove  them  if  the  “four  leakages”  are  found.   (4) Check if various accessory devices are fastened. (5) After starting the engine, listen if the engine is running properly, and check the working conditions of instruments, they should be fixed or replaced if damaged. (6) Keep the diesel engine clean, especially pay attention to that there should be no oil stains on the electrical equipment and no foreign material on the radiator of water tank.

Fig. 2-8-4 Checking the connection between the turbocharger and the diesel engine

Rubber ball Rubber pipe

Electrolyte

Gravimeter core Glass tube Storage battery

(7) inspect and tighten the connection between the turbocharger and diesel engine (see Fig. 2-8-4), remove the malfunctions such as oil leakage, air leakage and so on, and keep the surface of turbocharger clean. Caution: If the diesel engine works in a dusty condition, the air cleaner should be cleaned everyday to ensure a good working condition for the air cleaner. 2.2 First class technical maintenance On the basis of fulfilling daily maintenance content, the following maintenance content should be added after the diesel runs for 100h or the vehicle travels for 4000~5000km: (1) Check the battery electrolyte specific gravity (see Fig. 2-8-5) or battery voltage (see Fig. 2-8-6).

Fig. 2-8-5 Measuring the electrolyte specific gravity

(2) Check the appearances (wear conditions) of timing belt and generator belt. (3) clean the air cleaner, (4) Check if diesel engine is fastened. 2.3 Second Level Technical Maintenance It includes the first level technical maintenance contents. The following maintenance contents should be added after the diesel engine runs for 250 h or the vehicle travels for 10000 ~ 12500 km(for new engines or the second level maintenance for the first time after overhauling in the third level maintenance, the maintenance time should be advanced to 100 h or 4000 ~ 5000 km).

Voltmeter Electric resistance Discharge tongs contact pin Storage battery

Fig. 2-8-6 Measuring the battery voltage

(1) Replace the engine oil. (2) Replace filter cores of the fuel filter, oil filter and air cleaner. (3) Inspect the dripping condition of the water pump overflow, replace the water pump if serious dripping is found. (4) Inspect if the connectors of the electrical equipment

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Chapter II Technical Information of Engine and wirings are firmly connected, replace them if any blowout found. (5) Wash the incrustation in the pipe of cooling system and radiator. (6) Wash the vent system of crankcase. 2.4 Third Level Technical Maintenance Cylinder head gasket

Under the normal circumstance, in addition to the second level technical maintenance, replace the timing belt, inspect the transitional wheel and tension wheel and clean the cooling system of the complete machine after the diesel engine runs for 1000 h or the vehicle travels for 50000 ~ 100000 km (normally per 80000 km).According to the operating condition of the diesel engine, the following maintenance items should be carried out if necessary:

Cylinder body

Fig. 2-8-7 Checking the cylinder head gasket Cylinder head Mounting assembly

(1) Unpick and wash the diesel engine, remove carbon deposit, oil dirt and incrustation, and wash all lubricating oil pipes and oil tubes. (2) Check the wear conditions of the valves, hydraulic adjuster and contact face of rocker arm, repair or replace them if necessary. (3) Check the wear conditions of the piston ring, cylinder, connecting rod small end bushing and connecting rod bearing shell, replace them if necessary. (4) Check the wear conditions of the main shaft bearing shell and thrust plate.

Air intake manifold pipe gasket

Air intake manifold pipe

Fig. 2-8-8 Checking the air intake manifold pipe gasket

(5) Check the cam driving mechanism, the sealing condition of the camshaft front oil seal and the axial clearance of camshaft, and the transitional wheel subassembly and tension wheel subassembly. (6) Check the wear condition of the intake/exhaust valves and their valve seats, repair and grind the parts, and check leakage of the parts, replace them if necessary.

Cylinder head Mounting assembly

Air intake manifold pipe gasket

(7) Check the oil pump, overhaul or measure the vulnerable parts, and adjust them. (8) Check the cylinder head gasket and intake/exhaust manifold pipe gasket (see Fig. 2-8-7, Fig. 2-8-8 and Fig. 2-8-9), the damaged or faulty gasket should be replaced.

Air intake manifold pipe

Fig. 2-8-9 Checking the exhaust manifold pipe gasket

(9) Check the generator and starter (see Fig. 2-8-10), wash various parts and bearings, fill them with new grease after they are dried, check the wear condition of the starter gear and check if the driving device is flexible. 2.5 Seasonal Technical Maintenance (1) It is recommended to replace the antifreeze/antirust fluid in the diesel engine cooling system as the winter is coming, see Fig. 2-8-11.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (2) In winter, a suitable fuel (vehicle diesel) grade should be chosen according to the ambient temperature. (3) In winter, the lubricating oil for winter use in the lubricating system should be used. Generator

(4) The concentration of battery electrolyte should be changed in accordance with the season.

3. Technical Maintenance for Air cleaner Generator

Fig. 2-8-10 Checking the generator and starter

The function of air cleaner is to filter the dust and other impurities in the air so as to avoid abrasion wear on the cylinder hole, piston ring, valve and valve seat. Therefore, the air cleaner should have a high efficiency. The GW4D20／GW4D20B turbocharged diesel engines are not allowed to operate without an air cleaner, because this will easily damage the airflow sensor. The diesel engine cannot operate properly when the airflow sensor is damaged. The GW4D20／GW4D20B turbocharged diesel engines may be mounted with the oil bath air cleaners which are equipped with inertial steel wool filter cores or the paper filter core air cleaners. The diesel engine for vehicle isn't equipped with the air cleaner when delivery, it will be equipped by the vehicle manufacturer, and the airflow of the selected air cleaner should be no less than 450 m3/h.

diesel

Anti-freeze/an ti-rust fluid

oil

Storage battery

Fig. 2-8-11 Seasonal technical maintenance for diesel engine

It is very important to maintain the air cleaner on schedule,   if   you   don’t   do   this,   the   air   cleaner will be blocked by dust and the air intake resistance will be increased, which will cause smoking when the diesel engine is operating, power decrease and early wear of the engine. The user is required to maintain the air cleaner regularly in strict accordance with the vehicle application and maintenance instruction. 3.1 Maintenance for Oil Bath Air Cleaner Generally, a diesel engine vehicle which is equipped with the inertial steel wool filter core air cleaner should be washed per 4000 ~ 5000 km of traveling distance, and the distance may be changed upon the density of dust in the environment. Take out the steel wool and put it in the degreaser or parts cleaner to wash it, dry it by using compressed air after washing. Meanwhile, clean the oil bath of air cleaner, fill a proper amount of new oil in the oil bath. Attention: Use professional greaser or parts cleaner but not petrol when washing the parts,. 3.2 Maintenance for Paper Core Air Cleaner Generally, for the vehicle equipped with a diesel engine, the dust in the housing of air cleaner should be removed

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Chapter II Technical Information of Engine and the filter core should be cleaned per 4000 ~ 5000 km of traveling distance. (1) Cleaning of the air cleaner housing and cover: Wipe away the dust inside the housing, on the cover and on the surface of air cleaner when maintaining and replacing the filter core of air cleaner.

Air cleaner cover

(2) Cleaning of the filter core: when the filter core is polluted by dust and is in a dry condition, the compressed air may be used to clean the dust. Blow the filter core from the inner side to remove the dust by use of the compressed air. The pressure of the compressed air should be less than 490 kPa.

Filter core

Air cleaner housing

Fig. 2-8-12 Air cleaner (for reference only)

Caution: Do not blow the filter core from the outer side, or else the dust will enter the inner side of filter core (clean face). The filter core should be replaced with a new one in following cases. ——The filter core is polluted by carbon deposit or grease. ——The filter core is seriously contaminated and the contamination is hard to remove. ——The filter core is deformed and damaged. Caution:

Fig. 2-8-13 Cleaning the air cleaner filter core

(1) The paper filter core is not allowed to be washed with oil or fresh water, or else the filter core will be easily contaminated by dust, and this will cause insufficient air intake; as a result, power loss and black smoke in exhaust may result. (2) The tightness at the joint between the air intake pipe and the air cleaner must be checked regularly, the packing and the connecting pieces for tightening should be replaced if a leakage is found to avoid abnormal wear of the diesel engine.

4. Technical Maintenance for Oil Supply System 4.1. Technical Maintenance for Fuel Filter The function of fuel filter is to filter the impurities in diesel so as to prevent precision accessories in oil supply system from wear.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Fuel outlet

Fuel inlet

Fuel return port

Water leakage sensor

Drain screw plug

Fig. 2-8-14 Integral fuel filter (for matching with Delphi electronic fuel injection system) Hand pump

fuel

Fuel inlet pipe connector Filter core of filter cartridge

Fuel return pipe connector Electric connector

The fuel filter is mounted on the low pressure fuel circuit. The diesel enters the filter and the mechanical impurities are eliminated by the filter core. The filtered diesel enters the fuel delivery pump of high pressure fuel pump via the fuel outlet pipe. The GW4D20／GW4D20B turbocharged diesel engines adopt integral fuel filters (see 2-8-14) and rotary fuel filters ( see Fig. 2-8-15) respectively, these filters are used for DELPHI and BOSCH electric fuel injection systems respectively. Normally, the fuel filter which is used for the DELPHI electronic fuel injection system should be replaced after the engine runs for 500 h or the vehicle travels 20000 ~ 25000 km, while the filter used for the BOSCH electronic fuel injection system should be replaced after the engine runs for 200 h or the vehicle travels 8000 ~ 10000 km. If poor quality diesel is used in the diesel engine or fuel is contaminated by impurities, it is recommended that the time to replace the filter core should be advanced, because the filter will be blocked soon. After the integral fuel filter has been replaced, press the hand fuel pump mounted on the chassis to remove the air in the fuel circuit. After the rotary fuel filter has been replaced, press the manual fuel delivery pump to remove the air in the fuel circuit.

Drain plug

Caution: Fig. 2-8-15 Rotary fuel filter (for Bosch electronic fuel injection system)

(1) The fuel filter is disposable and is not allowed to be reused. (2) The fuel filter should be replaced regularly in accordance with the technical maintenance requirements. 4.2 Drain of Fuel Supply System Take the diesel engine for vehicle as an example. When the water level in the fuel-water separator reaches the hazard level, the alarm lamp of fuel water separator will light up (on the instrument panel, as shown in Fig. 2-8-16).

Figure 2-8-16 Water level alarm lamp of fuel-water separator

Attention: When the diesel engine is running, the lighting of the water level alarm lamp means that the water in the fuel-water separator needs to be drained out. Method to drain the fuel filter: (1) Park the vehicle in a safe and flat location. (2) Open the engine hood, place the container (volume:

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Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter II Technical Information of Engine about 0.2 L) to the end of vinyl hose under the fuel-water separator drain plug.

Hand fuel pump

(3) For the rotary fuel filter，anticlockwise unscrew the drain plug (about 5 circles).Press the hand fuel pump about 10 times till the fuel filter is filled with fuel. For the integral fuel filter, anticlockwise unscrew the drain plug, press the hand fuel pump mounted on the chassis till the fuel filter is filled with fuel.

Fuel return pipe connector

Fuel inlet pipe connector Filter core of filter cartridge

Electric connector unscrew

tighten

(4) After the water is drained, press the manual fuel delivery pump or the hand fuel pump several times.

Drain plug

(5) Start the engine, confirm the drain plug is tight and check if the indicator lamp of the fuel water separator is out.

Fig. 2-8-17 Fuel filter

Attention: If there is water need to be drained frequently, it means the fuel used is undesirable. If there is water in the fuel tank, it should be drained in the service station.

5. Technical Maintenance for Fuel Lubrication System

It is recommended to use the APICI-4 or above diesel engine oil produced by Mobil Oil Corp.

5.1 Selection of Lubricating Oil Lubricating oil (engine oil, see Fig. 2-8-18) for the diesel engine lubrication system should be selected upon the ambient temperature. Caution: different grades of oil should not be mixed. 5.2 Measuring of the Oil Level

Ambient temperature for operation of diesel engine

Figure 2-8-18 Selecting lubricating oil (engine oil) in accordance with the ambient temperature

Engine oil is a consumable which ensures the diesel engine to operate formally, therefore, the oil level should be checked regularly. For example, check the oil level when adding fuel or before a long journey. The oil consumption depends on the driving condition, weather and traveling condition. The oil consumption rate may reach 1 L/1000 km, and the oil consumption rate of the new diesel engine may be higher. When checking the oil level, make sure that the diesel engine has been preheated and the vehicle is parked on a flat floor, stop the engine and wait for 3 minutes. Then check the oil level.

Engine oil dipstick assembly

Figure 2-8-19 Checking the oil level with an oil dipstick

Measure the oil level in the oil pan with the dipstick mounted on the left side of diesel engine (see Fig. 2-8-19), draw out the dipstick and wipe away the oil on the dipstick with a piece of cleaning cotton cloth, then insert it into the oil pan till to its end, draw it out again to check the oil level. There are upper/lower scale marks on the dipstick to help to check the oil level (see Fig. 2-8-20), the oil level

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Engine oil dipstick Engine oil dipstick guide

Upper scale mark Lower scale mark

Figure 2-8-20 Checking the oil level with an engine oil dipstick

should not be below the lower scale mark, because it will result in that the oil pump cannot pump up the oil. It is also not appropriate that the oil level is higher than the upper scale mark, because the crank of crankshaft will strike on the surface of oil, which will cause malfunctions such as oil consumption increase, exhaust deterioration, serious carbon deposit on the piston top and the combustion chamber walls, and piston ring stuck due to coking, etc. Therefore, in addition to the oil pressure, the oil level also should be checked with the dipstick before traveling and per 300 ~ 500 km of traveling distance. Attention: In addition to checking the oil pressure, the oil level also needs to be checked before traveling. 5.3 Replacement with New Oil After the oil is used for a long time, there are not only impurities and dust, but also unburned fuel which makes the oil thinner. Some exhaust gas enters and brings anhydride which deteriorates the oil and then corrodes the parts; therefore, after the oil has been used for some time (e.g. after the vehicle traveling distance accumulates to 8000 ~ 10000 km), the oil should be overall replaced. Method to replace the engine oil: (1) Place the diesel engine or park the vehicle in a flat location. (2) Run the diesel engine, and stop it when the oil temperature reaches 80 ℃. (3) Place an oil collection pan under the engine, unscrew the oil drain screw plug (see Fig. 2-8-12), drain out the oil in the oil pan. Warning: Take care of hot oil so as to avoid burning, and dispose the used oil properly to protect the environment. (4) Place a new sealing ring, screw the oil drain screw plug and tighten it according to requirements, add new engine oil and check the oil level with the dipstick. Tightening torque for oil drain screw plug

Copper washer Oil drain screw plug

40 N·m ± 5 N·m Oil collection pan

Fig. 2-8-21 Screwing the oil drain screw plug and draining out the engine oil

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If a large number of impurities deposit in the oil pan, the lubrication system should be washed with 5# and 7# machinery oil (light spindle oil) when the new engine is running in, petrol or kerosene is not allowed. When cleaning the inner side of diesel engine, fill the oil pan with 5# or 7# machinery oil, the oil level should be at the center of lower and upper scale marks on the

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter II Technical Information of Engine dipstick; remove all oil injectors and rotate the crank of diesel engine for 2 ~ 3 minutes, then drain out the washing oil quickly.

oil filler cap oil filler cap sealing ring

Each time after replacing the oil, the diesel engine should operate without any load for a while to ensure the lubrication system and locations required to be lubricated can obtain adequate oil. When filling oil through the oil filler on the valve shield (see Fig. 2-8-22), the oil filler should be cleaned to prevent from impurities and dust. After the filling, close the filler cap. Attention: The filled oil can flow into the oil pan only through the push rod hole on the cylinder cover and the hole on the tappet side of cylinder body, checking for the oil level can only be carried out 5 min later. 5.4. Technical Maintenance for Oil Filter

Fig. 2-8-22 Filling oil through the oil filler on the valve shield Cylinder body

The oil filter should be replaced after the new vehicle travels for 2500 km; afterward, the oil and the oil filter assembly should be replaced at the same time per 8000 ~ 10000 km of traveling distance. Method to replace the engine oil filter and precautions: (1) Place a container under the oil filter to collect the lubricating oil overflown. (2) Use a special spanner to dismount the oil filter assembly in the anticlockwise direction, see Fig. 2-8-24. Oil filter spanner: 5-8840-0020-0.

Oil filter

Fig. 2-8-23 Replacing the oil filter

(3) Check and clean the oil filter seat to ensure good fitting of the new oil filter. (4) When mounting the oil filter, apply a thin layer of oil on the O-ring (see Fig. 2-8-25), screw the new oil filter assembly on the engine oil cooler seat by hand until a resistance is created, then use a spanner to tighten the oil filter for 3/4 ~ 1 circle in the clockwise direction. APICI-4 lubricating oil from Mobil Oil Corp. (5) Do not start the engine before there is enough lubricating oil in the oil pan. (6) Start the diesel engine after the mounting, and check if the oil filter leaks. Then stop the diesel engine, check the lubricating oil level with a dipstick, add lubricating oil if necessary.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Caution: (1) The rotary oil filter is disposable and is not allowed to be reused.

Special tool Remove and reinstall the engine oil filter with the special tool

Fig. 2-8-24 Removing and reinstalling the oil filter

(2) The oil filter should be replaced regularly in accordance with the technical maintenance requirements. Special attention should be paid to the rubber sealing ring when the oil filter is removed and reinstalled so as not to damage the sealing ring and cause leakage. If the rubber sealing ring of oil filter is damaged, it should be replaced. 5.5 Low Oil Pressure Indicator Lamp The low oil pressure indicator lamp of vehicle diesel engine (see Fig. 2-8-26) will light up when the ignition switch  is  in  the  “ON”  position  and  go  out  after  the  diesel   engine is started, and it always be off while the diesel engine is running. If the indicator lamp flashes or keeps on, it means that the oil pressure is low or there is no oil pressure. In this case, the diesel engine may be seriously damaged and it must be repaired immediately. Attention: The diesel engine running in the low engine oil pressure condition may cause serious mechanical damage.

Fig. 2-8-25 Installing the oil filter

(1) When the low oil pressure indicator lamp flashes or keeps on, park the vehicle in a safe place and stop the engine. (2) Let the vehicle rest for several minutes. Open the engine hood and check the oil level. (3) Add oil to make the oil level back to the upper scale mark on the dipstick if necessary. (4) Start the diesel engine and observe the low oil temperature indicator lamp, stop the diesel engine if the lamp does not go out within 10 s. At this moment, the diesel engine has mechanical malfunctions and it should be repaired.

6. Technical Maintenance for Cooling System Fig. 2-8-26 Low oil pressure indicator lamp

6.1 When the diesel engine is running, there must be enough antifreeze and antirust fluid (coolant) to ensure the diesel engine can run properly. Check the coolant level every time before traveling, and replenish antifreeze and antirust fluid in time. See Fig. 2-8-27 If the coolant level in the fluid reservoir is at or lower than the lower limit (MIN) mark, add coolant and make the coolant level back to the upper limit (MAX) mark. Then close the fluid reservoir lid, and check if there is leakage. If the fluid reservoir is empty, it is required to check the level of the coolant in the radiator.

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Chapter II Technical Information of Engine Warning: Opening the radiator cover when the diesel engine has not been cooled completely may cause spraying of coolant and cause serious scalding. The engine and the radiator must be cooled before the radiator cover is opened.

Fluid reservoir

Fill coolant into the radiator (see Fig. 2-8-28): (1) Make sure that both the engine and the radiator are cooled.

Fig. 2-8-2 Checking the coolant level（for reference only）

(2) Press the radiator cover and rotate it in the anticlockwise direction, the radiator cover can be removed.

(3) The coolant level should reach the bottom of filler neck. If the coolant is not enough, add coolant.

Radiator cover

(4) Add coolant slowly to avoid coolant overflowing. Remove all the overflown coolant if the coolant overflows. (5) Close the radiator cover and tighten it. 6.2 Check the stopping or working conditions of the radiator at a low temperature ( lower than 90℃) and at a high temperature (higher than 90℃), send it for repair if any problem is found. See Fig. 2-8-29.

Radiator Water drain plug

Fig. 2-8-28 Radiator (for reference only)

6.3 Generally, the service life of the long-acting antifreeze and antirust fluid is 1 ~ 2 years, the fluid should be replaced when expired. When replacing the antifreeze and antirust fluid, run the diesel engine for 5 minutes after adding new fluid to make the system fill with the new fluid; stop the diesel engine and check the fluid level, add fluid if not enough. Attention: (1) Unprocessed hard water such as tap water, mineral water is not allowed for use. (2) Poor quality antifreeze and antirust fluid or mixture of different grades of antifreeze and antirust fluid is not allowed for use in order to prevent from corrosion.

Fan assembly

Fig. 2-8-29 Checking the radiator fan assembly

(3) If the antifreeze and antirust fluid loses, firstly, check if the density of the antifreeze and antirust fluid increases; if it does not, the loss is caused by leakage, then eliminate the leakage and add the same grade of antifreeze and antirust fluid in; if it increases, the loss is caused by water evaporation, add distilled water in. After adding distilled water or concentrated solution in and mixing it evenly, check the density of the antifreeze and antirust fluid again until it reaches the value corresponding to the freezing point required. Send it to a professional service station for check and maintenance in time if users do not have required conditions.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

7. Additional Maintenance in Severe Driving Conditions If your vehicle is driven in one or more of the following conditions, the distance/time for replacing the engine oil, oil filter and air cleaner should be shortened. Maintenance for other parts is carried out in accordance with the maintenance items in the typical driving conditions. Severe Conditions: A: The traveling distance is less than 8 km every time or less than 16 km at a temperature lower than the freezing point. B: Drive the vehicle in a hot ( higher than 35 ℃) condition. C: The vehicle continuously travels at the idle speed or intermittently ( stop-and-go) travels for a long time. D: The vehicle tows a trailer, or travels with luggage on the roof rack, or travels on a mountainous road. E: The vehicle travels on a muddy, dusty or frozen road. F: The vehicle travels more than 20000 km every year, or often travels at a high speed. Replace the oil filter

A, B, C, D, E

Per 5000 km or per 6 months (accumulative working time: 100 h)

Replace the air cleaner filter core

E, F

Per 5000 km or per 6 months (accumulative working time: 100 h)

8. Technical Maintenance During Storage If the storage period is less than 1 month, only technical maintenance is required to be carried out in accordance with the accumulative working time and traveling distance, special protection procedures are not required. If the diesel engine has been stored for more than 1 months, special sealing storage technical maintenance must be carried out carefully.

9. Precautions in Technical Maintenance (1) Users need to abide by the technical maintenance regulations and maintain the diesel engine according to the maintenance level, item and quality. Especially when the user is busy, the maintenance items are no allowed to be reduced and the maintenance cycle is not allowed to be prolonged. (2) The third level maintenance should be carried out indoors in order to prevent from dust. (3) For some complex maintenances or adjustments with higher technology requirements, send them to the professionals or Great Wall Baoding Combustion Engine Manufacturing Company.

Section IX Repair Process for Diesel Engine 1. Repair Process for Diesel Engine The repair process is comprised of a series of steps, as shown in Fig. 2-9-1.

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Chapter II Technical Information of Engine

Engine handover and exterior cleaning Removing Assembly components spare parts

Washing of spare parts

Qualified (available) spare parts

Parts need to be repaired

Scrapped parts

Repair and check for spare parts

Waste warehouse

Identification of spare parts

Combination Check and identification before assembling Assembling and testing spare parts components assembly Engine assembly Engine test run Delivery handover

Fig. 2-9-1 Steps of repair process for the engine

2. Engine Handover and Repair Class Identification 2.1 Engine handover for repair Before sending for repair, the user needs to thoroughly identify the technical conditions of the engine (vehicle) according to the service condition, relative technical records (vehicle files, etc.) and results of inspection under the condition of non-removing parts so as to make sure whether the engine (vehicle) needs to be repaired,. When the vehicle is handed over, the owner and the staff from the service station work together to check the engine and to define the repair class. Information about the engine completeness and the general technical conditions should be filled in the handover sheet.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 2.2 Engine repair class The engine (vehicle) repair class is divided into overhaul, minor repair, maintenance and adjustment. 2.2.1 Overhaul The overhaul is the regular repair. During the overhaul, thoroughly check the engine (vehicle), and repair or replace the parts which are overly worn. The performance of the engine which has gone through an overhaul should be equal or close to that of a new engine.

Fig. 2-9-2 Removing the parts on the cylinder

The overhaul should be carried out when the wear of the major parts reaches or is close to its limit; generally, you can make a repair plan according to the repair interval (e.g. the accumulative driving distance or the accumulative fuel consumption of the engine), but whether to repair depends on the technical condition determined according to inspection. 2.2.2 Minor repair The minor repair is balancing repair (or local repair), mainly aiming to the components or parts which are easy to wear. In order to balance uneven wear between parts of the engine, one or two minor repairs between two overhauls can ensure the engine to work properly within an overhaul cycle. The minor repair is also required to be carried out according to the repair interval (e.g. the accumulative driving distance or the accumulative fuel consumption of the engine). But whether to repair mainly depends on the engine's technical condition.

Fig. 2-9-3 Removing the electrical parts

The minor repair mainly aims at troubleshooting the engine, local inspection, adjustment and repair, and replacing the wearing parts. 2.2.3 Maintenance The maintenance refers to replacing the worn parts in order to remove the malfunctions and local damage caused during the use of engine. Different from the minor repair, the maintenance only aims at troubleshooting, keeping relevant parts or the assembly working properly, there is no need to recover the technical performance index of a certain part or the assembly. 2.2.4 Adjustment The adjustment refers to readjusting the worn or disordered parts in order to remove malfunctions caused during   the   use   of   engine.   Generally,   there   isn’t   much   removing work on the engine.

Fig. 2-9-4 Washing the diesel engine

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3. Exterior Washing for the Engine After reception of the engine, move it to the location for

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter II Technical Information of Engine exterior washing (in a cold season, first move it to a warm room for a day to melt the frozen fouling) and then wash it. 3.1 Drain out the lubricating oil (oil pan) and replace it with diesel to wash, then drain out the diesel. 3.2 Drain out the fuel and coolant. 3.3 Remove the electric devices such as the generator and starter, the parts of turbocharger and electric control system. See Fig. 2-9-2 and Fig. 2-9-3. 3.4 Wash the exterior of diesel engine. See Fig. 2-9-4.Spray pressured water with a hose to wash the engine exterior, to do this, use a centrifugal water pump or plunger water pump and a water gun; the pressure of water flow should be 147 ~ 216 kPa. This washing process has a high quality, high efficiency and low water consumption. It is recommended to recollect the washing water and reuse it for the purpose of environment protection and water conservation.

Section X Technical Requirements for Engine Removal and Reinstallation 1. General Technical Requirements for Assembling Assembling is to connect the engine parts in accordance with technical requirements, keep the parts in the correct positions and connecting relationship. Oil

Repair the abnormal parts immediately

Fig. 2-10-1 Assembling according to technical requirement

1.1 The spare parts assembled should be those manufactured according to the drawings and technical conditions of GW4D20／GW4D20B turbocharged diesel engines approved by our company, and their materials, metallurgical structures, performances, geometrical shapes, dimensions, positions, fitting, tightening torque, sealing, and reliability should comply with the requirements. 1.2 The spare parts assembled must be tested by the quality control department. “Caution”:   The   spare   parts   must   be   checked   seriously before assembled, do not assemble unqualified parts to avoid wasting time. 1.3 The parts must be washed and the edge or burr must be removed before the parts are assembled; the cleanness of the part should comply with relevant technical documents. 1.4 The assembling location, instruments, tooling and measuring apparatus should be cleaned; the staff getting Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES into the assembling location should be clean in order to maximally reduce impurities and dust brought into the location. 1.5 The assembling sequence should comply with the flow process   and   abide   by   the   rule   of   “from   interior   to   exterior”   and   “from   parts   to   assemblies”(parts→   components→assemblies→complete  machine). 1.6 In order to improve the assembling efficiency, parts should not be assembled on the assembling line if it can be assembled on the component.

Fig. 2-10-2 Tightening sequence for the fasteners

Indicating type torque spanner

Scale indicating type torque spanner

Fig. 2-10-3 Torque spanner

1.7 Combination of the spare parts should strictly comply with relative technical documents. The combination of the spare parts which are classified by size or quality should strictly comply with provisions. 1.8 All parts subjected to static balance test and dynamic balance test should be balanced, or else they are not allowed to be installed. 1.9 Fasteners should be tightened in accordance with tightening specifications. The fastener tightened with plastic zone tightening angle process should not be reused to ensure reliable connection of the connectors. Generally, the tightening sequence should be from center to two ends and from interior to exterior; the parts should be tightened diagonally. The tightening torque for fasteners of diesel engine are listed in Table 2-6-1, Table 2-6-2, and the fastener should be tightened as the sequence showed in Fig. 2-10-2.In order to avoid missing tightening, important fasteners which have been tightened should be marked. “Caution”:  Tightening  torque for the fastener should strictly comply with relative specifications, and use the torque spanner strictly according to technical requirements (see Fig. 2-10-3). 1.10 When assembling, fill or apply API CI-4 engine oil on the friction surfaces of dynamic matching parts (see Table 2-6-7)The thread engagement of fasteners should be lubricated with a proper amount of oil. See Fig. 2-10-4.

Front end

Lubricate it with engine oil.

Fig. 2-10-4 Applying a proper amount of lubricating oil to fasteners

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1.11 Water/air tight junction surfaces should be clean. Damage, oil dirt and dust which affect tightness are not allowed. Apply sealant in accordance with requirements (see Table 2-6-8). Apply a proper amount of lubricating oil to oil groove at the lip of oil seal assembly, and assemble it with guide tools. It is not allowed to damage the lip in order to ensure tightness. 1.12 The assembling position, sequence and matching of the parts should be correct; interference, missing assembling and wrong assembling are not allowed.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter II Technical Information of Engine 1.13 The moving parts should be flexible without seizure and bumping. 1.14 The spare parts should be handled gently during assembling; bumping and scratching are not allowed. For the electric control sensor, actuator and fuel injector, dropping, pressing and wetting are not allowed.

2. General Technical Requirements for Removal 2.1 The removal is the first step for the repair work. The purpose is to check and repair damaged parts. Fig. 2-10-5 Understanding the structure of the diesel engine

First, make clear the structures and characteristics of GW4D20／GW4D20B turbocharged diesel engines, and make clear the removing procedure and method to avoid damage of spare parts. See Fig. 2-10-5. 2.2 The removal should be carried out in a proper sequence. Generally, the rules for removal include from the complete machine to assemblies, from assemblies to components, from components to parts, from accessories to main parts and from exterior to interior. “Caution”:   In   order   to   remove   correctly   and   efficiently, it is necessary to make clear the structure of the GW4D20／GW4D20B turbocharged diesel engine first. 2.3 For the parts whose technical conditions are normal and can be judged without removal, it is unnecessary to remove them. But for the parts whose technical conditions are hard to define without removal, it is necessary to remove them for further examination and repair.

Fig. 2-10-6 Using special tools

2.4 Appropriate tools should be selected when the parts are removed in accordance with their structures. Fierce knock is not allowed to avoid damage and deformation of the parts. In order to improve efficiency, use special tools. See Fig. 2-10-6. When the bolts and nuts are removed, the proper sized fixed spanner should be selected, it is not recommended to use the adjustable spanner or randomly extend the torque for the spanner. Fig. 2-10-7 Marking the parts with positional, optional, directional and matching requirements

2.5 For the parts which have positional, optional and directional requirements such as main shaft bearing shells, valves, pistons and connecting rods, etc., in order to improve the assembling efficiency and ensure correct assembling, they should be marked on the non-working face in accordance with specific conditions. 2.6 The parts removed should not be left about or piled up, they should be classified and stored in accordance with their materials, sizes, shapes and precisions so as to avoid damage or missing and facilitate the next process.

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Section XI Special Tools and Instruments for Repair When adjusting, testing, maintaining, repairing, removing, assembling the diesel engine, you may use special tools, instruments and devices in order to conveniently and quickly remove and reinstall the spare parts, examine the spare parts and define malfunctions,. This will not only avoid damage, but also ensure service quality. Table 2-11-1 Special tools and instruments for repair Tool and Instrument Name

Tool and Instrument Code

Remarks

Crankshaft timing pulley puller

5-8840-2035-0

Crankshaft timing pulley installer

5-8522-0024-0

Valve spring compressor

9-8523-1423-0(J-29760)

See Page 106, 122, 127, 218

Valve oil seal remover

5-8840-0373-0

See Page 122, 219

Valve oil seal installer

5-8840-2033-0

See Page 106, 126, 219

Piston ring compressor

5-8840-9018-0

See Page 136,150,166,257,276,290

Tachometer

5-8840-2093-0

Valve guide replacer

5-8523-1212-0

Camshaft timing pulley puller

5-8840-0086-0

Rubber hardness tester

5-8840-0199-0

Compressed pressure gauge

5-8840-2008-0(J-27762)

Pressure gauge connector

5-8531-7002-0

Measuring device

5-8840-0145-0

Oil filter spanner

5-8840-0020-0

Goniometer

5-8840-0266-0

Oil injector tester

5-8840-9016-0

Oil injector body remover

5-8840-2034-0

Bearing replacer

5-8840-2038-0

Radiator water inlet cover tester

5-8840-2036-0

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See Page 163, 168, 238, 239

See Page 48, 329, 330

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Chapter II Technical Information of Engine

Tool and Instrument Name

Tool and Instrument Code

Remarks

Oil filter spanner

5-8840-0253-0(J-22700)

See Page 47, 308, 309

Front oil seal remover

5-8840-2362-0

See Page 130,158,163,264,273,286, 336

Front oil seal installer

5-8840-2361-0

See Page 166, 245, 290, 336

Rear oil seal remover

5-8840-2360-0

See Page 131,164,268,274,287

Rear oil seal installer

5-8840-2539-0

See Page 135, 268, 275, 289

Slide hammer

5-8840-0019-0

See Page 241

Transmission first shaft front bearing remover

5-8840-2000-0

See Page 241

Transmission second shaft front bearing remover

5-8522-0024-0

See Page 242

Guide centering device

5-5825-3001-0

See Page 242, 268, 269, 286

Fuel injection system measuring device

0-986-613-100

Oil return amount measuring device

0-986-612-900

KTS 650 diagnostic apparatus

0-986-612-901

See Page 86

The special tools listed in this manual are for reference only; users may purchase appropriate special tools in accordance with maintenance requirements.

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Section XII Repair Operation for Engine Attention: The general repair operation should be done by qualified maintenance personnel.

1. Model Mark Engine number The diesel engine number is printed on the central front of left side of cylinder body, as shown in Fig.2-12-1. Example of the engine number printed on cylinder body:

Model number

Position of model mark

Fig.2-12-1 GW4D20 turbocharged diesel engine assembly

Asterisk

Year

Month

Sequence number

Asterisk

2. Air Cleaner Dry paper filter core Cleaning methods may differ according to filter core conditions. Filter core blocked by dust Filter core of air cleaner

Fig.2-12-2 Cleaning the filter core of air cleaner

Move the filter core with hands and blow the filter core from the inner side to the outer side with compressed air, the dust will be removed by doing this. See Fig.2-12-2. Caution: Do not blow the filter core from the outer side to the inner side with compressed air; if so, the dust will enter the interior of filter core (clean face). The pressure of compressed air 392 ～ 490 kPa

Cleaner cover

Caution: Do not strike the filter core on other objects to clean the filter core, if so, the filter core will be damaged. If the following cases appear, the filter core should be replaced:

Cleaner housing

——the filter core is contaminated by carbon deposit or grease. ——the filter core is seriously contaminated, and the contamination is hard to remove.

Fig.2-12-3 Washing the air cleaner cover and housing

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——the filter core is deformed and damaged.

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Chapter II Technical Information of Engine When replacing or cleaning filter core, clean the inside of air cleaner housing. See Fig. 2-12-3.

Cylinder body

Caution: (1) The paper filter core is not allowed to be washed with oil or fresh water, or else the filter core will be contaminated and blocked by dust very easily, and this will cause insufficient air intake; as a result, power loss and black smoke in exhaust may result. Oil filter

(2) The tightness at the joint between the air intake tube and air cleaner must be checked regularly. If leakage is found, the packing and tightening connector should be replaced to avoid abnormal wear of the diesel engine.

Fig.2-12-4 Maintaining the oil filter

3. Lubrication System Oil filter Caution: The oil filter is disposable and is not allowed to be reused. Replacing Sequence: (1) Protect the generator with plastic cloth or paper boards. Loosen the oil drain plug to drain out the oil. Fig. 2-12-5 Applying a thin layer of oil to the new filter core O-ring before assembling

Warning: Collect the used oil, and dispose it properly to protect the environment. (2) Retighten the oil drain plug after several minutes. (3) Unscrew the used oil filter in the anticlockwise direction with a filter spanner.

Special tool

(4) Clean the matching surface of engine oil cooler, this will make the oil filter installed properly. (5) Apply a thin layer of oil to the O-ring. See Fig. 2-12-5.

Removing and reinstallation with a special tool

API CI-4 lubricating oil produced by Mobil Oil Company.

Fig. 2-12-6 Removing and reinstalling the oil filter

(6) Screw into the new oil filter until the filter O-ring fits into the sealing face. (7) Screw the filter with a filter spanner for 3／4 ~ 1 circle, as shown in Fig. 2-12-6. Oil filter spanner: 5-8840-0020-0. After the assembling, there should be no leakage at the filter sealing ring. (8) Check the oil level in the engine lubrication system with an engine oil dipstick (see Fig.2-12-7), add oil till it reaches the specified level if necessary.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES It is recommended to use APlCl-4 or above diesel engine oil produced by Mobil Oil Corporation.

Engine oil dipstick Engine oil dipstick guide pipe

Start the diesel engine and check if the lubrication system works properly, and check if there is leakage in the oil filter.

Upper scale Lower scale

Fig.2-12-7 Checking the oil level in the diesel engine

4. Fuel System

Hand fuel pump

Oil inlet pipe connector Cartridge and filter core

Fuel filter Oil return hose connector Electric connector

Water drain plug

Fig. 2-12-8 Fuel filter

Caution: The fuel filter is disposable and is not allowed to be reused. The cartridge and filter core of the fuel filter assembled on the CW4D20／CW4D20B turbocharged diesel engine is integral; when they are replaced, the whole filter assembly should be replaced. Replace the fuel filter regularly in accordance with technical Maintenance requirements. Replacing Sequence: (1) Loosen the fuel filter in the anticlockwise direction with a filter spanner. Fuel filter spanner: 5-8840-0253-0. (2) Clean the matching surface of the upper cover of the fuel filter. (3) Install a new fuel filter and tighten it until it contacts with the sealing face.

Fig.2-12-9 Water level indicator lamp of water-fuel separator

(4) Screw it for additional 3/4 ～ 1 circle with a filter spanner. (5) Operate the hand fuel pump several times and check if there is fuel leakage. Attention: It is recommended to use the original fuel filter produced by our company. Water drain sequence for the fuel-water separator When the water content in the fuel-water separator exceeds the specified value, the indicator lamp on the instrument panel will light up. See Fig. 2-12-9. Drain the water and other impurities in the fuel-water

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Chapter II Technical Information of Engine separator in the following sequence. (1) Park the vehicle in a secure and flat location. (2) Open the engine hood and place a container (volume: about 0.2 L) under the hose end of fuel-water separator. (3) Loosen the water drain plug (about 5 circles) and press the hand fuel pump for about 10 times to drain out about 0.1L of water, as shown in Fig. 2-12-10. Loosen the drain plug in the anticlockwise direction

Fig.2-12-10 Drain the water with the fuel-water separator (4) Tighten the water drain plug immediately after draining and pressing the hand fuel pump several times, as shown in Fig.2-12-11. After starting the diesel engine, check if there is water leaked from the water drain plug; meanwhile, check if the indicator lamp of fuel-water separator has gone out. Tighten the drain plug in the anticlockwise direction

Fig.2-12-11 Checking after draining water

Attention: If there is too much water in fuel, it indicates that the fuel is not qualified. If there is water deposit, remove it in time.

5. Cooling System 5.1 Coolant level

Fluid reservoir

Check the coolant level, and fill the fluid reservoir (water tank) if necessary. If the coolant level is lower than the “MIN”   scale   mark,   check   carefully   if   there   is   leakage   in   the cooling system. Then add coolant until the coolant level is between the lower limit(MIN) and the upper limit (MAX). See Fig. 2-12-12. Close the fluid reservoir cover after adding coolant.

Fig. 2-12-12 Checking the coolant level in the fluid reservoir (for reference only)

Attention: (1) Do not overfill the fluid reservoir. (2) The radiator water filler cover can only be opened when absolutely necessary.

Freezing point

Warning: (1) Checking coolant level should be carried out when the engine is cold. Mixing ratio(%)

Fig. 2-12-13 Mixing ratio of coolant

(2) The coolant is poisonous, thus must be stored in the original container to avoid the direct touch from human. It is recommended to use the coolant produced by our company. When replenishing coolant, never add any antirust additive or other additives into the cooling Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES system. Because they may be incompatible with the coolant or engine parts. See Fig. 2-12-13 to determine the correct mixing ratio of coolant and water. 5.2 Check for the cooling system Mount the radiator tester on the radiator. Apply the test pressure to the cooling system to check leakage. See Fig. 2-12-14. The test pressure should not exceed the specified pressure. Fig. 2-12-14 Checking the cooling system with a tester

196 kPa 5.3 Check for the radiator cover The radiator filler cover is designed to keep a 88 ~ 118 kPa pressure in the cooling system. Check if the filler cover meets requirements with a radiator filler cover tester. See Fig. 2-12-15. During testing, the radiator filler cover must be replaced if it cannot keep the specified pressure. Design pressure of the radiator filler cover

88～118 kPa

Pressure valve Fig. 2-12-15 Checking the water filler cover with a tester

Negative pressure valve (reference value)

1.0 ～3.9 kPa

Radiator filler cover tester: 5-8840-2036-0. 5.4 Check for the thermostat mounting assembly 5.4.1 Check for the thermostat cover and thermostat Check if the thermostat cover and thermostat are deformed; they must be replaced if deformed. 5.4.2 Operation test for the thermostat (1) Dip the thermostat completely in water. (2) Heat the water and stir it to avoid direct heating to the thermostat.

Fig. 2-12-16 Checking the lift of thermostat valve

(3) Observe temperature changes through the thermometer in the water; check the initial opening temperature of the thermostat. Initial opening temperature of the thermostat 76 ℃ ± 2 ℃ (4) Check the temperature when the thermostat is completely opened. See Fig. 2-12-17. Temperature when the thermostat is completely opened

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Chapter II Technical Information of Engine 88 ℃ The thermostat should be replaced if the opening temperature of valve is not correspondent with provisions. (5) Check the lift when the valve is completely opened. See Fig. 2-12-18. Lift when the valve is completely opened When the water temperature is at 88 ℃ >8.5 mm If the lift of thermostat is not correspondent with provisions, the thermostat should be replaced.

Fig. 2-12-17 Checking the opening temperature of thermostat valve

(6) Check if the valve is closed when the thermostat is at a low temperature. The thermostat should be replaced if the valve cannot be closed. Valve size when completely opened

(7) Check if the thermostat rubber sealing ring is aged and deformed; the sealing ring should be replaced if it is aged and deformed.

6. Engine Control 6.1 Check idling speed

The lift of valve should be at least 8.5 mm when the water temperature is 88 ℃

Fig. 2-12-18 Checking the lift of thermostat valve

(1) Operate the parking brake and brake the driving wheels (2) Place the transmission to neutral gear. (3) Start the diesel engine and heat it. (4) Remove the diesel engine control cable from the control rod. (5) Mount the tachometer on the diesel engine. Check the idling speed of the diesel engine: if the idling speed exceeds the specified range, it should be adjusted in the service station authorized by our company.

Fig. 2-12-19 Adjusting the idling speed

Idling speed of the diesel engine 750 r/min ± 50 r/min

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 6.2 Adjustment to the throttle control cable (1) Loosen the throttle wiring bracket bolt. (2) Check if the idling control button is located in the idling position of diesel engine. (3) Make sure that the throttle connecting rod is completely closed, and then tighten the control cable to remove looseness. 6.3 Adjustment to throttle pedal (1) Loosen the lock nut. Fig. 2-12-20 Adjusting the throttle pedal

(2) Adjust the height between bolt and base plate. Adjust the height between bolt and base plate. 18 ～ 28 mm (3) Check if the throttle pedal is 5 ～ 10mm upper the pedal buffer. See Fig. 2-12-20. (4) Press the throttle to its end and check if the diesel engine operates at the highest speed and check if all connections operate stably.

7. Quick start-up system Checking procedure for the quick start-up system II: Fig. 2-12-21 Measuring the voltage at the glow plug end with a universal meter

(1) Place the start-up  switch  to  the  “OFF”  position. If the quick start-up system II works formally, the glow relay will give clicking sounds within 15 s after the switch is connected. (2) After the start-up   switch   is   switched   to   the   “OFF” position, measure the voltage at the glow plug end with a universal meter. Voltage at the glow plug end About 12 V

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Chapter II Technical Information of Engine

Section XIII Engine Parts and Tightening Torques 1. Engine Bracket Mounting Assembly

Cylinder body assembly

Cylinder body assembly

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2. Cylinder Body Mounting Assembly

Cylinder body component

Sectional view of the upper cylinder body

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Chapter II Technical Information of Engine

3. Cylinder Body Component

Upper cylinder body

Crankshaft

Lower cylinder body

Step 1

Step 2

Step 3

Turn for 90° Turn for 90° again

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4. Cylinder Head Mounting Assembly ——1

DELPHI cylinder cover assembly

BOSCH or XINFENG cylinder cover assembly

BOSCH or XINFENG cylinder head

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Chapter II Technical Information of Engine

5. Cylinder Head Mounting Assembly ——2

DELPHI camshaft bearing cap

BOSCH or XINFENG camshaft bearing cap

Cylinder head assembly

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6. Cylinder Head Mounting Assembly ——3

Step 1

Step 2 Turn for 90° ± 5°

Step 3 Turn for 120° ± 5°

Step 1

Step 2 Turn for 90° ± 5°

Step 3 Turn for 120° ± 5°

Camshaft bearing cap

Cylinder head

Cylinder head gasket

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7. Piston Connecting Rod Mounting Assembly

Step 1

Step 2 Turn for 90° ± 5°

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8. Crankshaft Flywheel and Clutch Mounting Assembly

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Chapter II Technical Information of Engine

9. Air Intake and Exhaust Systems Mounting Assembly ——1

DELPHI air intake manifold pipe

BOSCH or XINFENG air intake manifold pipe

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10. Air Intake and Exhaust Systems Mounting Assembly ——2

Cylinder head mounting assembly

Air intake manifold pipe

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Chapter II Technical Information of Engine

11. Oil Pan and Engine Oil Collector Mounting Assembly

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12. Engine Oil Pump Mounting Assembly

Cylinder body assembly

Engine oil pump mounting assembly

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Chapter II Technical Information of Engine

13. Engine Oil Cooler and Cooling Pipelines Mounting Assembly

Upper cylinder body

Engine oil filter mounting assembly

Engine oil cooler mounting assembly

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14. Timing Mechanism Mounting Assembly ——1

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Chapter II Technical Information of Engine

15. Timing Mechanism Mounting Assembly ——2

BOSCH or XINFENG crankshaft timing belt pulley component

DELPHI crankshaft timing belt pulley component

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16. Fuel Supply System Mounting Assembly ——1

①

Note: ① DELPHI fuel supply system mounting assembly.

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Chapter II Technical Information of Engine

17. Fuel Supply System Mounting Assembly ——2①

Note: ① BOSCH fuel supply system mounting assembly.

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18. Fuel Supply System Mounting Assembly ——3①

Note: ① XINFENG fuel supply system mounting assembly.

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Chapter II Technical Information of Engine

19. Turbocharger Mounting Assembly ——1①

Note: ① VGT turbocharger mounting assembly.

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20. Turbocharger Mounting Assembly ——2①

Note: ① WGT turbocharger mounting assembly.

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Chapter II Technical Information of Engine

21. EGR System Mounting Assembly

Air intake manifold pipe

Cylinder head

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22. Electronic Control System Sensor

Cylinder body assembly

Crankshaft position sensor (XINFENG)

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Chapter II Technical Information of Engine

23. Generator Mounting Assembly

Cylinder body assembly

Generator belt

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24. Throttle Mounting Assembly

Exported AT vehicle model Air intake manifold pipe

Common vehicle model

Air intake manifold pipe

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Chapter II Technical Information of Engine

25. Thermostat and Water Pump Mounting Assembly

Cylinder body assembly

Thermostat shield

Cylinder body assembly

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26. Engine and Compressor Mounting Assembly

Cylinder body assembly

Cylinder body assembly

Lower cylinder body

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27. Vacuum Pump and Steering Pump Mounting Assembly

Cylinder head assembly

Cylinder body assembly

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Chapter III Malfunction Diagnosis and Troubleshooting Section I Troubleshooting When the diesel engine works, due to wearing, distortion, usage and improper maintenance and so on, the technical condition of each part will worsen gradually; when some technical indicators surpass the tolerant limits, it indicates that the diesel engine is malfunctioning. When a malfunction appears, the diesel engine may not work normally if the malfunction is not eliminated in time. In such a case, the dynamic and economical properties of the diesel engine will degrade and the operation performance will worsen. Moreover, the parts will be worn too early, and even accidental damage may result. Some malfunctions such as air presence in the fuel system, air cleaner blockage, and excessive looseness of the driving belt can be eliminated by necessary technical maintenance and adjustment. While some malfunctions such as damage of the cylinder head gasket, serious wear of the piston ring, valve taper face and timing belt, and excessive wear of the bearing shell can not be eliminated by general maintenance and adjustment due to the defects in relevant mechanisms. In order to eliminate such malfunctions, it is necessary to remove and repair the diesel engine or replace the parts involved.. Principles for malfunction diagnosis and elimination (1) Diesel engine malfunctions are usually caused by improper operation or deficient maintenance. When a malfunction appears, first check if the operation and maintenance regulations are carried out seriously. (2) Eliminate the malfunction in time. First check carefully and analyze the cause of the malfunction, do not remove any part blindly. (3) The diagnosis and elimination for complex malfunctions should be done by professional persons by means of appropriate apparatus and specialized equipment. If the user can not judge or cope with the malfunction, please contact the authorized service station of our company (4)  Only  if  the  diesel  engine  is  in  good  technical  condition  can  it  go  on  working;;  working  in  “ill”  technical   condition is not allowed. For in such condition, the parts will wear rapidly and the service life of the whole vehicle will shorten. Even malignant accidents may be aroused. Precautions for malfunction diagnosis and elimination. (1) Do not start the diesel engine when the storage battery is not connected. (2) Do not disconnect the storage battery from the internal circuits of the vehicle when the diesel engine is running. (3) The polarities of the storage battery and the control unit should not be matched reversely. (4) Always start the diesel engine with the help of storage battery other than the quick start-up device. (5) Always remove the vehicle storage battery before charging it. (6) Remove or insert each kind of plug of the electrical control circuit only under the condition that the storage battery is disconnected (the ignition switch is off). (7) Diagnose the electronic control diesel engine with suitable equipment as required by the manufacturer. The diagnostic equipment should be earthed with the cylinder body of diesel engine during diagnosis. (8) Do not use traditional methods to diagnose the new type of electronic control diesel engine. (9) The diagnostic equipment and the control unit of the diesel engine should be connected properly. (10) Anti-source diagnostics is often applied to the electronic control diesel engine system, and its process is: first use the diagnostic equipment to find out the possible cause, and then find the exact position from the peripheral equipment to the control unit gradually and eliminate the malfunction at last.

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Chapter III Malfunction Diagnosis and Troubleshooting

1. Failure to Start the Diesel Engine Phenomenon and Cause of Malfunction (1) Wrong wiring or poor contact in circuits Electrical System

(2) Insufficient storage battery

power in

the

(3) Poor contact between the carbon brush and the commutator of starter (1) Air in the fuel supply system (3) Fuel filter blockage (4) No oil supply or discontinuous oil supply in the fuel delivery pump

Fuel Supply System

(5) Malfunction in the electronic control parts of fuel supply system

Troubleshooting (1) Check whether the wiring is correct and firm. (2) Check the specific gravity of electrolyte, the voltage of storage battery, and charge the storage battery according to the technical requirements if necessary. (3) Repair or replace the carbon brush, clean the surface of the commutator with water abrasive paper and blow it clean. (1) Check whether the connectors of fuel supply pipelines are loose, remove the connector of the high pressure fuel pump fuel return hose, supply fuel with the manual fuel delivery pump until the overflowed fuel is air bubble free, then install the fuel return hose. (2) Check whether the pipeline of fuel supply system is smooth. Replace the fuel filter (4) Check whether the fuel inlet pipe is leaking and whether the filter screen on the fuel inlet pipe connector is blocked, reinstall the screen after eliminating the blockage. (5) See Subsection 11 of this chapter for troubleshooting the fuel supply system (see Page 86 ~ 88).

Mechanical System

(1) Excessive wear of the piston ring (2) Air leakage in the valve

(1) Replace the piston ring (2) Check the sealing performances of the valve spring, the valve guide and seat, examine and repair them when the sealing performances are poor and grind the valve and valve seat if necessary.

2. Difficulty in Starting the Diesel Engine at a Low Temperature Phenomenon and Cause of Malfunction

Troubleshooting

Fuel

Failing to select the motor diesel (fuel oil) as required in winter or severe cold areas, or the diesel oil getting thick and frozen at a lower temperature.

Select the motor diesel (fuel, GB19147 ——2009) with a low freezing point according to the working temperature of the diesel engine.

Lubricating Oil

Failing to select the engine oil as required in winter or severe cold areas, or the engine oil getting excessively sticky and the internal frication increasing at a low temperature, or the starting resistive torque of diesel engine increasing.

Select the engine oil with a low viscosity according to the working temperature of the diesel engine in order to reduce the power required when starting. (the engine oil above APl CI – 4 of Mobil Oil Corp. is recommended)

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Battery

Failing to select the storage battery as required in severe cold areas; the battery capacity lower than 100 Ah.

Select the low temperature storage battery with the capacity higher than 100 Ah according to the working temperature of the diesel engine.

Oil Supply System

See Subsection 11 of this chapter for positions and phenomena of malfunctions in the oil supply system.

(5) See Subsection 11 of this chapter for troubleshooting the oil supply system. (see Page 86 ~ 88)

3. Insufficient Power in the Diesel Engine Insufficient power in the diesel engine means that the power of the diesel engine fails to meet the design requirements, and a lack of power appears when the vehicle carries heavy load or climbs an abrupt slope, and the diesel engine tends to stall. Insufficient power in the diesel engine always comes with and has a close relation with difficult engine start-up, you should refer to each other for analysis. Phenomenon and Cause of Malfunction Malfunction in the oil supply system: failing to increase the power or rotation speed after stepping on the gas.

See Subsection 11 of this chapter for positions and phenomena of malfunctions in the oil supply system.

Malfunction in air intake and exhaust systems: exhaust temperature higher than the normal one and poor exhaust gas color.

(1) Air cleaner blockage

The performance of each rotation speed getting worse

(2) Blockage in exhaust pipes or excessively long connecting tubes, too small turning radius and too many elbows.

(1) Malfunction in the oil supply system (2) Air leakage in the valve

(1) Overtemperature of coolant Overheat of Diesel Engine

(2) Overtemperature of engine oil (3) Overtemperature of exhaust air (4) Malfunction in the oil supply system

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Troubleshooting See Subsection 11 of this chapter for troubleshooting the oil supply system.(see Page 86 ~ 88)

(1) Clean the dust in the filter core of air cleaner, replace it if necessary. (2) Eliminate the carbon deposit in the exhaust pipe; and reinstall the exhaust connecting pipe with its elbows no more than 3, and the exhaust cross section should be big enough. (1) See Subsection 11 for troubleshooting of “insufficient power within all ranges pf the diesel engine”  in  the  oil  supply  system. (2) Check the sealing spring, the valve guide repair them when the poor and grind the necessary.

performances of the valve and the seat, examine and sealing performances are valve and valve seat if

(1) Check the coolant system, eliminate the encrustation and test the thermostat. (2) Check the capacity of engine oil, add oil in the engine if insufficient; if the shaft bearing shell or some moving parts heat, find out the position and the cause of heating, and eliminate it. (3) Check the injection pressure and atomization situation of the fuel injector.

the

(4) See Subsection 11 in this chapter for troubleshooting the oil supply system. (see Page 86~88)

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Chapter III Malfunction Diagnosis and Troubleshooting

Malfunction in cylinder head components: insufficient power, poor performance, air leakage, black smoke and abnormal knocking sounds.

(1) Air leakage in the junction surface of the cylinder head and the cylinder body; loose cylinder head bolt or damaged cylinder body gasket. (2) Loose air intake and exhaust valves (3) Air leakage in the fuel injector hole or damaged copper gasket

(1) Screw up the cylinder head bolt according to the specified torque or replace the cylinder head gasket. (2) Remove and check the air intake and exhaust valves, repair or grind the valve or the matching surface of the valve. (3) Remove the fuel injector for repair, clear up and replace the damaged parts.

Malfunction in the crank connecting rod mechanism

Seizure between the connecting rod small end bushing and the piston pin

Remove the oil pan, check whether the connecting rod big end is axially wobbling, if not, remove the piston connecting rod components for examination and repair.

High pressure oil pump, fuel injector

Malfunctioning high pressure oil pump and fuel injector

Examine and repair or replace the high pressure oil pump and the fuel injector

Malfunction in the pressure sensor of high pressure oil track

Damaged pressure sensor of high pressure oil track

Replace the pressure sensor of high pressure oil track

Turbocharger

Air leakage or failure in the air outlet pipe of turbocharger

Tighten up the connecting air outlet pipe of turbocharger or replace the connecting piece

4. Excessive Fuel Consumption of Diesel Engine Part, Phenomenon and Cause of Malfunction

Troubleshooting

Fuel system

Fuel leakage

Examine and repair, and replace the relevant parts in the fuel system if necessary

Air cleaner

Blockage in the air cleaner elements

Clean or replace the air cleaner elements

Fuel injector and control circuits

Poor fuel injection or poor controlling for fuel injection

Check the fuel injector and fuel injection control system

Compression pressure

Damaged cylinder gasket, sticky piston ring

Examine and repair, and replace the cylinder gasket and piston ring and relevant parts

Valve spring

Too loose or fractured valve spring

Examine and repair, and replace the valve spring

5. Abnormal Noise During the Diesel Engine Running First, identify the abnormal noise, whether the knocking noise is due to abnormal erupting or due to abnormal running of parts within the engine body. Then check and diagnose the noise source according

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Troubleshooting

(1) Malfunction in the fuel supply system

(1) See Subsection 11 of this chapter for relevant troubleshooting   of   “engine   knocking”   in   malfunctions in the fuel supply system (see Page 86 ~ 88)

(2) Slight but sharp noise now and then from the engine, and such noise is especially clear during idling, and sharper when you suddenly step on the gas.

(2) Replace the bush of the connecting rod small end, and make it within the specified clearance scope.

(3) Excessive clearance between the piston and the valve, knocking noise from the outside of the engine body during running, and such noise intensifies when the rotation speed increases.

(3) Replace the piston and piston ring

(4) Excessive matching clearance between the connecting rod bearing bush and the main bearing bush due to too much wearing, clashing noise from the engine parts at the running crankshaft, heavy and strong knocking noise during abrupt deceleration.

(4) Remove and check the connecting rod bearing bush, the main bearing bush, and replace them if necessary, and keep them within the specified matching clearance.

(5) The valve clashing with the piston; heavy, even and rhythmed knocking noise from the cylinder head during running.

(5) Find out the cause; check the valve timing; examine and repair the relevant parts.

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6. Abnormal Noise from Diesel Engine Check whether the diesel engine is adequately preheated before malfunction diagnosis. Phenomenon

Cause of Malfunctions (1) Inappropriate fuel

Sound of knocking the diesel engine cylinder

(2) Malfunction of the fuel injector or bad connection of the circuit (3) Damage of the cylinder gasket, breakage of the piston ring (4) Wrong output signal of the coolant temperature sensor, knocking the cylinder when the heater accelerates

Noise from gas leakage

Troubleshooting (1) Choose the specified fuel according to the ambient temperature. (2) Replace the fuel injector and fasten the cable connection. (3) Check the cylinder compression pressure and replace relative parts. (4) Replace the coolant temperature sensor.

(1) Loose connection and breakage of the exhaust pipe

(1) Fasten the exhaust pipe connection, replace the exhaust pipe.

(2) Looseness of the fuel injector and/or the glow plug

(2) Fasten the fuel injector and/or the glow plug, replace the gasket.

(3) Looseness of the exhaust manifold pipe

(3) Fasten the exhaust manifold pipe. (4) Replace the cylinder gasket.

(4) Damage of the cylinder gasket

Continual noise

(1) Wear or damage of the water pump bearing

(1) Replace the water pump bearing. (2) Replace or repair the generator.

(2) Damage of the generator

Slapping noise

(1) Looseness of the flywheel bolts

(1) Fasten the flywheel bolts..

(2) Damage or wear of the crankshaft and/or the thrust plate

(2) Replace the crankshaft and/or the thrust plate.

(3) Wear of the crankshaft and the connecting rod bearing shell

(3) Replace the crankshaft and/or the connecting rod bearing shell.

(4) Wear or damage of the connecting rod bushing and the piston pin

(4) Replace the connecting bushing and the piston pin.

(5) Wear or damage of the piston

(5) Replace the piston.

rod

7. Abnormal Smoke from Diesel Engine If the technical status of the diesel engine is fine, the exhaust emitted from the exhaust pipe should be colorless, or light blue and light grey when the engine is under normal load. The exhaust at the moment consists of carbon dioxide, vapor, a little carbon monoxide and non-completely burned lubricating oil (which makes the exhaust light blue or light grey). When the exhaust pipe of the diesel engine emits black, blue or white smoke, it means that the technical status of the diesel engine is abnormal.

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Phenomenon and Cause of Malfunction (1) Overload of the diesel engine (2) Malfunction of the oil supply system

Troubleshooting (1) Reduce the diesel engine load to the rated operating range. (2) See Chapter 11 for troubleshooting the oil supply system. (see Page 86 ~ 88) (3) Check the sealing taper face, abrade the valve seat if necessary.

Exhaust with black smoke

(3) Leakage of the exhaust valve caused by bad sealing (4) Insufficient inlet airflow, blockage of the air cleaner or the air inlet pipe (5) Severe wear of the cylinder hole and the piston ring

(4) Clear and wash off the dirt and foreign substances in the air cleaner, and replace the filter core if necessary. (5) Replace the piston ring. (6) Overhaul or replace the turbocharger.

(6) Malfunction or damage of the turbocharger

Exhaust with white smoke

(1) There is water in the cylinder or in the diesel

(1) Find out the cause of malfunction and resolve it.

(2) Insufficient combustion of fuel in some cylinders when the diesel engine is started

(2) Increase the rotation speed and load of the diesel engine properly, and run the engine longer.

(3) Malfunction of the oil supply system (1) Stuck or overly worn piston ring, insufficient elasticity; the chamfer of piston ring is reversely installed, leading to engine oil flowing into the combustion chamber Exhaust with blue smoke

(2) Long-term low load operation; big clearance between the piston and the cylinder hole, leading the engine oil slipping into the combustion chamber

(3) See Chapter 11 for troubleshooting the oil supply system. (see Page 86~88) (1) Check the piston ring, replace it if necessary. (2) Increase the load properly or repair the corresponding parts. (3) Examine with a dipstick and drain off the excessive oil.

(3) Too much oil added in the oil pan

8. Heavy Oil Consumption and Low pressure of the Diesel Engine Lubrication System In order to avoid seizure and early wear of components, the high speed rotating kinematic pairs of the diesel engine must be adequately lubricated to reduce the wear and take away the heat. Additionally, lubricating oil can be used to fill up the small clearance between kinematic pairs (such as the piston and the cylinder inwall) so as to enhance the sealing effect, stop the high pressure gas from leakage and make the diesel engine easy to start and maintain its original power. As a result, the pressure and the flow  of  lubricating  oil  are  required  to  be  at  certain  levels  (idle  speed  ≥  0.1  MPa, 0.35 ——0.55 MPa at other rotation speeds), and the lubricating oil should also be cleaned.

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Chapter III Malfunction Diagnosis and Troubleshooting Caution: It is strictly forbidden for a diesel engine to operate when there is no oil pressure or the oil pressure is low in the lubrication system, stop the vehicle and check to eliminate the malfunction immediately if it occurs. Phenomenon and Cause of Malfunction (1) Applied inappropriate oil (2) Invalidation and leakage of the sealing gasket and the oil seal High oil consumption

(3) Wear of the piston ring or the ring slot (4) Blockage of the piston ring (5) Wear of the valve oil seal, valve guide pipe or valve rod

Troubleshooting (1) Drain off the unqualified oil and fill with specified oil. (2) Replace the sealing gasket and the oil seal. (3) Replace the piston ring or the piston. (4) Replace the piston ring or the piston. (5) Replace the oil seal, valve or valve guide pipe. (6) Repair the cylinder aperture.

(6) Wear of the cylinder (1) Applied inappropriate oil (2) Blockage of the safety valve (3) Blockage of the oil collector (4) Wear of the oil pump rotor Too low oil pressure

(5) Breakage, crack or connector looseness of the oil pipe

(2) Replace the safety valve. (3) Wash or replace the meshy filter. (4) Replace the oil pump assembly. (5) Overhaul or replace the oil pipe.

(6) Malfunction of the oil pump

(6) Overhaul or replace the oil pump assembly.

(7) Over wear of the main shaft bearing shell or the connecting rod shaft bearing shell

(7) Replace the main shaft bearing shell or the connecting rod shaft bearing shell.

(8) Damage of the oil pressure alarm device Engine oil unable to reach the valve system

(1) Drain off the unqualified oil and fill with specified oil.

(1) Blockage of the oil hole on the cylinder body and the cylinder head

(8) Overhaul or replace the oil pressure alarm device. (1)

Wash or repair it.

(2)

Wash or repair it.

(2) Blockage of the rocker arm upper oil hole

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9. Abnormal Coolant Temperature, Lack of Coolant in the Diesel Engine Cooling System Phenomenon and Cause of Malfunction

Troubleshooting

(1) Low coolant level (lack of coolant) (2) Damage of the thermostat (3) Thermostat valve unable to be opened (4) Malfunction of the water pump (5) Malfunction of the oil supply system (6) Damage of the radiator cap or blockage of the radiator core Overheating diesel engine

(7) Damage of the coolant temperature sensor (8) Coolant leakage caused damage of the cylinder gasket

by

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(4) Overhaul or replace the water pump assembly. (5) See Chapter 11 for troubleshooting the oil supply system. (see Page 86~88) (6) Replace the radiator cap or the wash radiator. (7) Replace the coolant temperature sensor. (9) Replace the thermostat.

(10) Blockage of the cooling system caused by foreign materials

(10) Clean the cooling system.

(13) Low engine oil level or unqualified engine oil

Too long preheating time for the diesel engine

(3) Replace the thermostat assembly

(9) Damage of the thermostat

(12) Blockage of the exhaust system

Cooling system lack of water

(2) Replace the thermostat device

(8) Replace the cylinder gasket.

(11) Open circuit of the cooling fan, damage of the fan

Too cold diesel engine

(1) Refill coolant, check the cooling system for leakage and repair it if necessary.

(1) Damage of the thermostat valve or the thermostat valve unable to be closed (2) Malfunction water——thermometer

of

(11) Replace the cooling fan circuit or the fan. (12) Clean exhaust system. (13) Add or replace the engine oil, adjust the engine oil volume; it is recommended to use API CI-4 or better oil from Mobil Oil Corporation. (1) Overhaul or replace the thermostat. (2) Measure the coolant temperature and replace the water thermometer.

the

(1) Leakage of the radiator

(1) Repair or replace the radiator.

(2) Looseness of the radiator hose connector or damage of the hose

(2) Screw up the radiator hose connector clip or replace the hose.

(3) Leakage of the water pump

(3) Overhaul or replace the water pump assembly.

(4) Looseness of the heater hose connector or damage of the hose

(4) Screw up the heater hose connector clip or replace the hose.

(1) Damage of the thermostat

(1) Overhaul or replace the thermostat.

(2) Damage of the thermostat device

(2) Overhaul or replace the thermostat device.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chapter III Malfunction Diagnosis and Troubleshooting Caution: (1) It is not allowed to stop the diesel engine immediately or add coolant abruptly when the diesel engine is overheating. Reduce the throttle and let the engine run with no load; stop the engine for further inspection when the temperature of coolant in the cooling system is low. (2) Do not remove the water filler cap while the diesel engine is still hot to prevent scalding. Take care when adding coolant. (3) If the reason for overheat can not be found and eliminated, contact the service station or the repair factory, otherwise, it may cause damage to other parts.

10. Malfunction of the Diesel Engine Turbocharging System Phenomenon and Cause of Malfunction (1) Foreign materials in the oil depositing at the sealing area of the turbine side (2) Excessive engine oil temperature, insufficient oil supply, burning damage of the floating bearing (3) Blockage and deformation of the turbocharger oil return hose, leading to oil leakage from the turbo and the compressor shaft end Insufficient power

(4) Damage and malfunction of the turbocharger sealing ring (5) Turbo shaft rotor out of balance (6) Friction and damage of the turbo blades and the compressor blades (7) Blockage of the air cleaner (too dirty) (8) Too much dirt in the air intake/exhaust pipes or leakage at the joint part

Troubleshooting (1) Replace the engine oil, it is recommended to use API CI-4 or better oil from Mobil Oil Corporation, overhaul the turbocharger. (2) Check the oil supply system; overhaul the turbocharger. (3) Repair or replace the fuel return hose. (4) Replace the turbocharger sealing ring. (5) Replace the turbocharger assembly. (6) Replace the turbocharger assembly. (7) Maintain the air cleaner; replace the filter core. (8) Wash, overhaul or replace the air intake and exhaust pipe components. (9) Overhaul or replace the turbocharger.

(9) Bad performance or damage of the turbocharger

High fuel consumption

(1) Too much dirt in the air intake/exhaust pipes or leakage at the joint part

(1) Overhaul the air intake and exhaust pipes or replace the damaged parts.

(2) Bad performance of the turbocharger

(2) Wash, adjust turbocharger.

(3) Wear of the piston ring

or

replace

the

(3) Check or replace the piston ring.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (continued) Phenomenon and Cause of Malfunction

High oil consumption

Troubleshooting

(1) Wear and damage turbocharger sealing ring

of

the

(2) Oil leakage at compressor blades

end

of

the

(1) Replace the turbocharger assembly. (2) Overhaul.

(3) Looseness of screws at the joint part of the oil inlet pipe and oil return hose; damage of the gasket

(3) Overhaul the oil inlet pipe, oil return hose; replace the gasket. (4) Replace the engine oil as specified, it is recommended to use API CI-4 or better oil from Mobil Oil Corporation.

(4) Low oil quality (1) Too much oil dirt in the turbo end air passage, leading to obvious reduction of the air flow Abnormal sounds

(2) Too much oil dirt in the compressor end, leading to obvious reduction of the air flow

(1) Clean or replace it. (2) Clean or replace it. (3) Replace the turbocharger assembly.

(3) Excessive wear of the floating bearing; friction among the turbo, gas compressor impeller and housing Vibration caused by friction among the turbo, gas compressor impeller and housing

(1) Foreign materials in

(1) Clean or replace it.

(2) Excessive wear of the floating bearing

(2) Replace the turbocharger assembly. (3) Check, repair or replace it.

(3) Poor dynamic balance of the turbo shaft

Caution: (1) When the diesel engine is disassembled and reinstalled for troubleshooting, it is strictly forbidden to let foreign materials enter the air intake and exhaust systems. Since the turbocharger rotor rotates at an extremely high speed and the clearance between the rotor and the housing is very small, the rotor operation will be affected and the blades will be damaged as long as foreign materials enter the impeller despite of the size and the hardness of the foreign materials. When the blades are damaged, the turbocharger will vibrate abnormally and make noise. Stop the vehicle immediately and overhaul the turbocharger. (2) When oil leakage occurs in the turbocharger, do not replace the turbocharger hastily as long as the impeller  of  the  revolving  shaft  isn’t  rubbing  the  inner  housing  and  moves  smoothly.  The  turbocharger  can   still be used after the oil leakage malfunction is eliminated.

11. Malfunction of the Diesel Engine Oil Supply System Do not randomly disassemble and reinstall the electronic oil supply system because most parts are special precision pieces and rarely malfunction; if it is verified that a malfunction does exist, check and repair it in a professional service station. Check and inspection requires special testing equipment and special diagnostic apparatus. The model of diagnostic apparatus is KTS 650.Strictly follow the diagnostic principle and cautions during inspection.

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Position and Phenomenon of Malfunction (1) Anti-theft system

(1) Check the anti-theft system.

(2) Power supply voltage

(2) Check the power supply voltage.

(3) Main relay

(3) Check the main relay.

(4) Fuse connector

/

(5) Diesel sensor Diesel engine unable to be started

Troubleshooting

Connecting engine

cable

rotation

/

(4) Check whether the fuse / connecting cable / connector is firmly connected.

speed

(5) Check the diesel engine rotation speed sensor.

(6) No fuel or wrong fuel grade

(6) Add the specified grade of fuel.

(7) Air left in the fuel system

(7) Exhaust air from the fuel system.

(8) Blockage or leakage of the low pressure oil circuit

(8) Check the low pressure oil circuit.

(9) Preheat circuit (winter) (10) High pressure fuel pump or high pressure fuel rail pressure control device (11) Injector electromagnetic valve

(9) Check the preheat circuit (winter). (10) Check the high pressure fuel pump or the high pressure fuel rail pressure control device. (11) Check the injector electromagnetic valve. (12) Check the control unit.

(12) Control unit

Diesel engine stalls, but it can be restarted

(1) Looseness of the fuse / connecting cable /connector

(1) Check whether the fuse / connecting cable / connector is firmly connected.

(2) Ignition switch contactor

(2) Check the ignition switch contactor.

(3) Wrong fuel grade

(3) Add the specified grade of fuel.

(4) Blockage or overlow pressure of the low pressure oil circuit

(4) Check the low pressure oil circuit.

(5) Air left in the fuel system (reignite the low pressure oil circuit) (6) High pressure oil circuit (high pressure oil pump, pressure control device)

(5) Exhaust air from the fuel system. (6) Check the high pressure oil pump and the pressure control device. (7) Check the high pressure oil pump and the injector control circuit.

(7) High pressure oil pump and injector control circuit

Difficulty in starting the diesel engine

(1) Storage battery voltage

(1) Check the storage battery voltage.

(2) Starter

(2) Overhaul the starter.

(3) Relay and starting switch

(3) Overhaul the relay and the starting switch.

(4) Incorrect fuel

(4) Add the specified grade of fuel.

(5) Air left in the fuel system

(5) Exhaust air from the fuel system.

(6) Preheat system

(6) Check the preheat system.

(7)

Coolant

temperature

sensor

(7) Check the coolant temperature sensor

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (winter)

(winter).

(8) Blockage or overlow temperature of the low pressure oil circuit

(8) Check the low pressure oil circuit.

(9) overlow pressure of the high pressure oil circuit

(9) Check the high pressure oil circuit, high pressure fuel pump and pressure control device.

(10) High pressure fuel rail pressure adjustor

(10) Check the high pressure fuel rail pressure adjustor.

(11) Bad performance or control malfunction of the fuel injector

(11) Check or replace the fuel injector. (continued)

Position and Phenomenon of Malfunction

Troubleshooting

Diesel engine running at a high idle speed

Accelerator pedal position sensor

Check the accelerator pedal position sensor.

Cylinder knocking during warming-up or acceleration of the engine

(1) Coolant temperature sensor

(1) Check the coolant temperature sensor.

(2) Fuel injector connecting circuit

(2) Check the fuel injector connecting circuit.

(3) Malfunction of the injector

(3) Check or replace the fuel injector.

(1) Incorrect fuel

(1) Add the specified grade of fuel.

(2) Air left in fuel system

(2) Exhaust air from the fuel system.

(3) Blockage of overlow pressure of the low pressure oil circuit

(3) Check low pressure oil circuit.

Diesel engine wobble during idling

(4) Bad performance of the fuel injector (5) Fuel injector circuit (6) High pressure fuel rail pressure sensor, high pressure fuel rail pressure adjustor (7) High pressure fuel pump (1) Vacuum system (2) Blockage of the air cleaner

In sufficient power of the diesel engine in all ranges

(3) Incorrect fuel (4) Blockage of overlow pressure of the low pressure oil circuit (5) Failure of the turbocharger (6) Wrong position of the accelerator pedal position sensor or signal

102

(4) Check or replace the fuel injector. (5) Check the fuel injector circuit. (6) Overhaul the high pressure fuel rail pressure sensor, high pressure fuel rail pressure adjustor (7) Check and adjust the high pressure fuel pump. (1) Check whether the vacuum adjustor is normal. (2) Maintain or replace the filter core of air cleaner. (3) Add the specified grade (CBI9147-2009 motor diesel).

of

(4) Check the low pressure oil circuit. (5) Overhaul or replace the turbocharger.

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

fuel

Chapter III Malfunction Diagnosis and Troubleshooting problem (7) Malfunction of the exhaust gas bypass valve (8) Leakage of the turbocharger gas compressor (9) Coolant temperature sensor (10) High pressure fuel rail pressure sensor (11) Fuel injector, high pressure oil pump

Diesel engine exhausting white or blue smoke

(7) Overhaul the exhaust gas bypass valve. (8) Check the sealing condition of the turbocharger, replace the sealer if necessary. (9) Overhaul the coolant temperature sensor. (10) Overhaul the high pressure fuel rail pressure sensor. (11) Check and test the fuel injector and the high pressure oil pump.

(1) Coolant temperature sensor

(1) Check the coolant temperature sensor.

(2) Air left in the fuel system

(2) Exhaust air from the fuel system.

(3) Blockage of the low pressure oil circuit

(3) Check the low pressure oil circuit.

(4) Preheat system (5) Overhigh oil level of the lubrication system (1) Blockage of the air cleaner (2) Coolant temperature sensor

Diesel engine exhausting black smoke

(6) Adjust the position of the accelerator pedal position sensor.

(3) Malfunction of the turbocharger (4) Fuel injector and its control circuit (rare) (5) Vacuum pump

(4) Overhaul the preheat system. (5) Check the lubrication system oil level and drain off the excessive engine oil. (1) Maintain or replace the filter core of the air cleaner. (2) Check the coolant temperature sensor. (3) Check the turbocharger. (4) Check the fuel injector and its control circuit. (5) Check whether the vacuum system is normal.

Overheating diesel engine

(1) Incorrect fuel

(1) Add the specified grade of fuel.

(2) Coolant temperature sensor

(2) Check the coolant temperature sensor.

(3) Cooling fan

(3) Overhaul the cooling fan.

(4) Cooling fan circuit

(4) Overhaul the cooling fan circuit.

12. Diesel Engine Wobble During Idling Checking Item and Part

Cause of Malfunction

Troubleshooting

Fuel

Unqualified fuel

Replace it with the specified grade of fuel.

Fuel system

Air and water left in the fuel system

Exhaust air and water from the fuel system.

Low pressure oil circuit

Blockage or overlow pressure of the low pressure oil circuit; oil

Check, repair or replace the corresponding parts of fuel

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Fuel injector

Fuel injector circuit

High pressure fuel rail pressure sensor, high pressure oil rail pressure adjusting system

Mechanical part of the diesel engine

leakage or blockage of the fuel system

system.

Bad performance or blockage of the fuel injector

Replace the fuel injector. Whenever the fuel injector is replaced, it is required to input the 13C code of the new fuel injector into the ECU again.

Overlow pressure for injection and opening of the fuel injector

Check the high pressure fuel rail pressure or replace the fuel injector.

Bad control of fuel injection

Repair it after diagnosis, input the newly composed 13C code of the repaired fuel injector into the ECU.

Breakage of the fuel injector circuit

Check, repair or replace wire.

Looseness of the injector circuit

Fasten the fuel injector circuit.

Damage of the high pressure fuel rail pressure sensor

Replace the high pressure fuel rail pressure sensor.

High pressure fuel rail pressure adjusting system

Check the metering valve and the oil return valve, replace the damaged parts.

Damage of the cylinder gasket, gluing of the piston ring, excessive wear of the piston ring

Check or replace the cylinder gasket and the piston ring.

13. Diesel Engine Running at a High Idle Speed Checking Item and Part Pedal position sensor

Cause of Malfunction

Troubleshooting

Damage of the pedal position sensor

Replace the pedal position sensor and calibrate the ECU.

14. Starter not Working, Lacking Power, and Making noise Phenomenon and Cause of Malfunction (1) Disconnection of the control circuit such as the starter switch Starter not working

(2) Bad contact between the carbon brush and the commutator

Troubleshooting (1) Check whether the circuit is firmly connected. (2) Adjust the carbon brush spring pressure and clean the commutator. (3) Overhaul the starter.

(3) Open circuit or short circuit in the starter (continued)

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Chapter III Malfunction Diagnosis and Troubleshooting Phenomenon and Cause of Malfunction (1) Insufficient storage battery

capacity

Troubleshooting

of

the

(2) Screw up the wire joints.

(2) Bad contact of the wire Weak starting of the starter, unable to start the diesel engine

(1) Charge the storage battery as specified.

(3) Burning damage or oil stain on the commutator surface. (4) Excessive wear or insufficient elasticity of the carbon brush, leading to its poor contact with the commutator (5) Ablation and bad contact of the

(3) Polish the commutator surface or clean off the oil stain. (4) Replace the carbon brush or adjust the carbon brush spring pressure. (5) Polish the electromagnetic switch main contact with 0# non-metal abrasive paper.

(6) Check and replace the bearing.

electromagnetic switch main contact

(6) Excessive wear of the bearing, armature rubbing the shell Starter keeping rotating and making sharp noise after the diesel engine is started

(1) Adhesion of the copper contact disc in the starter relay with the two contacts (2) Breakage or bending of the starter armature shaft (3) Sticking or galling of the gear teeth face

(1) Disconnect the power supply immediately; check, fasten the circuit and repair the contacts. (2) Disconnect the power supply immediately and replace the starter. (3) Disconnect the power supply immediately and repair the gear teeth face.

15. Working Starter but Non-working Diesel Engine Checking Item and Part

Storage battery

Starter

Diesel engine

Anti-theft system Main relay

Cause of Malfunction

Troubleshooting

(1) Looseness of the storage battery terminal due to oxidization

(1) Clean and/or refasten the storage battery terminal.

(2) Storage battery uncharged or inadequately charged

(2) Recharge or replace the storage battery as specified.

(1) Damage of the pinion

(1) Replace the pinion.

(2) Malfunction of the electromagnetic switch

(2) Repair or replace the electromagnetic switch.

(3) Damage of the electrical brush or too soft electrical brush spring

(3) Replace the electrical brush and/or the electrical brush spring.

Sticking of the piston and the crankshaft bearing or damage of other parts

Overhaul or replace the corresponding parts of diesel engine.

Unable to protection

Overhaul the anti-theft system.

remove

the

Damage of the main relay

anti-theft

Replace the main relay.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Fuse cable connector Rotation speed sensor Fuel (diesel)

Looseness or bad contact of the fuse cable

Clean and fasten the fuse cable.

Damage of the rotation speed sensor

Replace the rotation speed sensor.

No fuel in the inappropriate fuel

Add fuel or apply the motor diesel (specified by CB 19147-2009).

fuel

tank,

or

(continued) Checking Item and Part

Cause of Malfunction

Troubleshooting

Air left in the fuel system

Fuel system not exhausted completely

Exhaust the air in the fuel system through the fuel filter.

Low pressure oil circuit

Blockage or leakage of the low pressure oil circuit

Repair the low pressure oil circuit, replace the damaged parts of low pressure oil circuit and exhaust the air in the fuel system.

High pressure fuel pump and high pressure fuel rail

Unable to build up the pressure of the high pressure fuel rail

Check the high pressure fuel pump, high pressure fuel rail and pressure sensor; replace defective parts if necessary. Check the working status of the fuel injector electromagnetic valve and replace the fuel injector if necessary.

Fuel injector electromagnetic valve

Fuel injector electromagnetic valve not

Electronic control unit (ECU)

Abnormal work of the electronic control unit (ECU)

Replace the ECU, and input the currently used injector code when replacing the ECU.

Preheat system

Abnormal work of the glow plug in winter

Replace the glow plug, and check the glow plug control unit.

working or bad contact

16. Diesel Engine Rotating but Unable to be Started Checking Item and Part

Cause of Malfunction

Troubleshooting

Fuel pipe system

Blockage or damage of the fuel pipe; looseness of the fuel pipe connector

Repair or replace the fuel pipe, and refasten the fuel pipe connector.

(1) Overflow valve of the fuel filter cannot be closed

(1) Repair or replace the fuel filter overflow valve.

(2) Blockage of the fuel pipe or the fuel filter element

(2) Check the fuel pipe and replace the fuel filter element or the filter core.

Air left in the fuel system

Exhaust the air in the fuel system through the fuel filter.

Overlow pressure of the low pressure oil circuit

Fuel system

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Chapter III Malfunction Diagnosis and Troubleshooting

Fuel (motor diesel)

Low voltage of the storage battery

(1) Applied inappropriate fuel

(1) Choose the qualified fuel according to the ambient temperature.

(2) Water in the fuel system (1) Looseness of the storage battery wiring, corrosion of the terminal

(2) Drain out the water in the fuel system or replace the fuel. (1) Clean the storage battery terminal and fasten the wiring.

(2) Storage battery inadequately charged

(2) Charge the storage battery.

Low pressure of the high pressure oil circuit

Bad control of the high pressure fuel pump and high pressure fuel rail pressure.

Check the high pressure fuel pump or the high pressure fuel rail pressure control system.

Bad performance of the fuel injector

Damage of the fuel injector nozzle; bad performance of the electromagnetic valve

Check the fuel injector or replace it; when it is replaced, it is required to input the new injector code into the ECU.

Coolant temperature sensor (winter)

Wrong information for the coolant temperature in winter; glow plug not working

Replace the coolant temperature sensor.

17. Difficulty in Starting Due to Malfunction in the Quick Start-up System Preparation for troubleshooting (1) Disconnect the temperature switch connector. (2) Check whether the glow plug is energized. ——Make  sure  the  starting  switch  is  in  the  “OFF”  position. ——Use a voltmeter to connect the cylinder wall and one of the glow plugs. ——Set the starting switch to  the  “ON”  position. If the glow plug is energized, the voltmeter will show the voltage (12 V); it means the glow plug is not energized if the hand stands still. Checking Item and Position

Cause

Troubleshooting

The indicator lamp of glow plug is off.

Damaged glow plug indicator lamp

Replace the glow plug indicator lamp.

Quick start-up timer

Damaged quick start-up timer

Repair or replace the quick start-up timer.

The glow plug indicator lamp is on for 0.3 s.

Damaged quick start-up timer

Repair or replace the quick start-up timer.

The glow plug indicator lamp is on for 3.5 s.

(1) Start the diesel engine, set (1) Replace the quick start-up the   starting   switch   from   “ST”   to   timer. “ON”,   and   the   glow   plug   relay  

When the glow plug is energized,

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Checking Item and Position

Cause

Troubleshooting

should be on for at least 14 s, otherwise the quick start-up timer may be damaged. (2) Set the starting switch from “OFF”  to  “ON”  and  the  glow  plug   (2) Replace the quick start-up relay should be on for at least 14 timer. s, otherwise the quick start-up timer may be damaged. Temperature switch

Damaged temperature switch

Replace the temperature switch.

Glow plug connection

Disconnection of the glow plug

Check the glow plug connecting harness and replace the glow plug.

The glow plug indicator lamp is off.

Blowout of the indicator lamp fuse

Replace the glow plug indicator lamp fuse.

Quick start-up timer

Damaged quick start-up timer

Replace the quick start-up timer.

The glow plug indicator lamp is on for 3.5 s.

(1) The glow plug relay is damaged. The glow plug relay is not connected after the starting switch  is  set  from  “OFF”  to  “ON”.

(1) Replace the glow plug.

Glow plug not energized glow

plug

(2) Damaged glow plug relay wire

(2) Repair or replace the glow plug relay circuit wire. (3) Replace the fuse or wire.

(3) The fuse or circuit wire is broken. The glow plug relay is not connected after the start switch  is  set  from  “OFF”  to  “ON”.

18. No Power Generation, Undercharge or Overhigh Charging Current of Generator Phenomenon and Cause of Malfunction (1) Improper wiring, broken wiring or poor contact of wiring No power generation

Troubleshooting (1) Repair the circuit.

(2) Open circuit of rotor coil

(2) Repair or replace the generator assembly.

(3) Damaged rectifier diode

(3) Replace the diode.

(4) Poor contact of carbon brush

(4) Clear the dirt or replace the carbon brush.

(5) Damaged regulator

(5) Repair or replace the regulator. Undercharge of generator

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(1) Poor contact of carbon brush or oil pollution on the slip ring

(1) Adjust the carbon brush and clean the slip ring.

(2) Damaged regulator

(2) Replace the regulator.

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Chapter III Malfunction Diagnosis and Troubleshooting (3) Insufficient electrolyte in the storage battery or sulphation or ageing of polar plates

(3) Add electrolyte to the required level or replace the storage battery when the capacity can not recover in case of sulphation of polar plates.

19. Insufficient Capacity, Difficulty in Starting or Overhigh Self Discharge of the Storage Battery Phenomenon and Cause of Malfunction (1) Low level of electrolyte Insufficient capacity of the storage battery and hard to start the diesel engine

(2) Short circuit between polar plates

(1) Add distilled water or dilute sulphuric acid with the density of 1.1 as required.

(3) Sulphation of polar plates

(2) Clear the sediment and replace the electrolyte.

(4) Poor contact of circuit connectors, too much oxide on the terminal pole or undercharge

(3) Charge and discharge repeatedly to clear the sulphation. (4) Fasten the connecting circuit, clear the oxide on the terminal pole or charge the storage battery if necessary.

(1) Foreign matters in the electrolyte (2) Short circuit of the storage battery outer wire (3) Short circuit of positive/negative poles due to electrolyte spilled out on the storage battery surface Overhigh self discharge of the storage battery

Troubleshooting

(4) Serious short circuit due to metal tools or bars left between the positive and negative poles. (5) Short circuit of pole plates due to active substance falling off from the pole plates and excessive sediment; short circuit of pole plates due to damage of the baffle plate; short circuit between positive and negative poles due to warpage of pole plates.

(1) Add electrolyte mixed up with pure sulphuric acid and distilled water as required. (2) Check the part with short circuit and clear the malfunction. (3) Use alkaline water or warm water to clean the storage battery surface and pole end and keep the outer surface clean   (Don’t   get   the   alkaline   water   or   warm water entered the storage battery). (4) It is prohibited to leave metal tools or bars on the surface of storage battery. (5) Repair or replace the storage battery.

Warning (1) The gas from the storage battery can be easily ignited by sparks, so ignition, naked fire or smoking should  be  forbidden  during  repair  and  maintenance  for  the  storage  battery.  During  maintenance,  don’t   get your skin or cloth spilled by the electrolyte of storage battery and make sure to wear goggles. (2) Never get the two terminal poles in short circuit, or the storage battery may heat up quickly, which may lead to explosion. (3) To avoid short circuit, the storage battery earthing wire should be removed before the electrical equipment is removed; but to replace a bulb, you need only disconnect the relevant switches. (4) Remove the storage battery in the sequence of earthing wire, positive pole wire, storage battery baffle plate and then the storage battery. Installation the storage battery in the opposite sequence.

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Section II Malfunction Diagnosis 1. Start-up system malfunction diagnosis Check whether the storage battery is normal and then conduct the diagnosis as follows. Non-working starter

Check the storage battery.

Charging failure or out of service

Check the storage battery

Disconnection of terminal

Clean the storage battery terminal and then reconnect it

Normal storage battery

Check the terminal

Normal connection of terminal

Check the starter or starting switch

Malfunction

Repair or replace it Connect the headlamp and the starting switch

Headlamp off or dim

① Undercharge of storage battery ② Short circuit of starter coil ③ Malfunction of starter parts

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Headlamp on

① Open circuit of starter ② Open circuit of starter coil ③ Malfunction of starting switch

Chapter III Malfunction Diagnosis and Troubleshooting Engagement malfunction between the pinion and the gear ring

Turn the start switch to the “ST” Position and check whether there is a voltage on the terminal “S” of solenoid switch

Yes

No Or

Serious wear between the pinion and the gear ring

Repair or replace the starter and replace the gear ring

In this case, check whether the voltage for the electromagnetic switch connector 3BW of restarting relay is normal

High slipping resistance for starter

Repair or replace the starter. Normal

Open circuit or connection malfunction between the starting switch and the electromagnetic switch

Abnormal

Check whether there is a voltage at the starting switch connector of restarting relay.

Repair it

No

Yes

Connection malfunction of the starting switch

Replace the starting switch

Open circuit or connection malfunction between the starting switch and the storage battery

Repair it

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES The electromagnetic switch doesn’t work after the starting switch is turned to the “ST” position Turn the starting switch to the “ST” Position and check whether there is a voltage at the electromagnetic switch terminal “S”

Yes

No

Check the earthing cable

Proper

Check whether the indicator lamp is normal

Improper

Abnormal

Normal

Repair it

Check whether the connection between the starting switch and the electromagnetic switch terminal “s” is on

Or The slipping part of pinion cannot move

instrument

Open circuit or burnout of the electromagnetic switch or the coil

Check the starter relay

Check the clutch and starting switch.

Repair or replace the starter

Open circuit or connection malfunction between the storage battery and the starting switch.

Connection malfunction of the starting switch

Repair it

Replace the starting switch

The engine cannot work after the pinion is engaged in the gear ring Check the earthing cable

Improper

Proper

Repair or replace the earthing cable

Connection malfunction between the electric brush and the rectifier

Burnout of the electromagnetic starting switch

Open circuit or damage of the excitation coil

Repair or replace the starter

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Open circuit or damage of the armature coil

Slipping pinion clutch

Chapter III Malfunction Diagnosis and Troubleshooting The starter is still working after the starting switch is turned from “ST” to “ON”

Disconnect the connecting wire of the starting switch and check the starting switch Connector No. Terminal No. The position of the starting switch key

OFF

ON

Terminal No.

Lock Accessories

ON ST

All the wires except the wires above should be disconnected

Yes No

The contact of electromagnetic switch is melted and cannot move or the return spring is broken or damaged

Replace switch

the

Replace the starter switch

electromagnetic

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2. Turbocharging System Malfunction Diagnosis Malfunction diagnosis: ① The malfunction diagnosis means to find out the position and cause of the turbocharging system malfunction and clear the malfunction accordingly.②   Don’t   replace   the   turbocharger before clearing the malfunction.③ The malfunction diagnosis method and procedure for the turbocharged engine are the same as those of the non-turbocharged engine.④ The malfunction diagnosis cannot be conducted after the turbocharger is removed.

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Blockage in the compressor exhaust pipe

Clear the foreign matters or replace the broken components accordingly.

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Blockage in the engine air intake pipe

Clear the foreign matters in the air intake pipe.

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Air leakage from the pipe connecting the air cleaner and the compressor

Replace the sealer or tighten the fastener to the required torque accordingly.

●

Air leakage from the pipe connecting the compressor and the engine air intake pipe

Replace the sealer or tighten the fastener to the required torque accordingly.

Air leakage from the junction surface between the engine air intake pipe and the cylinder head

Replace the gasket or tighten the fastener to the required torque accordingly.

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Blockage in the engine exhaust pipe

Clear the foreign matters in the exhaust pipe.

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Blockage in the silencer or the exhaust pipe behind

Clear the foreign matters in the exhaust pipe or replace the broken components accordingly.

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Air leakage from the junction surface between

Replace the gasket or tighten the fastener to

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Oil leakage from the turbocharger turbo side

Blue smoke from the engine

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Oil leakage from the compressor side

High fuel consumption of the engine

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Periodical noise from the turbocharger

Black smoke from the engine

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Too much noise from the turbocharger

Insufficient engine power

Diagnosis phenomenon

Malfunction diagnosis for the turbocharged engine

Possible cause

Troubleshooting

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Dirty air cleaner

Replace the filter core of the air cleaner

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Blockage in the compressor air intake pipe

Clear the foreign matters or replace the broken components accordingly.

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Chapter III Malfunction Diagnosis and Troubleshooting

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the engine exhaust pipe and the cylinder head

the required torque accordingly.

Air leakage from the connection between the turbo intake port and the engine exhaust pipe

Replace the gasket or tighten the fastener to the required torque accordingly.

Air leakage from the turbo exhaust pipe

Clear the air leakage from the turbo exhaust pipe.

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Blockage in the turbocharger fuel return hose

Clear the foreign matters or replace the exhaust pipe accordingly.

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Blockage in the engine crankcase respirator

Clear the foreign matters in the crankcase respirator.

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Dirt deposit or coking in the intermediate housing of turbocharger

Replace the engine oil and engine oil filter core, overhaul or replace the turbocharger accordingly. Replace or adjust the high pressure fuel pump and relevant components accordingly.

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Improper control of the high pressure fuel pump or fuel injector

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Improper timing of engine

Replace the worn components and adjust the engine timing.

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Blow-by resulting from engine piston ring wear or cylinder wear

Repair the engine and replace the components accordingly.

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Internal malfunction of engine (valve or piston)

Repair the engine accordingly.

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Dirt deposit on the compressor impeller or the diffuser blade

Clean, check and clear the malfunction which makes the air unfiltered. Replace the engine oil or the engine oil filter.

Damage of turbocharger

Find out the reason and clear the malfunction which results in damage. Overhaul or replace the turbocharger accordingly.

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Attention: If a turbocharger is of a proper appearance, the rotor can work properly and the blade has no interference with its housing, it means the turbocharger is in good condition.

3. Turbocharger Oil Leakage Malfunction Diagnosis Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES The seal of turbocharger is achieved by the higher air pressure established in the housings at both ends of the turbocharger than the air pressure in the intermediate body fuel return chamber (equal to the air pressure in the crankcase). Before diagnosis, make sure there is no malfunction such as engine oil in the pipe before the gas compressor housing intake port, oil pollution in the exhaust pipe before turbine housing intake port, etc. Malfunction diagnosis for oil leakage at the compressor: ① Check whether the compressor impeller is broken by foreign matters

Yes

Clean and repair the air intake system or replace the turbocharger

Yes

Eliminate the factors that largen the turbocharger clearance or replace the turbocharger

Yes

Clean the lubricating oil and avoid long time idling

No ② Check whether the axial/radial clearance of turbocharger is largened (whether the compressor blade has interference with its housing) No ③ Check whether the idle speed time of engine is too long (more than 20 min) No ④ Check whether the air cleaner is too dirty No

Yes

⑤ Check whether the turbocharger air intake pipe is throttled

Replace the filter core of air cleaner

Eliminate the factors that throttle the turbocharger air intake pipe

No ⑥ Check whether there is looseness or breakage in the air intake/exhaust pipe

Yes

Tighten the pipe or replace the broken pipe

No ⑦ Check whether the lubricating oil return hose of turbocharger is blocked

Yes

Clean it and clear the throttling factor. Replace the lubricating oil and the oil return hose if necessary

No ⑧ Check whether the engine crankcase respirator is blocked

⑨ Check whether there is malfunction in the engine (serious blow-by of piston or overhigh pressure in the crankcase)

⑩ Check whether there is too much lubricating oil in the crankcase

Yes

Yes

Yes

See the maintenance manual of engine manufacturer for check and repair

See the maintenance manual of engine manufacturer for check and repair

Adjust the oil in the crankcase to a proper level

It is advised to measure the air intake pressure (reference value: ≤6.5 kPa)

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Chapter III Malfunction Diagnosis and Troubleshooting Malfunction diagnosis for oil leakage at the turbo ① Check whether the axial/radial clearance of turbocharger is largened (whether the compressor blade has interference with its housing)

Yes

Eliminate the factors that largen the turbocharger clearance or replace the turbocharger

No ② Check whether the idle speed time of engine is too long (more than 20 min)

Yes

Clean the lubricating oil and avoid long time idling

Yes

The redundant lubricating oil will be burnt and no measures are needed

Yes

See the maintenance manual of engine manufacturer for check and repair

Yes

Clean it and clear the throttling factor, replace the lubricating oil and oil return pipe if necessary

Yes

Repair the engine lubrication system and replace the turbocharger

Yes

Adjust the oil in the crankcase to a proper level

No ③ There is too much lubricating oil added before No ④ Check whether the engine crankcase respirator is blocked No ⑤ Check whether the turbocharger lubricating oil return hose is blocked No ⑥ Check whether there is dirt deposit or lubricating oil coking in the intermediate housing of turbocharger No ⑦ Check whether there is too much lubricating oil in the crankcase

No ⑧ Check whether there is malfunction in the engine (serious blow-by of piston or overhigh pressure in the crankcase)

Yes

See the maintenance manual of engine manufacturer for check and repair

Oil leakage is a common malfunction for the turbocharged engine. Find out and clear the malfunction in time to avoid failure of the turbocharger. The following shows the malfunctions that can result in oil leakage: (1) The blockage in the engine air cleaner or in the air intake pipe results in an overhigh air intake pressure. (2) The bending or damage of turbocharger oil return hose results in throttled oil return. (3) The carbon deposit in the intermediate body fuel chamber results in improper oil return. (4) Air leakage from the connecting pipe between the gas compressor housing exhaust port and the engine air intake pipe. (5) Air leakage from the connector between the turbo housing intake port and the exhaust pipe exhaust port

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES (6) Long idle speed time. (7) Overhigh pressure or oil level in the crankcase or blockage of crankcase vent. (8) Overhigh engine lower blow-by. Improper diagnosis method for oil leakage: Remove the connecting pipe between the gas compressor housing exhaust port and the engine air intake port, and then start the engine and check whether there are oil drops injected from the gas compressor housing exhaust port with air flow.

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Chpter IV Mechanical System

Chapter IV Mechanical System Section I Cylinder Head

Removal procedure ① Engine accessories ② Timing system ③ Fuel inlet pipes of both fuel injector and fuel rail ④ Fuel return hose component ⑤ Heater water return pipe component ⑥ Cylinder head cover assembly ⑦ Fuel injector assembly ⑧ GER condenser air intake pipe, EGR condenser air outlet pipe, EGR condenser ⑨ Air intake manifold pipe ⑩ Turbocharger 11 ○ Exhaust manifold pipe 12 ○ Glow plug assembly 13 ○ Vacuum pump assembly 14 ○ Camshaft bearing cap 15 ○ Air intake/exhaust camshaft assembly 16 ○ Hydraulic clearance adjuster and rocker arm 17 ○ Cylinder head Installation procedure Install them in the opposite order of removal.

Fig. 4-1-1 Disassembly and reassembly sequences for cylinder head

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Disassembly precautions: (1) Before disassembly, you should fully make yourself be familiar with the structural principle and disassembly sequence of parts to prevent parts damage. (2) During disassembly, the parts of the valve component should be collected together and identified with marks for the convenience of their reinstallation into their original positions. (3) During disassembly, the position of the fuel injector should be marked, and the fuel injector should be reassembled to its original place without misplacement. Fig. 4-1-2 Removing the engine accessories

(4) Before removing the cylinder head from the engine and disassembling the valve mechanism, a compression test should be carried out and its results should be recorded. Disassembly Disassembling engine accessories ① (1) Removing the engine belt: Rotate the tension pulley with tools to make the belt loose enough, and then remove the belt, as shown in Fig. 4-1-2. (2) Removing the wedge idle wheel: loosen the fastening bolt of wedge idle wheel, and remove the wedge idle wheel.

Fig. 4-1-3 Removing the timing hood component and timing system

Fuel inlet pipe of injector

Fuel return hose component

Disassembling the timing system ② (1) Remove timing hood component I and the timing hood. See Fig. 4-1-3. (2) Removing the timing belt: Loosen the timing tension pulley to make the timing belt loose and then remove it. See Fig.. 4-1-3. (3) Remove the timing tension pulley. (4) Remove the camshaft timing pulley. Disassembling the fuel inlet pipes of both fuel injector and fuel rail ③

Fuel inlet pipe of fuel rail

Fig. 4-1-4 Removing the fuel inlet pipes of both fuel injector and fuel rail

(1) Equally loosen the pipe connectors located at the ends of the four fuel pipes of fuel injector with a spanner, and take down the four fuel inlet pipe components of the fuel injector. See Fig. 4-1-4. (2) Equally loosen the pipe connectors located at the ends of the fuel inlet pipes of the fuel rail, and take down the fuel inlet pipes of fuel rail. Attention: ——When removing the fuel inlet pipes of both the fuel injector and fuel rail, loosen the pipe connectors at both ends of the pipes equally to prevent pipe deformation.

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Chpter IV Mechanical System ——After removing the fuel inlet pipes of both fuel injector and fuel rail, use clean plug covers to cover the fuel inlet ports for fuel injector and high-pressure fuel rail and cover both ends of fuel inlet pipe of fuel injector and fuel rail, in order to prevent impurities from blocking the fuel injector. Disassembling the fuel return hose component ④ (1) Remove the fuel return hose bracket and clamp. (2) Select the DELPHI fuel injector, pull out the 4 fuel return hoses connected to fuel injector, and then take down the fuel return hose component. See Fig. 4-1-4. Fig. 4-1-5 Removing heater water return pipe component

(3) Use the BOSCH or XINFENG fuel injector. Use a tool to push out the clip, pull out the fuel return connector from the fuel injection circuit, and then remove fuel return hose component. Disassembling component ⑤

the

heater

water

return

pipe

(1) Remove the 2 hexagon flange bolts (M6×16) connecting the heater water return pipe component to the cylinder head cover. See Fig. 4-1-5. (2) Remove the 1 hexagon flange bolt (M6×16) connecting the heater water return pipe component to the cylinder head cover, and take down the heater water return pipe. See Fig. 4-1-5.

Cylinder head cover

Water outlet pipe connecting pipe component

Disassembling the cylinder head cover assembly ⑥ (1) Remove the 2 hexagon flange bolts (M8×16) fastening the water outlet pipe connecting pipe component, and take down the water outlet pipe connecting pipe component. (2) Remove the 16 hexagon flange bolts (M6×20) fastening the cylinder head cover to the cylinder head, and take down the cylinder head cover. See Fig. 4-1-6. (3) Take out the packing from the sealing groove of cylinder cover.

Cylinder head cover packing

Fig. 4-1-6 Removing the cylinder head cover assembly

Check the cylinder head packing and replace it if there is any damage or deformation.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Disassembling the fuel injector assembly ⑦ (1) Removing the fuel injector harness plug: Pull out the harness plug self-locking device, and then remove the fuel injector harness plug. (2) Remove the fastening bolts of fuel injector ballast. See Fig. 4-1-7. (3) Remove the fuel injector ballast. (4) Take out the fuel injector assembly from the cylinder head.

Fuel injector assembly

Fig. 4-1-7 Removing the fuel injector assembly Air intake pipe

Water outlet pipe

Disassembling the GER condenser air intake pipe, EGR condenser air outlet pipe and EGR condenser ⑧

EGR condenser

(1) Remove the 2 high-temperature resistance hexagon flange bolts (M8×1.25) connecting the EGR condenser air intake pipe to exhaust manifold pipe. See Fig.. 4-1-8.

Exhaust manifold pipe Water inlet pipe

(2) Remove the 2 hexagon flange bolts (M8×20) connecting the EGR condenser air intake pipe to EGR condenser. (3) Remove the 2 hexagon flange bolts (M8×16) connecting the EGR condenser to EGR condenser air outlet pipe.

Fig. 4-1-8 Removing the EGR Condenser

Air intake manifold pipe

Air intake manifold pipe gasket

(4) Remove the single-ear stepless clamp connecting EGR condenser to water inlet pipe. See Fig. 4-1-8. (5) Remove the hexagon flange bolt (M10×16) connecting EGR condenser to cylinder head, and take down the EGR condenser. See Fig. 4-1-8. Disassembling the air intake manifold pipe ⑨ (1) Remove the 7 hexagon flange bolts (M8×105 & M8×25) connecting the air intake manifold pipe to cylinder head. See Fig. 4-1-9.

Air outlet component of EGR condenser

(2) Take down the air intake manifold pipe and its gasket from the air intake side of the cylinder head. See Fig. 4-1-9.

Fig. 4-1-9 Removing the air intake manifold pipe and gasket

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Prompt: Place the removed fuel injectors carefully according to the cylinder serial numbers 1, 2, 3 and 4, and make corresponding marks on these fuel injectors. Protect them from being contaminated or bumped.

Check the air intake manifold pipe gasket. It must be replaced if there is any damage or deformation.

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Chpter IV Mechanical System Disassembling the turbocharger ⑩ (1) Pull out the harness plug of the turbocharger.

Turbocharger

(2) Remove the 3 hexagon flange bolts (M6×12) for fastening the turbocharger heat shield, and take down the heat shield (VCT turbocharger). See Fig. 4-1-10.

Fuel return hose

(3) Remove the fuel return hose connected to the turbocharger. (4) Remove the fuel inlet bolts connecting turbocharger fuel inlet pipe to turbocharger.

Heat shield

Fig. 4-1-10 Removing the turbocharger and its heat shield

Exhaust manifold pipe gasket

Exhaust manifold pipe

the

(5) Remove the single bolt and the 2 fastening nuts connecting turbocharger to exhaust manifold pipe, and take down the turbocharger and its gasket. See Fig. 4-1-10. Check the supercharger gasket and replace it if there is any damage or deformation. 11 Disassembling the exhaust manifold pipe ○

(1) Remove the 4 hexagon flange bolts (M6×12) fastening the heat shield of exhaust manifold pipe, and take down the heat shield of exhaust manifold pipe. (2) Remove the 8 fastening nuts (M8×1.25) connecting the exhaust manifold pipe to cylinder head, and take down the exhaust manifold pipe and exhaust manifold pipe gasket. See Fig. 4-1-11. Fig. 4-1-11 Removing the air exhaust manifold pipe and gasket

Check the exhaust manifold pipe gasket and replace it if there is any damage or deformation. 12 Disassembling the glow plug ○

Cylinder head

(1) Remove the glow plug wiring harness. (2) Remove the 4 glow plugs inside the hole of the air intake port of cylinder head with a hexagon socket head spanner, as shown in Fig. 4-1-12. (3) The removed glow plugs should be placed separately, and be protected against contamination or being bumped. Heater plug

Fig. 4-1-12 Removing the glow plug

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 13 Disassembling the vacuum pump assembly ○

Cylinder head

(1) Pull out the vacuum connecting hose from the vacuum pump. (2) Remove the 3 hexagon flange bolts (M6×20) connecting the vacuum pump to cylinder head ring flange. See Fig. 4-1-13.

Vacuum pump assembly

(3) Remove the vacuum pump assembly from the rear end of the cylinder head exhaust camshaft.

Fig. 4-1-13 Removing the vacuum pump assembly 14 Disassembling the camshaft bearing cap ○

(1) Remove the supporting bolts for the 4 fuel injector ballasts.

Camshaft bearing cap

(2) Remove the 22 hexagon flange bolts (M6×35 and M6×20) fastening the camshaft bearing cap in the sequence from the two sides of camshaft bearing cap to the center. See Fig. 4-1-14. (3) Remove the camshaft bearing cap from cylinder head. Cylinder head

Fig. 4-1-14 Removing the camshaft bearing cap Camshaft

15 Disassembling the intake/exhaust camshaft ○

(1) Take out the intake camshaft and the exhaust camshaft respectively from the cylinder head. See Fig. 4-1-15. (2) Remove the plug cover and the front oil seal of camshaft from the cylinder head. Check the front oil seal of camshaft and replace it if it is damaged.

Cylinder head

Fig. 4-1-15 Removing the intake/exhaust camshaft

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Chpter IV Mechanical System 16 Disassembling the hydraulic clearance adjuster ○

(1) Take the 16 pair of hydraulic clearance adjusters and rocker arms respectively out from the corresponding holes in the cylinder head. See Fig. 4-1-16. (2) Mark the removed hydraulic clearance adjusters and rocker arms in cylinder groups to facilitate the reassembling in their original sequence. 17 Disassembling the cylinder head ○

Caution: The cylinder head should not be removed during warm-up, which may cause deformation. Fig. 4-1-16 Removing the hydraulic clearance adjuster and rocker arm

(1) Gradually and evenly loosen the 10 bolts of the cylinder head in the order shown in Fig. 4-1-17. Caution: If the cylinder cap bolts are not orderly loosened in gradually specified order, the lower surface of the cylinder cap might be damaged.

Cylinder head bolt

(2) Take down the cylinder head and cylinder head gasket from the cylinder body. Check the cylinder head gasket and replace it if there is any damage, deformation or lost elasticity. Cylinder head

(3) Remove the valves and valve springs.

Fig. 4-1-17 Removing the tightening bolts of cylinder head in order

Cleaning (1) Cylinder head bolt. (2) Cylinder head.

Cylinder head gasket

Attention: Carefully clean all greasy dirt, soot and carbon depositions until the original mental color is revealed. Never apply electric wire brush on any sealing surface or sealing gasket. Inspection and repair Cylinder body

The parts should be adjusted, repaired or replaced if any excessive worn or damage is detected during inspection.

Fig. 4-1-18 Checking the cylinder head and its gasket

(1) Check whether there is any leakage, rust or blow-by on the cylinder sealing gasket and fitting surfaces. If a sealing gasket failed, the failure reason should be determined. ——Incorrect installation. ——Looseness or warp. ——Insufficient tightening torque for cylinder head bolt. ——Warped surface of cylinder body. (2) Check whether there is any damage or elongation of

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES threads of the cylinder head bolts (see Fig. 4-1-19), and any damage caused by incorrect tool usage. Attention: Any suspicious bolt should be replaced. (3) Check whether there is any crack in the cylinder head, especially in the area between valve seats and at the exhaust port. (4) Check whether there is any corrosion on the base plane of the cylinder head, or any sand inclusion or spongy pore in the cylinder head. Fig. 4-1-19 Inspection for Cylinder Head Bolt

Attention: Do not try to weld up the cylinder head. The damaged cylinder head should be replaced immediately. (5) Check the flatness of cylinder head plane and the flatness of fitting surface between air intake and exhaust manifold pipes. These   surfaces   can   be   grinded.   If   the   “irregularities”   of   these surfaces excesses the specified limits, these surfaces should be grinded to make them meet the technical requirements, and if they excess too much, they should be replaced.

Fig. 4-1-20 Checking the cylinder head base plane

Warp of the base plane of cylinder head

Standard

Limitation

≤0.05  mm

0.10 mm

(6) Measure the warp of the fitting surface between air exhaust manifold pipe and cylinder head with straight scale and feeling gauge. If the measured value is between the specified limitation and the standard value, then the fitting surface between the air exhaust pipe and the cylinder head should be reground. Replace the air exhaust manifold pipe if the measured value excesses the specified limitation. Wrap of exhaust pipe Standard ≤0.05  mm

Fig. 4-1-21 Measuring the warps of the air exhaust manifold pipe and the fitting surface

Limitation 0.10 mm

Reassembly 17 Reinstalling the cylinder head ○

(1) Installing the valve ——Before installing the valve, the engine oil should be applied onto the external surface of the valve stem and the internal surface of the valve guide. Mobil APICI-4 lubricating oil

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Chpter IV Mechanical System ——After the installation, the valve stem should be able to move flexibly inside the valve guide without seizure. (2) Installing valve spring gasket (3) Installing valve oil seal assembly ——Apply a little lubricating oil onto the sealing face of the valve oil seal. Exhaust valve

Inlet valve

Mobil API CI-4 lubricating oil. ——Press the valve oil seal into the valve guide head with special tools.

Fig. 4-1-22 Installing the valve

Valve oil seal installer: 5-8840-2033-0 ——Carry out an air pressure leakage test on valve oil seal.

Valve lock clamp

Air pressure specification: under an air pressure of 50～ 70 kPa, the blow-by flow should not excess 20 mL/min.

Valve spring seat

(4) Installing the valve spring ——Mount the valve spring onto the valve spring gasket.

Valve spring

——The valve spring should come into contact with, but not seized on, the base plane of the retaining column of the valve spring seat. (5) Installing the valve lock clamp

Fig. 4-1-23 Installing the valve spring and valve lock clamp

——Compress the valve spring with special tools to install the valve lock camp into the valve spring seat. Valve spring compressor: 9-8523-1423-0

Cylinder bolt

head

Cylinder head

Fig. 4-1-24 Installing the cylinder head, tightening the bolts in order

——The valve lock clamp should be in tight contact with the annular pressure-bearing surface of the taper surface of valve stem end, and the external conical surface of the valve lock clamp should be in tight contact with the internal conical surface of the valve spring seat. The two pieces of lock clamps should be aligned. After the installation, use a hammer to tap on the head of the valve to make sure the valve lock clamps will not pop up. (6) Check whether there is any foreign matters on the junction surface between the cylinder head and cylinder body, if there is, clean it up with silk; fit the locating hole of the cylinder head gasket onto the cylinder body fixed pin, and keep the gasket flat on the cylinder body upper plane. (7) Fix the cylinder head to the cylinder body, and align the 10 screw holes, then fit and screw the 10 cylinder head bolts (M11×1.5×162) according to specified sequences. See Fig. 4-1-24. Tightening torque for cylinder head fastening bolt

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Step 1 50 N·m±3 N·m

Step 2 Turn for 90°

Step 3 Turn further for 120°

Lubrication

Attention: Check the cylinder head bolt before installation and replace it when there is any deformation, elongation, thread sliding or other faults. Reinstalling the hydraulic clearance adjuster and 16 rocker arm ○ Hydraulic clearance adjuster

Fig. 4-1-25 Installing the hydraulic clearance adjuster and rocker arm

(1) Apply an appropriate amount of lubricating oil onto the globular head of hydraulic clearance adjuster, then make it engage into the clip at the rear end of the rocker arm. See Fig. 4-1-25. (2) Lubricate the surfaces of the rocker arm and the hydraulic clearance adjuster with lubricating oil again, and then insert the whole part into the corresponding hole, with the other side of the rocker arm overlapping on the valve. See Fig. 4-1-25. Mobil APICI-4 lubricating oil 15 Reinstalling the intake and exhaust camshafts ○

Camshaft

(1) Apply an appropriate amount of lubricating oil onto the surface of the camshaft journal and inside the bearing holes of the intake and exhaust camshafts in the cylinder head. Mobil API CI-4 lubricating oil (2) Fix the intake and exhaust camshafts into the cylinder head as shown in Fig. 4-1-26.

Cylinder head

(3)  Align  the  marks  “·”  on  the  driving  gears  of  exhaust  and   intake camshaft and get it in line with the upper surface.

Fig. 4-1-26 Installing the exhaust/intake camshaft Camshaft bearing cap

Axial clearance of camshaft Standard

0.060～0.115 mm

14 Reinstalling the camshaft bearing cap ○

(1) Apply anaerobic plane sealant to the junction surface between the camshaft bearing cap and the cylinder head. See Fig. 4-1-27.

Apply the sealant

LOCTTTE510 anaerobic plane sealant Cylinder head

Fig. 4-1-27 Installing the camshaft bearing cap and applying sealant

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Attention: If the former cylinder head is to be used, clean the junction surface between the camshaft bearing cap and the cylinder cap before applying sealant. The camshaft bearing cap and the cylinder head should be used in sets.(2) To install the camshaft bearing cap, screw down 16 hexagon flange bolts (M6×35) of camshaft bearing cap to the specified torque and in the

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chpter IV Mechanical System specified order, then tighten the surrounding 6 hexagon flange bolts (M6×20) from the center to both sides. See Fig. 4-1-27.

Camshaft bearing cap

Tightening torque for the fastening bolt of camshaft bearing cap 9 N·m±3 N·m

Cylinder head

Fig. 4-1-28 Installation for camshaft bearing cap

(3) Install the plug cover and the front oil seal of camshaft: apply an appropriate amount of lubricating oil onto the front oil seal lip and the cylindrical surfaces of both front oil seal and camshaft plug cover. Use special tools to install the front oil seal and plug cover into the corresponding holes properly without causing any oil leakage. Mobil API CI-4 lubricating oil

Cylinder head

Vacuum pump assembly

13 Reinstalling the vacuum pump assembly ○

(1) Install the vacuum pump to the rear end of the cylinder head exhaust camshaft, with the flat bump of its bearing inserted into the groove of the rear end of the cylinder head exhaust camshaft and the rabbet and the rabbet round hole matched perfectly. (2) Screw down the 3 hexagon flange bolts (M6×20) connecting the vacuum pump to the cylinder head to the specified torque. See Fig. 4-1-29.

Fig. 4-1-29 Installing the vacuum pump assembly

(3) Fix the vacuum coupling hose to the vacuum pump. There should be no deflection or misplacement after installation. Tightening torque for vacuum pump fastening bolt 9 N·m±3 N·m

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES 12 Reinstalling the glow plug assembly ○

(1) Screw the 4 glow plugs into the corresponding mounting hole of the cylinder head air intake end, and tighten the glow plugs using a hexagon socket head spanner to the specified torque. See Fig. 4-1-30.

Cylinder head

Tightening torque for glow plug 9N·m～3N·m Heater plug

Fig. 4-1-30 Installing the glow plug assembly

(2) Check the assembled glow plugs and eliminate any misplacement and leakage. (3) Assemble the wiring harness of glow plugs and connect the harness securely. 11 Reinstalling the exhaust manifold pipe ○

Exhaust manifold pipe gasket

(1) Install the exhaust manifold pipe gasket and exhaust manifold pipe to the exhaust side of the cylinder head, and tighten the 8 fastening nuts （ M8×1.25 ） to the specified torque, as shown in Fig. 4-1-31. Tightening torque for fastening bolt of exhaust manifold pipe

Exhaust manifold pipe

30N·m±3N·m

Fig. 4-1-31 Installing the air exhaust manifold pipe Exhaust manifold pipe gasket

Exhaust manifold pipe

(2) Install the heat shield of exhaust manifold pipe, and tighten the 4 hexagon flange bolts (M6×12) to the specified torque. See Fig. 4-1-32. Tightening torque for the fastening bolt of exhaust manifold pipe heat shield 9 N·m±3 N·m Reinstalling the turbocharger ⑩

Heat shield

Fig. 4-1-32 Installing the heat shield of exhaust manifold pipe

(1) Install the turbocharger gasket and turbocharger, and tighten the single connecting bolt and the 2 fastening nuts for the turbocharger with specified torque. See Fig. 4-1-33. Tightening torques for the connecting bolt and fastening nut of turbocharger 45 N·m±3 N·m (2) Install the fuel return hose gasket and fuel return hose of turbocharger, and tighten the 2 hexagon flange bolts (M6×16) to the specified torque. See Fig. 4-1-33. Tightening torque for fastening bolt of turbocharger fuel return hose 9 N·m±3 N·m

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Chpter IV Mechanical System (3) Install the fuel inlet pipe of supercharger and fuel inlet bolt connecting the supercharger and tighten it according to the required torque.

Supercharger

Tightening torque for supercharger fuel inlet bolt 22 N·m±3 N·m Fuel hose

return

(4) Install the heat shield of turbocharger, and tighten the 3 hexagon flange bolts (M6×12) to the specified torque. See Fig. 4-1-33.

Heat shield

Tightening torque for fastening bolt of supercharger heat shield

Fig. 4-1-33 Installing the turbocharger

9 N·m±3 N·m (5) Connect the supercharger harness connector. Reinstalling the air intake manifold pipe ⑨

Air intake manifold pipe gasket

(1) Install the air intake manifold pipe gasket and the air intake manifold pipe to the exhaust side of the cylinder head. (2) Tighten the 7 hexagon flange bolts (M8×105, M8×25) and 2 hexagon flange nuts fastening the air intake manifold pipe, using specified torque. See Fig. 4-1-34. Tightening torque for fastening bolt and nut of air intake manifold pipe

Air intake manifold pipe

23 N·m±3 N·m Fig. 4-1-34 Installing the air intake manifold pipe Air intake pipe

Reinstalling GER condenser air intake pipe, EGR condenser air outlet pipe, EGR condenser ⑧ (1) Use 2 hexagon flange bolts (M10×16) to install the EGR condenser onto the cylinder head, but do not screw down the bolts right now.

Water outlet pipe

(2) Fit the water inlet pipe on the water pipe connector of EGR condenser, and clamp them with a single-ear step-less clamp.

EGR condenser

(3) Install the EGR condenser air intake pipe and gasket between the EGR condenser and air exhaust manifold pipe. Do not tighten them right now. See Fig. 4-1-35.

Exhaust pipe Water inlet pipe

Fig. 4-1-35 Installing the EGR Condenser

(4) Install the EGR condenser air exhaust pipe and the gasket on the EGR condenser, and tighten the 2 hexagon flange bolts (M8×16) to the specified torque. (5) Tighten the single hexagon flange bolt (M10×16) fastening EGR condenser, the 2 high-temperature resistant hexagon flange bolts (M18×1.25) connecting the air intake pipe to the air exhaust manifold pipe of the EGR condenser, and the 2 hexagon flange bolts (M18×20) connecting the air intake pipe and EGR condenser, using specified torques, as shown in Fig.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Air intake pipe

Water outlet pipe

4-1-36. Tightening torque for EGR system fastening bolt

EGR condenser

23N·m±3N·m Reinstalling the fuel injector assembly ⑦

Exhaust manifold pipe Water inlet pipe

(1) Tighten the supporting bolts of the fuel injector ballast by using the required torque onto the cylinder head. Tightening torque for supporting bolt of fuel injector ballast 25 N·m～3 N·m

Fig. 4-1-36 Installing the EGR Condenser

(2) Install the copper washer and O-ring to the fuel injector and make sure there is only one copper washer on the fuel injector and the copper washer is laid horizontally. (3) Plug the fuel injectors into the mounting holes on the cylinder head corresponding to cylinders 1, 2, 3 and 4 respectively according to the numbers 1, 2, 3 and 4 on fuel injector. Fuel injector assembly

(4) Place one end of the fuel injector ballast on ballast supporting bolt and the other end in fuel injector ballast groove. See Fig. 4-1-37.

Fig. 4-1-37 Installing the fuel injector assembly

(5) Install and tighten the fastening bolt washer component of fuel injector ballast as per the required torque.

Cylinder head cover

Tightening torque for fastening bolt of fuel injector ballast 23 N·m～35 N·m

Cylinder head cover packing

图 4-1-38 装配气缸盖罩密封垫 Fig. 4-1-38 Installing cylinder head packing

After the installation, make sure there is no gas leakage from the oil injector gasket. Reinstalling the cylinder head cover assembly ⑥ (1) Clean the cylinder head cover packing groove. (2) Check if the cylinder head cover packing is intact, and embed it into the cylinder head cover sealing groove, as shown in Fig. 4-1-38. (3) Install the cylinder head cover to the cylinder head, tighten the 16 hexagon flange bolts (M6×20) fastening the cylinder head cover to the cylinder head as per specified torque. See Fig. 4-1-39. Tightening torque for fastening bolt of cylinder head cover 9 N·m±3 N·m

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Chpter IV Mechanical System

Cylinder head cover

Reinstalling the heater water return pipe component ⑤

Water outlet pipe connecting pipe component

(1) Install the heater water return pipe component and tighten the 2 hexagon flange bolts (M6×16) connecting the heater water return pipe and cylinder head cover. See Fig. 4-1-40. (2) Tighten the hexagon flange bolt (M8×16) connecting the heater water return pipe and cylinder head cover. See Fig. 4-1-40. Tightening torques for fastening bolts of heater water return pipe component

Fig. 4-1-39 Installing the cylinder head cover and the water outlet pipe connecting pipe component

M6×16 M8×16

9 N·m±3 N·m 23 N·m±3 N·m

(3) Install the water outlet pipe connecting pipe, and tighten the 2 hexagon flange bolts (M8×16) connecting the water outlet pipe and cylinder head cover. See Fig. 4-1-39. Tightening torque for fastening bolt of water outlet pipe connecting pipe component 23 N·m±3 N·m Reinstalling the fuel return hose component ④

Fig. 4-1-40 Installing the heater water return pipe

Fuel inlet pipe of injector

Fuel return hose of fuel injector

(1) Use DELPHI fuel injector. Insert respectively the fuel return rubber hoses into 4 injector heads and position them in place. See Fig. 4-1-41. (2) Use BOSCH or XINFENG fuel injector. Remove the dust cap from the upper end of the fuel injector. Install 4 short connectors of the fuel return hose into the 4 holes at the upper end of the fuel injector, and fix them tightly with the spring clips. Install the other long connector to the fuel return tee on the high pressure pump, and fix it tight with a small steel strip type elastic hoop. (3) Install the fuel return hose support and clamp. Make sure the fuel return hose is sealed properly without leakage after installation.

Fig. 4-1-41 Installing the fuel inlet pipe and return hose of fuel injector

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Reinstalling the fuel inlet pipes of fuel injector and fuel rail ③

Bone-line

(1) Remove the dust cap from the upper end of the fuel injector. Install the fuel inlet pipe for the fuel injector, and tighten evenly the pipe connectors at both ends of the 4 fuel pipe as per the specified torque, as shown in Fig. 4-1-41.

Camshaft timing pulley

(2) Install the fuel inlet pipe of fuel rail, and tighten the pipe connectors at both ends of the fuel pipe to the specified torque. See Fig. 4-1-41.

Timing mark

Fig. 4-1-42 Installing the camshaft timing pulley Timing mark of damping pulley

Tightening torque for fuel inlet pipe connector of fuel injector and fuel rail 32 N·m±3 N·m Attention: Tighten the pipe connectors at both ends of the fuel injector fuel inlet pipe and ends of the fuel rail fuel inlet pipe simultaneously and evenly during installation so as to avoid pipe deformation. Make sure the fuel inlet pipe of fuel injector and fuel rail is sealed without leakage after installation.

Timing mark of timing hood component II

Damping pulley

Fig. 4-1-43 Installing the timing system Horizontal Timing mark bar

Fuel pump pulley

Reinstalling the timing system ② (1) Install the woodruff key to the exhaust camshaft, install the timing pulley to the exhaust camshaft and tighten the fastening bolt washer component to the required torque. The camshaft timing pulley should be pressed and installed to the right position without deflection. (2) Adjust the scale mark on camshaft timing pulley to align it with the joint (at exhaust side) between cylinder head and camshaft bearing cap. See Fig. 4-1-42. Tightening torque for bolt washer component of camshaft timing pulley 110 N·m±5 N·m

Fig. 4-1-44 Installing the timing system

(3) Align the timing marks on damping pulley and timing hood II. See Fig. 4-1-43. (4) Align the timing mark on the fuel pump pulley with the horizontal bar on the water pump housing. See Fig. 4-1-44. (5) Install the timing belt. During the installation, make sure the belts, except the timing tension pulley, are connected with the pulley firmly without any looseness. See Fig. 4-1-45. (6) Install the timing tension pulley. Fix the limit bracket of the timing tension pulley in the place where the bowl

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Chpter IV Mechanical System

Timing pulley

Timing tension pulley

Fig. 4-1-45 Installing the timing belt

shaped plug is installed on the cylinder head, and then use a hexagon socket head spanner to turn the pinhole-mounting position clockwise until it is slightly over 30°past the vertical direction and the tension pulley arm indicator is 1°~2°past the lower verge of the installation arm notch, and tighten the fastening bolts. After taking off the hexagon socket head spanner, camshaft pulley dowel pin and crankshaft locking tooling, turn the crankshaft 2 circles clockwise with the spanner to make sure the damping pulley, camshaft timing pulley and fuel pump pulley align with the timing mark and the belt fits properly. If there is any pulley that is not aligned properly, loosen the fasting bolt of timing pulley and install them again to align the pulley properly. So that one cylinder is just at the top dead center of the compression stroke, and the valve timing is accurate. See Fig. 4-1-46. Attention: If any pulley mark is not aligned and it is required to turn the vehicle to align or inspect it, never turn the vehicle anticlockwise. See Fig. 4-1-46. Tightening torque for timing tension pulley bolt 22 N·m～26 N·m

Use a hexagon socket head spanner to adjust the mounting hole.

Analog

notch

Fig. 4-1-46 Installing the timing tension pulley

(7) Install the timing hood and timing hood component I. Screw down 10 hexagon flange bolts (M6×16, M10×35 and M10×50) to the front end of cylinder head and cylinder body by using the specified torque. See Fig. 4-1-47. Tightening torque for fastening bolt of timing hood 45 N·m±3 N·m Tightening torque for fastening bolt of timing hood component I 9 N·m±3 N·m Reinstalling the engine accessories ① (1) Reinstall the wedge idle wheel to the front end of the cylinder body and tighten it to the required torque.

Fig. 4-1-46 Installing the timing hood component

Visually checked, the pulleys should be on the same plane. Tightening torque for wedge idle wheel 22N·m～26N·m (2) Reinstall the generator belt, use a special tool to turn the tension pulley, and install it after the belt is loose enough.

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Rotary installation position of tension pulley

After the installation, check the generator belt. Make sure the belt wedge-shaped teeth perfectly match the pulley wedge slot.

Generator belt

Caution: The excessive or insufficient tightening of belt is not allowed.

Fig. 4-1-48 Installing the engine accessories

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Chpter IV Mechanical System

Section II Camshaft

Dismounting procedure ① Engine accessories ② Timing system ③ Fuel inlet pipe component of fuel injector ④ Fuel return hose component ⑤ Heater water return pipe component ⑥ Cylinder head cover assembly ⑦ Fuel injector assembly ⑧ Vacuum pump assembly ⑨ Camshaft bearing cap ⑩ Intake/exhaust camshaft assembly

Reinstallation procedure Reinstall them in the opposite order of dismounting.

Fig. 4-2-1 Disassembly and reassembly sequences for camshaft

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Disassembly Disassembling the engine accessories ① Rotary installation position of tension pulley

(1) Remove the generator belt Generator belt

Turn the tension pulley with tools until the belt is loose enough, and then remove the engine belt, as shown in Fig. 4-2-2. (2) Remove the wedge idle wheel. Loosen the fastening bolts of the wedge idle wheel, and then remove the wedge idle wheel.

Fig. 4-2-2 Removing the engine accessories

Disassembling the timing system ② (1) Remove timing hood component I and the timing hood. See Fig. 4-2-3. (2) Removing the timing belt: Loosen the timing tension pulley to disassemble the timing belt after it is loosened enough. See Fig. 4-2-3. (3) Removing the timing tension pulley assembly: Loosen the combined fastening bolt of timing tension pulley and remove the camshaft timing belt pulley. (4) Removing the camshaft timing pulley: Loosen the bolt component of camshaft timing pulley and remove the camshaft timing pulley.

Fig. 4-2-3 Removing the timing system

Fuel inlet pipe of injector

Fuel return hose of fuel injector

Disassembling the fuel inlet pipe component of the fuel injector ③ (1) Loosen evenly the pipe connectors at both ends of the 4 fuel injectors with a spanner. (2) Take off the 4 fuel inlet pipes of the fuel injector respectively. See Fig. 4-2-4. Attention:

Fig. 4-2-4 Removing the fuel inlet pipe and fuel return hose components of the fuel injector

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——When removing the fuel inlet pipe of the fuel injector, loosen the pipe connectors at both ends of the fuel pipe simultaneously and evenly to prevent the fuel pipe from deforming. ——After removing the fuel inlet pipe of the fuel injector, use plug covers to cover the fuel inlet of the fuel injector, the fuel port of the high pressure fuel rail, and both ends of the fuel inlet pipe of the fuel injector, so as to prevent sundries from blocking the fuel injector.

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Chpter IV Mechanical System Disassembling the fuel return hose component ④ (1) Remove the fuel return hose bracket and clamp. (2) Select the DELPHI fuel injector, pull out the 4 fuel return hoses connected to fuel injector, and then take down the fuel return hose component. See Fig. 4-2-4. (3) Use the BOSCH or XINFENG fuel injector. Use a tool to push out the clip, pull out the fuel return connector from each fuel injector, and then remove the fuel return hose component.

Fig. 4-2-5 Removing heater water return pipe component

Attention: The removed fuel return hose can be used again and should be kept safely and cleanly. Disassembling the heater water return hose component ⑤ (1) Remove the 2 hexagon flange bolts (M6×16) connecting the heater water return pipe component to the cylinder head cover. (2) Remove the 1 hexagon flange bolt (M8×16) connecting the heater water return pipe component to the cylinder head cover. See Fig. 4-2-5. Disassembling the cylinder head cover assembly⑥

Cylinder head cover

Water outlet pipe connecting pipe component

(1) Remove the 2 hexagon flange bolts (M8×16) for fixing the water outlet pipe connecting pipe component, and take down the water outlet pipe connecting pipe component. (2) Remove the 16 hexagon flange bolts (M6×20) fastening the cylinder head cover to the cylinder head, and take down the cylinder head cover. See Fig. 4-2-6. (3) Take out the packing from the sealing groove of cylinder cover.

Cylinder head cover packing

Fig. 4-2-6 Removing the cylinder head cover assembly

Check the cylinder head packing and replace it if there is any damage or deformation. Disassembling the fuel injector⑦ (1) Removing the fuel injector harness plug: Pull out the harness plug self-locking device, and then remove the fuel injector harness plug. (2) Remove the bolts of fuel injector ballast bolts. See Fig. 4-2-7. (3) Remove the fuel injector ballast

Fuel injector assembly

Fig. 4-2-7 Removing the fuel injector assembly

(4) Take out the fuel injector assembly from the mounting hole of fuel injector on the cylinder cover. Prompt: Place the removed fuel injectors carefully according to the cylinder serial numbers 1, 2, 3 and 4, and make corresponding marks on these fuel injectors. Protect them from being contaminated or bumped. Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES Disassembling the vacuum pump assembly⑧ Cylinder head

(1) Pull out the vacuum connecting hose from the vacuum pump. (2) Remove the 3 hexagon flange bolts (M6×20) connecting the vacuum pump and cylinder head flange. See Fig. 4-2-8.

Vacuum pump assembly

(3) Remove the vacuum pump assembly from the rear end of the cylinder head exhaust camshaft.

Fig. 4-2-8 Removing the vacuum pump assembly Disassembling the camshaft bearing cap ⑨ (1) Remove the 22 hexagon flange bolts (M6×35 and M6×20) for fastening the camshaft bearing cap in the order from the two sides of camshaft bearing cap symmetrically to the center. See Fig. 4-2-9.

Camshaft bearing cap

(2) Remove the camshaft bearing cap from the cylinder head.

Cylinder head

Fig. 4-2-9 Removing the camshaft bearing cap Camshaft

Disassembling assembly ⑩

the

Intake/exhaust

camshaft

(1) Take out the intake/exhaust camshaft assembly respectively from the cylinder head, as shown in Fig. 4-2-10. (2) Remove the plug cover and the front oil seal of camshaft. (3) Check the front oil seal of camshaft and replace it if it is damaged. Cylinder head

Inspection and repair Fig. 4-2-10 Removing the intake/exhaust camshaft

The parts should be adjusted, repaired or replaced if any excessive worn or damage is detected during inspection. 1. Checking the outer diameter of the camshaft journal Use a micrometer screw to measure the outer diameter of each camshaft journal from two sides （① and ②）. See Fig. 4-2-11. Replace the camshaft if the measured value is below

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Chpter IV Mechanical System the limitation. Outer diameters of the camshaft journals Standard Intake camshaft

26.947～26.960 mm

Exhaust camshaft

26.947～26.960 mm， 26.947～26.960 mm

2. Checking the height of the cam Fig. 4 -2-11 Measuring the outer diameter of the camshaft journal

Use a micrometer to measure the height of the cam （H）. See Fig. 4-2-12. Replace the camshaft if any measured value is below the limitation. Heights of the cam Standard Intake camshaft

35.10～35.20 mm

Exhaust camshaft

33.58～33.68 mm

3. Checking the radial runout of the camshaft Put the camshaft on a V-block. Fig. 4 -2-12 Measuring the height of the cam

Use a micrometer to measure the radial runout of the camshaft. See Fig. 4-2-13. Replace the camshaft if the measured value exceeds the limitation. Radial runout of the camshaft Standard

Limitation

≤0.02  mm

0.10 mm

4. Measuring the camshaft bearing clearance

Fig. 4 -2-13 Measuring the radial runout of the camshaft

Use an inside micrometer to measure the inner diameter of the camshaft bearing. Inner diameters of the camshaft bearings Standard Intake camshaft

27.000～27.021 mm

Exhaust camshaft

30.000～30.021 mm， 27.000～27.021 mm

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

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MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES camshaft bearing clearance Camshaft

Standard

Limitation

0.025～0.085 mm

0.120 mm

Replace the cylinder head assembly if the camshaft bearing clearance exceeds the limitation. Reassembly Cylinder head

Reassembling assemblies⑩

Fig. 4-2-14 Installing the exhaust/intake camshaft assembly

intake/exhaust

camshaft

(1) Apply an appropriate amount of lubricating oil onto the surface of the and exhaust camshafts in the cylinder head.

Camshaft bearing cap Apply sealant

the

Mobil API CI-4 lubricating oil (2) Fix the intake and exhaust camshafts into the cylinder head as shown in Fig. 4-2-14.

the

(3)   Align   the  marks   “·”   on   the   driving   gears   of   exhaust   and intake camshaft and get it in line with the upper surface. Axial clearance of camshaft

Cylinder head

0.060～0.115 mm Fig. 4-2-15 Installing the camshaft bearing cap and applying sealant

Reassembling the camshaft bearing cap ⑨ (1) Apply anaerobic plane sealant to the junction surface between the camshaft bearing cap and the cylinder head. See Fig. 4-2-15.

Camshaft bearing cap

LOCTTTE510 anaerobic plane sealant Attention: ——The sealant on the junction surface between the camshaft bearing cap and the cylinder head should be cleared away properly if the former cylinder head is to be used.

Cylinder head

Fig. 4-2-16 Installing the camshaft bearing cap

——The camshaft bearing cap bolts should not be allowed for more than two times of removal and reinstallation. If they have to, they should be replaced. (2) To install the camshaft bearing cap, screw down 16 hexagon flange bolts (M6×35) of camshaft bearing cap to the specified torque and in the specified order, then tighten the surrounding 6 hexagon flange bolts (M6×20) from the center to both sides. See Fig. 4-2-15. Tightening torque for the bolt of camshaft bearing cap

142

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Chpter IV Mechanical System 9 N·m±3 N·m Cylinder head

Reassembling the vacuum pump assembly⑧ (1) Install the vacuum pump to the rear end of the cylinder head exhaust camshaft, with the flat bump of its bearing inserted into the groove of the rear end of the cylinder head exhaust camshaft and the rabbet and the rabbet round hole matched perfectly.

Vacuum pump assembly

(2) Tighten the 3 hexagon flange bolts (M6×20) connecting the vacuum pump and cylinder head flange and screw them down as per specified torque. See Fig. 4-2-17. Fig. 4-2-17 Installing the vacuum pump assembly Tightening torque for vacuum pump fastening bolt 9 N·m±3 N·m (3) Install the vacuum connecting pipe. There should be no deflection or misplacement after installation. Reassembling the fuel injector assembly ⑦

Fuel injector assembly

(1) Tighten the supporting bolts of the fuel injector ballast by using the required torque onto the cylinder head.

Fig. 4-2-18 Installing the fuel injector assembly

Tightening torque for supporting bolt of fuel injector ballast

Cylinder head cover

23 N·m±3 N·m (2) Install the copper washer and O-ring to the fuel injector and make sure there is only one copper washer on the fuel injector and the copper washer is laid flatly. (3) According to the numbers 1, 2, 3 and 4 on the fuel injector lines, install the fuel injectors into the corresponding fuel injector mounting holes in the cylinder heads 1, 2, 3 and 4.

Cylinder head cover packing

Fig. 4-2-19 Installing the cylinder head cover assembly

(4) Place one end of the fuel injector ballast on ballast supporting bolt and the other end in fuel injector ballast groove. (5) Install and tighten the fastening bolt component of fuel injector ballast to the required torque. No air leakage is allowed at the injector gasket. Tightening torque for fastening bolt component of fuel injector ballast

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

143

MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES

Cylinder head cover

Water outlet pipe connecting pipe component

25 N·m～35 N·m Reassembling the cylinder head cover assembly ⑥ (1) Clean the cylinder head cover packing groove. (2) Check whether the cylinder head cover packing is intact, and embed it into the cylinder head cover packing groove. See Fig. 4-2-19. (3) Install the cylinder head cover to the cylinder head, tighten the 16 hexagon flange bolts (M6×20 and M16×35) fastening the cylinder head cover as per specified torque. See Fig. 4-2-20.

Fig. 4-2-20 Installing the cylinder head cover assembly

Tightening torque for fastening bolt of cylinder head cover 9 N·m±3 N·m Reinstalling the heater water return pipe component ⑤ (1) Install the heater water return pipe component and tighten the 2 hexagon flange bolts (M6×16) connecting the heater water return pipe and the cylinder head cover. See Fig. 4-2-21. (2) Tighten the hexagon flange bolt (M6×16) connecting the heater water return pipe and cylinder head cover. See Fig. 4-2-21.

Fig. 4-2-21 Installing the heater water return pipe component

Fuel inlet pipe of injector

Fuel return hose of fuel injector

Tightening torques for fastening bolts of heater water return pipe component M6×16

9 N·m±3 N·m

M8×16

23 N·m±3 N·m

(3) Install the water outlet pipe connecting pipe component