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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

Great Wall Baoding Internal Combustion Engine


II 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.

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III
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

Great Wall Baoding Internal Combustion Engine


IV 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

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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
1. Model Mark ................................................................................................................................ 56
2. Air Cleaner ................................................................................................................................. 56
3. Lubrication System .................................................................................................................... 57
4. Fuel System ............................................................................................................................... 58
5. Cooling System .......................................................................................................................... 59
6. Engine Control ........................................................................................................................... 61

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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

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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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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

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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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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

Removing sequence
① Oil pump
Front oil seal ② Rubber seal ring
assembly of ③ Outer rotor
crankshaft 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:

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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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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;;  

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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.

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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

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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.
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
Fig. 1-7-1 Removing the Negative (-) Cable of connects to the vehicle body and constitutes the earth
Battery 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.
3.5 Unscrew the nut when connecting the cable terminal
Sealant
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
Fig. 1-7-2 Precoating Sealant on Parts 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.
6. Precoated parts: refer to parts that are coated with
Indicating torque spanner 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
Scale indication torque spanner in any way, it must be recoated with the specified
sealant.
6.2 When reusing a precoated part, clear the old sealant
Fig. 1-7-3 Torque Spanner 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.

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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.
9. Special repair tools, instruments (see Table 2-11-1)
and special repair materials (see Table 2-6-8, 2-6-9)
Hydraulic jack Scissor jack 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
Fig. 1-7-4 Jack
"Chapter II Technical   Information   of   Engine”   in   this  
manual.
10. Be sure to take care when jacking up and
Incorrect Correct
Correct supporting the vehicle. Be sure to lift and support the
vehicle at the proper locations.
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 11. Observe the following precautions to prevent
Vacuum Hose 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
Correct
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.
11.3 To pull apart the circuit connectors, pull the
connector itself but not the wires, as shown in Fig.
1-7-6.
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
Fig. 1-7-6 Checking the Conductor Connector 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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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.
(2) The antenna feeder should be installed more than
20 cm away from the ECU and sensors of automotive
Fig. 1-7-7 Electric Control System Elements
electronic system. For the positions of the ECU and
of Engine
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.
The function of the cylinder head is to seal the upper
part of the cylinder and make the upper part of the
Cylinder body 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,
Fig. 2-1-1 Cylinder Head and Cylinder Body 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
Connecting
mechanisms and systems of the diesel engine; it is the
rod 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.
The crank and connecting rod mechanism can
accomplish the interconversion between the linear
Connecting reciprocating motion of piston (in cylinder) and the
rod cap 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
Fig. 2-1-2 Crank and Connecting Rod
crank and connecting rod mechanism mainly consists of
Mechanism
the piston, connecting rod, crankshaft, flywheel, etc.
3. Valve Actuating Mechanism and
Intake/Exhaust System
Camshaft The valve actuating mechanism, intake and exhaust
assembly 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
Intake/exhaust possible timely. It mainly consists of the valve
valve component
components (the intake and exhaust valve, valve
Fig. 2-1-3 Valve Actuating Mechanism pin/clip, valve spring, spring seat, valve oil seal, etc.),
transmission mechanism (the belt, pulley,
intake/exhaust camshaft assembly, rocker arm,

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hydraulic lash adjuster, etc.), air filter, intake/exhaust


Cylinder head 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.

Air intake manifold

Cylinder head
installation assembly

Exhaust manifold

Fig. 2-1-4 Intake/Exhaust System


Cylinder head 4. Turbocharging System
installation assembly
The turbocharging system of engine is as shown in Fig.
2-1-5.
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
Cylinder body therefore the power per liter and output power of the
diesel engine are improved.
Turbocharger assembly

Fig. 2-1-5 Turbocharging System

Oil inlet pipe Oil return hose 5. Fuel Supply System


component component
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
High
pressure
pressure to provide necessary conditions for sufficient
Oil combustion of diesel; at the same time, it adjusts the oil
oil rail
injector supply quantity according to the loading condition of the
assembly
assembly
diesel engine, and ensures a steady output power. The
High pressure oil fuel supply system mainly consists of the fuel tank, fuel
pump assembly
filter, fuel delivery pump, high pressure fuel pump, high
pressure fuel rail, fuel injector, high/low pressure fuel
Fig. 2-1-6 Fuel Supply System pipe, and all kinds of sensors, etc.

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Chapter II Technical Information of Engine

6. Lubrication System
Cylinder body The lubrication system of engine is as shown in Fig.
2-1-7.
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
Engine oil filter prevention. The lubrication system is mainly composed
of the oil collector, oil pump, oil filter, oil cooler, oil
pressure alarm, lubricating oil pipeline, etc.
Fig. 2-1-7 Lubrication System
7. Cooling System
Cylinder body
The cooling system of engine is as shown in Fig. 2-1-8.
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
Water pump tank), water pump, thermostat, fan, etc.
installation
assembly 8. Startup Device
The startup device of engine is as shown in Fig. 2-1-9.
Thermostat assembly 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
Fig. 2-1-8 Cooling System
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
Starting motor 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
Fig. 2-1-9 Startup Device damage to engine parts may be caused.

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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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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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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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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.

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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.

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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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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 Technical Parameter
Model No. GW4D20/GW4D20B
Type 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
Number of Cylinders cylinder 4
Cylinder Diameter X Stroke mm 83.1×92
Total Displacement L 1.996
Compression Ratio 16.7:1
Rated Power and Corresponding r/min 110/4000 GW4D20
Rotation Speed 100/4000 GW4D20B
Max. Torque and Corresponding N·m/ 310/1800~2800
Rotation Speed (r/min)
Min. Fuel Consumption Rate g/kW·h 210
Max. No-load Rotation Speed r/min 4400
Idle Rotation Speed r/min 750±50
Fuel China IV diesel without nitro additives
Fuel Grade 0# vehicle fuel (-10# or -20#, -35# diesel can be used
in winter according to temperatures) (GB19147-2009)
Air Valve Clearance 0 (hydraulic tappet)
Fuel Injection Sequence 1—3—4—2
Rotation Direction (viewing from the Anticlockwise
flywheel end)
Max. Fuel Injection Pressure Bar 1600
Oil Injection Control Electric control
Intake valve opened ℃A 24°
(before the piston
arrives at the top dead
center (TDC))
Intake valve closed ℃A 50°
Valve (after the piston arrives
Actuating at the bottom dead
Phase center (BDC))
(℃A) Exhaust valve open ℃A 86°
(before piston arrives at
BDC)
Exhaust valve closed ℃A 16°
(after the piston arrives
at the TDC)
Note. ①1 bar = 105 Pa.

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(Continued)

Item Unit Technical Parameter

Lubrication Mode 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 3

Normal, Max. working water Normal water temperature: 80 ℃ ~ 90 ℃; Max.


temperatures of the diesel engine, water temperature: 110 ℃; thermostat full opening
opening temperature of large and temperature: 80 ℃ (the thermostat is located at
small cycles, and water circulation the water inlet)
direction

Net mass of diesel engine (including kg 215 GW4D20


the air condition compressor, power 210 GW4D20B
steering oil pump, cooling water)

Contour Dimensions (L x W x H), mm 694×625×829 GW4D20


transmission excluded 694×615×829 GW4D20B

Max. rotation speed r/min

Turbocharger Max. durative ℃ 210000


working
temperature

Noise Acoustic Power Limits dB/A 760 VGT/750 WGT

Exhaust Pollutants Limits g/km ≤  110  (complying  with  GB  14097-1999)

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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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

Rotation direction Clockwise (viewing from the direction of pulley)


Generator
Polarity Cathode earthing

Working mode Continuous rated type

High speed voltage of


V 14.5±0.3
regulator

Voltage V 12

Starting Output power kW 2


Motor
Clockwise (viewing from the direction of driving
Rotation direction
gear)

(Continued)

Item Unit Technical Parameter

Storage
Rated voltage V 14
Battery

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


80℃~90℃ Idle engine oil pressure ≥0.3Mpa
System

Engine oil pressure at


Engine Oil of
≤120℃ the calibrated rotation ≥0.4Mpa
Lubrication System
speed

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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 Specification Accessory System and Name Specification
Cross-section
Oil pump Rotor type VGT variable type
Lubrication Air intake turbocharger
Turbocharger
System system Turbocharger
Engine oil filter Rotary type WGT with bypass
valve
Integral type:
equipped with Centrifugal
DELPHI Water pump type
fuel-water type
separator
Rotary installation
type: equipped
Fuel filter BOSCH
with fuel-water
separator Pumping lift (4500
Cooling 16m
Rotary installation r/min)
system
type: equipped
Xin Feng
with fuel-water
separator
Double plungers,
DELPHI equipped with fan
blade pump, IMV Wax-type
High Thermostat type
thermostat
Oil Supply pressure Triplex plunger
System BOSCH
fuel pump pump
Double plunger
Xin Feng
pump Continuous
Working mode
Max. oil supply rated type
DELPHI
pressure 1600 bar
High
Max. fuel supply
pressure BOSCH
pressure 1600bar
fuel rail Max. rotation speed 2800
Vacuum
Max. fuel supply pump
Xin Feng
pressure 1600 bar
DELPHI 7-hole Max. vacuum degree 90
Fuel BOSCH 6-hole Time for
injector Time for achieving achieving 50
type the vacuum degree kPa < 5
Xin Feng 6-hole
(400r/min)

Note. ①1 bar=105 Pa.

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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 Installation Position Specification
Double plunger,
DELPHI equipped with fan blade
High Pressure Fuel Rear end face of water pump, IMV
Pump pump housing
BOSCH Triplex plunger pump
Xin Feng Double plunger pump
DELPHI 7-hole
Top surface of cylinder
Fuel injector BOSCH 6-hole
head
Xin Feng 6-hole
Max. fuel supply
DELPHI
pressure 1600 bar
Left side of cylinder Max. fuel supply
High pressure fuel rail BOSCH
body pressure 1600 bar
Max. fuel supply
Xin Feng
pressure 1600 bar
Electronic Control Unit
Inside the engine hood Working voltage 12 V
(ECU)
Rotation Speed Sensor Upper cylinder body Working clearance 0.5 ~ 1.5 mm
Camshaft Phase
Cylinder head cover Working clearance 0.5~1.5mm
Sensor
Rated voltage: 5 V ± 0.15 V, NTC-type, rated
Water Temperature
Cylinder head resistance:  2.5  kΩ  ±  0.6%  at  20  ℃ and  0.186  kΩ  ±  
Sensor
2% at 100 ℃
Air Intake Pressure
Air intake manifold DS-S3
Sensor
Lateral surface of
Heater Plug Heated to 800 ℃ in 8 s
cylinder head
Rear end of air intake
EGR Valve Vacuum type
manifold
Equipped with manual fuel delivery pump,
fuel-water separator, diesel heater (flow rate: 125
L/h), particle filterability of paper filter core: >15
Fuel filter Frame
μm100%,  3~5  μm  94.5%,  replacement  period  of  
filter core: every 25000 ~ 30000 km of driving
range

Note. ①1 bar=105 Pa.

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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 Parts Name and Installation Tightening Torque


Parts Code
No. Specification Position Value (N·m)

Connecting rod
Connecting rod 25 ± 3, rotation angle
1 1004303—ED01 ——connecting rod
bolt 90° ± 5°
cap

Cylinder body
Bolt and washer 50 ± 3, rotation angle
——cylinder head
2 1003700—ED01 component of 90°, rotating an
gasket ——cylinder
cylinder head additional 120°
head

Bolt and washer


component of Camshaft pulley
3 1021800—ED01 110±5
camshaft timing ——camshaft
pulley

Flywheel
4 1005011—ED01 Flywheel bolt 75±5
——camshaft

Cylinder body 40 ± 3, rotation angle


Main bearing cap
5 1002116—ED01 ——main bearing 90°, rotating an
bolt
cap additional 90°

Crankshaft timing
Bolt of crankshaft
6 1021014 一 ED01 pulley 185~195
timing pulley
——crankshaft

Damping pulley of
Hexagonal flange
7 Q1840820F32 crankshaft 23±3
face bolt
——crankshaft

8 1009106—ED01A Fuel drain bolt (hex Fuel pan assembly 40±5

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Chapter II Technical Information of Engine

Sequence Parts Name and Installation Tightening Torque


Parts Code
No. Specification Position Value (N·m)
head screw plug)

Filter pipe Cylinder body


9 101701l—ED01 50~60
connector ——filter

Coolant
temperature
10 3611070—ED01 sensor (water Cylinder head 18~22
temperature
sensor)

Fastening bolt of Timing idle wheel


11 1021031 一 ED01 43±4
timing idle wheel ——oil pump

12 1002800—ED01 Oil pressure alarm Upper cylinder body 13~17

Fastening
Timing tension
combination bolt of
13 1021032 一 ED01 pulley ——cylinder 22~26
timing tension
head
pulley

Fastening bolt of
Oil pump ——timing
14 3701014 一 ED01 accessory idle 22~26
hood
wheel

Fastening bolt of
15 3701016 一 ED01 accessory tension Compressor support 53~57
pulley

Heater plug
16 3770100—ED01 Cylinder head 9~12
assembly

All-metal High pressure oil


hexagonal pump pulley
17 Q33014T13F2 65±3
flange-face locknut ——high pressure
(M14X1.5) fuel pump

Fuel intake pipe


1118013 一 ED01 Fuel intake bolt of ——turbocharger
18 22±3
1118013 一 ED01B turbocharger Fuel intake pipe
——cylinder block

Hex head tapered


19 Q618B02F32 screw plug (water Upper cylinder body 25±3
drain screw plug)

Hexagonal flange Exhaust manifold


20 Q32008F32 30±3
face nut ——cylinder head

For the tightening torque standards for general fasteners of GW4D20/GW4D20B turbocharged diesel
engine, see Table 2-6-2.

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Table 2-6-2 Tightening Torque Standards for General Fasteners of GW4D20/GW4D20B


Turbocharged Diesel Engine

Torque Torque
Sequence Fastener Sequence Fastener
Limit Remarks Limit Remarks
No. Specification No. Specification
(N·m) (N·m)

1 M6 x1 9±3 Performance 4 M10 x1 45±3 Performance


grade 8.8, grade 8.8,
2 M8 x1 25±3 please refer to 5 M10 x1.25 45±3 please refer to
QC/T QC/T
3 M8 x1.25 23±3 518-1999 6 M12 x1.75 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
Name of Fit Clearance of Parts Fit Clearance Value (mm) Remarks
No.
See Page 153, 210,
1 Camshaft axial clearance 0.060~0.115
220, 230, 293
See Page 131, 165,
2 Crankshaft axial clearance 0.10~0.28
275, 288
0.055 ~ 0.100 (the first
compression ring)
Side clearance between piston ring 0.035 ~ 0.080 (the second See Page 147, 150,
3
and piston ring groove compression ring) 257
0.030 ~ 0.070 (oil ring
component)
0.20 ~ 0.40 (the first
compression ring)
0.65~0.85 (the second See Page 146, 150,
4 Opening clearance of piston ring
compression ring) 257
0.25 ~ 0.50 (oil ring
component)
Clearance between big end of See Page 151, 258,
5 0.22~0.37
connecting rod and crankshaft crank 276, 290
See Page 150, 258,
6 Piston cylinder clearance 0.07~0.09
276, 290
Clearance between piston pin and
7 0.005~0.012 See Page 147, 149
piston pin hole
Clearance between piston pin and
8 0.010~0.024 See Page 147, 149
connecting rod small end hole

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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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

Color of Main Bearing Shell 1 2 3

φ60.015~φ60.020 φ60.009~φ60.014 φ60.002~φ60.008

Thickness of Thickness of Thickness of


shell: 1.976 shell: 1.976 shell: 1.980 ~
~ 1.980 ~ 1.980 1.984
1 φ64.000~φ64.006 Yellow Yellow N/A
Clearance: Clearance: Clearance:
0.020 ~ 0.026 ~ 0.024 ~
0.040 0.046 0.044

Main Thickness of Thickness of Thickness of


Bearing shell: 1.976 shell: 1.980 shell: 1.984 ~
Aperture ~ 1.980 ~ 1.984 1.988
2 φ64.007~φ64.012 Yellow N/A Blue
of Clearance: Clearance: Clearance:
Cylinder 0.026 ~ 0.024 ~ 0.022 ~
Body 0.046 0.044 0.042

Thickness of Thickness of Thickness of


shell: 1.980 shell: 1.984 shell:
~ 1.984 ~ 1.988 1.984~1.988
3 φ64.013~φ64.018 N/A Blue Blue
Clearance: Clearance: Clearance:
0.024 ~ 0.022 ~ 0.022 ~
0.044 0.042 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
Fit Clearance
Group No. of Main Crankshaft code (number)
Journal (1, 2, 3)

=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

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

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Table 2-6-6 Matching Selection by Group of Cylinder Bores and Pistons

cylinder Bore
Mark Piston Dimension by Group Mark Fit Clearance
Dimension (φ)

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 Position for Daubing or Injecting


Remarks
No. Lubrication Oil on Assembly Parts

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

Between crankshaft thrust plate and crank


3 See Page 135, 165, 275, 289
arm thrust face

4 Cylinder bore wall See Page 135, 150, 166, 257, 276, 289

Internal surface of connecting rod bearing


5 See Page 136, 150, 166, 257, 276, 289
shell and surface of crankshaft crank pin

Surface of piston pin hole, piston ring groove,


6 piston pin surface, connecting rod small end See Page 136, 149, 257, 276, 290
hole

Internal surface of bearing hole of the


See Page 107, 117, 139, 203, 210, 220,
7 intake/exhaust camshaft of cylinder head,
230, 259, 279
surface of camshaft journal

See Page 107, 117, 139, 203, 210, 220,


8 Camshaft
230, 259, 279

Mounting hole of hydraulic tappet, and the See Page 106, 127, 139, 152, 210, 229,
9
surface of tappet 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 Name of the Coated


Position for Coating Sealant Specification and Model
No. Sealant

Joint surface between oil pump Silicon rubber flat


1 LOCTITE 587 flat sealant
and cylinder body/fuel pan sealant

Joint surface between fuel pan Silicon rubber flat


2 LOCTITE 587 flat sealant
and lower cylinder body sealant

Joint surface between upper Silicon rubber flat


3 LOCTITE 587 flat sealant
fuel pan and lower fuel pan sealant

Joint surface between upper


LOCTITE 510 anaerobic flat
4 cylinder body and lower Anaerobic flat sealant
sealant
cylinder body

Joint surface between cylinder


Anaerobic flag LOCTITE 510 anaerobic flat
5 head and camshaft bearing
sealant sealant
cap

Threaded section of water Anaerobic thread


6 LOCTITE 243 thread fixative
drain screw plug fixing sealant

Threaded section of oil Anaerobic thread


7 LOCTITE 243 thread fixative
pressure alarm assembly fixing sealant

Threaded section of water Anaerobic thread


8 LOCTITE 243 thread fixative
temperature sensor fixing sealant

Water outlet pipe component,


heater water return pipe Anaerobic fixative for TONSAN 1608 sealing fixative
9
connector, and all pipe cylindrical parts for bowl-shaped plugs
connectors on cylinder body

bowl-shaped plugs on cylinder Anaerobic fixative for TONSAN 1608 sealing fixative
10
body and cylinder head cylindrical parts 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 Capacity Recommended Lubricating oil Grades

Total Engine Oil


Amount
6.0 L
Replace Oil Filter Mobil Oil Corp., API CI-4 Plus diesel engine oil (choose
Refill 0.5 L
according to the ambient temperature)
Replace the
5.0 L
Compete Machine
Oil

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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
Vehicle Load Rotation Speed of Diesel Engine (r/min)
Distance (km)

Not over 50% the rated rotation speed of the


0~300 No-load
corresponding diesel engine

Not over 50% of the rated Not over 50% the rated rotation speed of the
>301~1000
load corresponding diesel engine

Not over 50% of the rated Not over 75% of the rated rotation speed of the
>1001~1500
load corresponding diesel engine

Not over the rated Max. rotation speed of diesel


>1501~2500 Full load
engine

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

Vehicle Traveling
Vehicle Load Rotation Speed of Diesel Engine (r/min)
Distance (km)

Not over 50% of the rated rotation speed of the


0~100 No-load
corresponding diesel engine

Not over 50% of the rated Not over 50% of the rated rotation speed of the
>101~250
load corresponding diesel engine

Not over 75% of the rated Not over 75% of the rated rotation speed of the
>251~450
load corresponding diesel engine

Not over the rated Max. rotation speed of diesel


>451~500 Full load
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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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 First level Second level Third level
cycle Daily Remarks
maintenance maintenance maintenance
technical
Maintenance maintenance 4000 ~ 4000 ~ 4000 ~ 100,000
Items 5000 km 12,500 km km
Check the oil level
Replace the oil (normally per 8000
Diesel engine oil (recommended to check it
~ 10000 km)
per 500 ~ 1000 km)
Replace the oil filter (normally per
Oil filter
8000~10000km)
Replace the diesel filter (normally
per 20000 ~ 25000 km for
GW4D20 turbocharged diesel
engine)
Fuel (diesel) filter
Replace the diesel filter(normally
per 8000 ~ 10000 km for
GW4D20B turbocharged diesel
engine)
coolant Check the fluid level
Normally, replace the filter core per
Air cleaner clean
30000 km.
Parts and various
electrical
connectors Check, tighten, repair
loosed and
damaged
Working condition
Check if it operates normally
of diesel engine
Check and remove oil leakage, water leakage, air leakage and
Four leakages
electricity leakage.
Appearance of
Keep clean
diesel engine
Belt of generator Inspect, adjust, replace
Connecting parts
Check,
of fuel pipes
tighten,
loosed and
repair
damaged
Radiator clean
Connection of
Check, maintain
turbocharger
To check it in
Check or replace it when
Fuel injector a professional
malfunction displays
service station
Replace the belt To repair it in
Timing driving Check the appearance of
(normally per a professional
belt driving belt
80000 ~ 100000 service station

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km)
when replacing the
belt, replace the
tension pulley
Tension pulley, Replace the
subassembly,
accessory wedge Check, tension pulley
accessory wedge
idle wheel and maintain after changing
idle wheel and flat
flat idle wheel the belt twice
idle wheel
depending on the
their conditions
Check the water leakage of
Water pump
overflow
Electrical
Check wiring, engine and starter
appliance
Crankcase vent
system (including Check, wash
intake pipeline)
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 First level Second level Third level
cycle Daily Remarks
maintenance maintenance maintenance
technical
Maintenance maintenance 4000 ~ 10000 ~ 50000 ~ 100000
Items 5000 km 12500 km km
Washing the Wash the cooling
cooling system system
Wash the carbon
Washing the deposit, oil stains,
engine incrustation, oil
duct, oil pipe.
Piston ring Inspect for wear
Cylinder inner
Inspect for wear
wall
Connecting rod
Inspect for wear
bearing shell Depending on
Main shaft the working
Inspect for wear
bearing shell condition of
Camshaft timing engine
Inspect for wear
driving gear
Thrust plate Inspect for wear
Intake/exhaust
Inspect for wear
valve

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Chapter II Technical Information of Engine

2. Technical Maintenance Contents


In order to ensure the engine operates properly,
Fluid
reservoir technical maintenance should be carried out in the
following procedure:
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.

Attention: correct inspection for various fluid levels


can only be carried out when the diesel engine is
Fig. 2-8-1 Checking the coolant level(for stopped.
reference only)
Diesel specification: use the diesel which complies with
GB 19147-2009 vehicle diesel
CBl9147-2009 provision, for south areas in winter (warm
zone) ——10# or 20#, for north areas (cold zone)
——– 35# ——35#.
diesel
————20# For the areas with environment requirements, use the
diesel
——– 10#
diesel complying with environmental regulations.
diesel
Choose fuel in accordance with the season and local
——0#
diesel temperature. See Fig. 2-8-2.

Attention: Never fill the fuel tank when the diesel


Ambient temperature for diesel engine is running. If the vehicle is running in the hot
engine operation climate, the fuel tank should not be fully filled, or else the
fuel will overflow due to fuel extension; wipe the fuel as
Fig. 2-8-2 Choosing fuel (vehicle diesel) in soon as it overflows.
accordance with the ambient temperature 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.

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
Fig. 2-8-3 Checking the battery electrolyte drops fast, the storage battery should be sent to the
level 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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(3) Check if there is oil, water, air or electricity leakage,


turbocharger 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.
(7) inspect and tighten the connection between the
turbocharger and diesel engine (see Fig. 2-8-4), remove
Fig. 2-8-4 Checking the connection between the malfunctions such as oil leakage, air leakage and so
the turbocharger and the diesel engine on, and keep the surface of turbocharger clean.

Caution: If the diesel engine works in a dusty


Rubber ball condition, the air cleaner should be cleaned everyday to
Rubber pipe ensure a good working condition for the air cleaner.
Gravimeter 2.2 First class technical maintenance
core
Electrolyte Glass tube
On the basis of fulfilling daily maintenance content, the
following maintenance content should be added after the
Storage
battery
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 (2) Check the appearances (wear conditions) of timing
gravity 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.
Voltmeter
The following maintenance contents should be added
after the diesel engine runs for 250 h or the vehicle
Electric resistance travels for 10000 ~ 12500 km(for new engines or the
Discharge tongs
contact pin
second level maintenance for the first time after
Storage overhauling in the third level maintenance, the
battery maintenance time should be advanced to 100 h or 4000
~ 5000 km).
(1) Replace the engine oil.
Fig. 2-8-6 Measuring the battery voltage
(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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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 Under the normal circumstance, in addition to the second
gasket
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
Cylinder body engine, the following maintenance items should be
carried out if necessary:
(1) Unpick and wash the diesel engine, remove carbon
Fig. 2-8-7 Checking the cylinder head gasket
deposit, oil dirt and incrustation, and wash all lubricating
Cylinder head oil pipes and oil tubes.
Mounting
assembly
(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 Air intake
pipe gasket manifold pipe (5) Check the cam driving mechanism, the sealing
condition of the camshaft front oil seal and the axial
Fig. 2-8-8 Checking the air intake manifold clearance of camshaft, and the transitional wheel
pipe gasket subassembly and tension wheel subassembly.
(6) Check the wear condition of the intake/exhaust
Cylinder head
Mounting assembly valves and their valve seats, repair and grind the parts,
and check leakage of the parts, replace them if
necessary.
Air intake (7) Check the oil pump, overhaul or measure the
manifold
pipe gasket
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 (9) Check the generator and starter (see Fig. 2-8-10),
manifold pipe wash various parts and bearings, fill them with new
grease after they are dried, check the wear condition of
Fig. 2-8-9 Checking the exhaust manifold the starter gear and check if the driving device is flexible.
pipe gasket
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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(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.
(4) The concentration of battery electrolyte should be
Generator changed in accordance with the season.
3. Technical Maintenance for Air cleaner
The function of air cleaner is to filter the dust and other
Generator 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.
Fig. 2-8-10 Checking the generator and The GW4D20/GW4D20B turbocharged diesel engines
starter 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.

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
diesel application and maintenance instruction.
oil
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
Storage battery washed per 4000 ~ 5000 km of traveling distance, and
Anti-freeze/an
ti-rust fluid 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
Fig. 2-8-11 Seasonal technical maintenance compressed air after washing. Meanwhile, clean the oil
for diesel engine 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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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
Air cleaner cover replacing the filter core of air cleaner.
(2) Cleaning of the filter core: when the filter core is
Filter core 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.
Air cleaner housing
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).
Fig. 2-8-12 Air cleaner (for reference only)
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:
(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.
Fig. 2-8-13 Cleaning the air cleaner filter
core (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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The fuel filter is mounted on the low pressure fuel circuit.


Fuel inlet The diesel enters the filter and the mechanical impurities
Fuel outlet
are eliminated by the filter core. The filtered diesel enters
Fuel return the fuel delivery pump of high pressure fuel pump via the
port 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
Water leakage Drain screw plug
used for the DELPHI electronic fuel injection system
sensor
should be replaced after the engine runs for 500 h or the
vehicle travels 20000 ~ 25000 km, while the filter used
Fig. 2-8-14 Integral fuel filter for the BOSCH electronic fuel injection system should be
(for matching with Delphi electronic fuel replaced after the engine runs for 200 h or the vehicle
injection system) travels 8000 ~ 10000 km.
Hand fuel If poor quality diesel is used in the diesel engine or fuel is
pump contaminated by impurities, it is recommended that the
time to replace the filter core should be advanced,
Fuel return because the filter will be blocked soon.
pipe
connector After the integral fuel filter has been replaced, press the
Fuel inlet pipe
connector Electric hand fuel pump mounted on the chassis to remove the
Filter core of connector air in the fuel circuit.
filter cartridge 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 (1) The fuel filter is disposable and is not allowed to be
(for Bosch electronic fuel injection system) 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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Hand fuel about 0.2 L) to the end of vinyl hose under the fuel-water
pump separator drain plug.
Fuel return (3) For the rotary fuel filter,anticlockwise unscrew the
pipe drain plug (about 5 circles).Press the hand fuel pump
connector about 10 times till the fuel filter is filled with fuel. For the
Fuel inlet pipe
connector Electric integral fuel filter, anticlockwise unscrew the drain plug,
connector press the hand fuel pump mounted on the chassis till the
Filter core of
filter cartridge fuel filter is filled with fuel.
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
Fig. 2-8-17 Fuel filter out.

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.

It is recommended to use the APICI-4


5. Technical Maintenance for Fuel Lubrication
or above diesel engine oil produced by System
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 Engine oil is a consumable which ensures the diesel
operation of diesel engine engine to operate formally, therefore, the oil level should
Figure 2-8-18 Selecting lubricating oil be checked regularly. For example, check the oil level
(engine oil) in accordance with the ambient when adding fuel or before a long journey.
temperature 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
Engine oil
a flat floor, stop the engine and wait for 3 minutes. Then
dipstick check the oil level.
assembly 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.
Figure 2-8-19 Checking the oil level with an
There are upper/lower scale marks on the dipstick to
oil dipstick
help to check the oil level (see Fig. 2-8-20), the oil level

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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
Engine oil
strike on the surface of oil, which will cause malfunctions
dipstick such as oil consumption increase, exhaust deterioration,
serious carbon deposit on the piston top and the
Upper scale combustion chamber walls, and piston ring stuck due to
Engine oil
dipstick guide
mark coking, etc. Therefore, in addition to the oil pressure, the
Lower scale oil level also should be checked with the dipstick before
mark 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.
Figure 2-8-20 Checking the oil level with an
engine oil dipstick 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 40 N·m ± 5 N·m


washer
Oil drain Oil If a large number of impurities deposit in the oil pan, the
screw plug collection lubrication system should be washed with 5# and 7#
pan
machinery oil (light spindle oil) when the new engine is
running in, petrol or kerosene is not allowed.
Fig. 2-8-21 Screwing the oil drain screw plug When cleaning the inner side of diesel engine, fill the oil
and draining out the engine oil pan with 5# or 7# machinery oil, the oil level should be at
the center of lower and upper scale marks on the

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dipstick; remove all oil injectors and rotate the crank of


oil filler cap diesel engine for 2 ~ 3 minutes, then drain out the
washing oil quickly.
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
The oil filter should be replaced after the new vehicle
Fig. 2-8-22 Filling oil through the oil filler on travels for 2500 km; afterward, the oil and the oil filter
the valve shield assembly should be replaced at the same time per 8000
~ 10000 km of traveling distance.
Cylinder body 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 (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
Fig. 2-8-23 Replacing the oil filter 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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Caution:
(1) The rotary oil filter is disposable and is not allowed to
be reused.
(2) The oil filter should be replaced regularly in
accordance with the technical maintenance
Special tool requirements.
Special attention should be paid to the rubber sealing
Remove and reinstall ring when the oil filter is removed and reinstalled so as
the engine oil filter not to damage the sealing ring and cause leakage.
with the special tool
If the rubber sealing ring of oil filter is damaged, it should
be replaced.
Fig. 2-8-24 Removing and reinstalling the oil
filter 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.
(1) When the low oil pressure indicator lamp flashes or
Fig. 2-8-25 Installing the oil filter 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
6.1 When the diesel engine is running, there must be
Fig. 2-8-26 Low oil pressure indicator lamp 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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Warning: Opening the radiator cover when the


diesel engine has not been cooled completely may
Fluid
reservoir cause spraying of coolant and cause serious scalding.
The engine and the radiator must be cooled before the
radiator cover is opened.
Fill coolant into the radiator (see Fig. 2-8-28):
(1) Make sure that both the engine and the radiator are
cooled.
(2) Press the radiator cover and rotate it in the
anticlockwise direction, the radiator cover can be
removed.
Fig. 2-8-2 Checking the coolant level(for
reference only)
(3) The coolant level should reach the bottom of filler
Radiator neck. If the coolant is not enough, add coolant.
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
6.3 Generally, the service life of the long-acting
Water drain antifreeze and antirust fluid is 1 ~ 2 years, the fluid
plug should be replaced when expired. When replacing the
antifreeze and antirust fluid, run the diesel engine for 5
Fig. 2-8-28 Radiator (for reference only)
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.
(3) If the antifreeze and antirust fluid loses, firstly, check
Fan assembly
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
Fig. 2-8-29 Checking the radiator fan caused by water evaporation, add distilled water in. After
assembly 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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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.

Per 5000 km or per 6 months


Replace the oil filter A, B, C, D, E
(accumulative working time: 100 h)

Replace the air Per 5000 km or per 6 months


E, F
cleaner filter core (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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Engine handover and


exterior cleaning

Removing
Assembly components
spare parts

Washing of spare parts

Identification of spare parts

warehouse
Qualified (available) Parts need to be repaired Scrapped parts
spare parts

Waste
Repair and check for 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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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.
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
Fig. 2-9-2 Removing the parts on the accumulative fuel consumption of the engine), but
cylinder 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.
The minor repair mainly aims at troubleshooting the
engine, local inspection, adjustment and repair, and
Fig. 2-9-3 Removing the electrical parts 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.
3. Exterior Washing for the Engine
Fig. 2-9-4 Washing the diesel engine
After reception of the engine, move it to the location for

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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 1.1 The spare parts assembled should be those
manufactured according to the drawings and technical
conditions of GW4D20/GW4D20B turbocharged diesel
Repair the abnormal
engines approved by our company, and their materials,
parts immediately metallurgical structures, performances, geometrical
shapes, dimensions, positions, fitting, tightening torque,
sealing, and reliability should comply with the
Fig. 2-10-1 Assembling according to requirements.
technical requirement 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

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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.
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
Fig. 2-10-2 Tightening sequence for the should strictly comply with provisions.
fasteners 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
Indicating type torque spanner 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
Scale indicating type torque spanner 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
Fig. 2-10-3 Torque spanner 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
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
Lubricate it with engine oil. assemble it with guide tools. It is not allowed to damage
the lip in order to ensure tightness.
Fig. 2-10-4 Applying a proper amount of 1.12 The assembling position, sequence and matching of
lubricating oil to fasteners the parts should be correct; interference, missing
assembling and wrong assembling are not allowed.

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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 First, make clear the structures and characteristics of
the diesel engine 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.

Fig. 2-10-6 Using special tools 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.
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, 2.5 For the parts which have positional, optional and
optional, directional and matching directional requirements such as main shaft bearing
requirements 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


Tool and Instrument Name Remarks
Code

Crankshaft timing pulley


5-8840-2035-0
puller

Crankshaft timing pulley


5-8522-0024-0
installer

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 See Page 163, 168, 238, 239

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


5-8840-2036-0 See Page 48, 329, 330
tester

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Tool and Instrument


Tool and Instrument Name Remarks
Code

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


5-8840-2000-0 See Page 241
bearing remover

Transmission second shaft


5-8522-0024-0 See Page 242
front bearing remover

Guide centering device 5-5825-3001-0 See Page 242, 268, 269, 286

Fuel injection system


0-986-613-100
measuring device

Oil return amount measuring


0-986-612-900
device

KTS 650 diagnostic


0-986-612-901 See Page 86
apparatus

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:

Position of model Model number


mark

Fig.2-12-1 GW4D20 turbocharged diesel Asterisk Year Month Asterisk


Sequence
engine assembly number
2. Air Cleaner
Dry paper filter core
Cleaning methods may differ according to filter core
conditions.
Filter core blocked by dust
Move the filter core with hands and blow the filter core
Filter core of air from the inner side to the outer side with compressed air,
cleaner the dust will be removed by doing this. See Fig.2-12-2.

Caution: Do not blow the filter core from the outer


Fig.2-12-2 Cleaning the filter core of air side to the inner side with compressed air; if so, the dust
cleaner will enter the interior of filter core (clean face).
The pressure of compressed air
392 ~ 490 kPa

Caution: Do not strike the filter core on other


Cleaner cover
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:
——the filter core is contaminated by carbon deposit or
Cleaner housing grease.
——the filter core is seriously contaminated, and the
contamination is hard to remove.
Fig.2-12-3 Washing the air cleaner cover
——the filter core is deformed and damaged.
and housing

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When replacing or cleaning filter core, clean the inside of


Cylinder body air cleaner housing. See Fig. 2-12-3.

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
Fig.2-12-4 Maintaining the oil filter found, the packing and tightening connector should be
replaced to avoid abnormal wear of the diesel engine.
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.
(4) Clean the matching surface of engine oil cooler, this
Special tool 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 API CI-4 lubricating oil produced by Mobil Oil
a special tool
Company.
Fig. 2-12-6 Removing and reinstalling the oil (6) Screw into the new oil filter until the filter O-ring fits
filter 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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It is recommended to use APlCl-4 or above diesel engine


oil produced by Mobil Oil Corporation.

Start the diesel engine and check if the lubrication


Engine oil system works properly, and check if there is leakage in
dipstick the oil filter.

Engine oil Upper scale


dipstick guide
pipe Lower scale

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


diesel engine

Hand fuel 4. Fuel System


pump Fuel filter
Oil return
hose Caution: The fuel filter is disposable and is not
connector allowed to be reused.
Oil inlet pipe Electric
connector connector The cartridge and filter core of the fuel filter assembled on
Cartridge and the CW4D20/CW4D20B turbocharged diesel engine is
filter core integral; when they are replaced, the whole filter
assembly should be replaced.
Water drain plug Replace the fuel filter regularly in accordance with
technical Maintenance requirements.
Fig. 2-12-8 Fuel filter 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.
(4) Screw it for additional 3/4 ~ 1 circle with a filter
spanner.
Fig.2-12-9 Water level indicator lamp of
water-fuel separator (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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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 Attention: If there is too much water in fuel, it
anticlockwise direction indicates that the fuel is not qualified. If there is water
Fig.2-12-11 Checking after draining 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.

Attention:
Fig. 2-12-12 Checking the coolant level in
the fluid reservoir (for reference only) (1) Do not overfill the fluid reservoir.
(2) The radiator water filler cover can only be opened
when absolutely necessary.

Warning:
(1) Checking coolant level should be carried out when the
Freezing point

engine is cold.
(2) The coolant is poisonous, thus must be stored in the
Mixing ratio(%) 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
Fig. 2-12-13 Mixing ratio of coolant antirust additive or other additives into the cooling

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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 196 kPa
with a tester
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
1.0 ~3.9 kPa
(reference value)

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.
(3) Observe temperature changes through the
thermometer in the water; check the initial opening
Fig. 2-12-16 Checking the lift of thermostat temperature of the thermostat.
valve
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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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


Fig. 2-12-17 Checking the opening
provisions, the thermostat should be replaced.
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.
(7) Check if the thermostat rubber sealing ring is aged
opened
completely
when
Valve

and deformed; the sealing ring should be replaced if it is


aged and deformed.
size

6. Engine Control
The lift of valve should be at least 8.5 mm 6.1 Check idling speed
when the water temperature is 88 ℃ (1) Operate the parking brake and brake the driving
Fig. 2-12-18 Checking the lift of thermostat wheels
valve
(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.
Idling speed of the diesel engine
Fig. 2-12-19 Adjusting the idling speed
750 r/min ± 50 r/min

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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.
(2) Adjust the height between bolt and base plate.
Fig. 2-12-20 Adjusting the throttle pedal
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 (1) Place the start-up  switch  to  the  “OFF”  position.
glow plug end with a universal meter 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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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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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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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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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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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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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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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

Note: ① DELPHI fuel supply system mounting assembly.

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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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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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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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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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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 Troubleshooting

(1) Wrong wiring or poor contact (1) Check whether the wiring is correct and firm.
in circuits
(2) Check the specific gravity of electrolyte, the
(2) Insufficient power in the voltage of storage battery, and charge the storage
Electrical storage battery battery according to the technical requirements if
System necessary.
(3) Poor contact between the
carbon brush and the commutator (3) Repair or replace the carbon brush, clean the
of starter surface of the commutator with water abrasive paper
and blow it clean.

(1) Air in the fuel supply system (1) Check whether the connectors of fuel supply
pipelines are loose, remove the connector of the high
(3) Fuel filter blockage
pressure fuel pump fuel return hose, supply fuel with
(4) No oil supply or discontinuous the manual fuel delivery pump until the overflowed
oil supply in the fuel delivery fuel is air bubble free, then install the fuel return hose.
pump
(2) Check whether the pipeline of fuel supply system
(5) Malfunction in the electronic is smooth.
Fuel
control parts of fuel supply
Supply Replace the fuel filter
system
System
(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).

(1) Excessive wear of the piston (1) Replace the piston ring
ring
Mechanical (2) Check the sealing performances of the valve
System (2) Air leakage in 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

Failing to select the motor diesel (fuel oil) Select the motor diesel (fuel, GB19147
as required in winter or severe cold ——2009) with a low freezing point according
Fuel
areas, or the diesel oil getting thick and to the working temperature of the diesel
frozen at a lower temperature. engine.

Failing to select the engine oil as required


Select the engine oil with a low viscosity
in winter or severe cold areas, or the
according to the working temperature of the
Lubricating engine oil getting excessively sticky and
diesel engine in order to reduce the power
Oil the internal frication increasing at a low
required when starting. (the engine oil above
temperature, or the starting resistive
APl CI – 4 of Mobil Oil Corp. is recommended)
torque of diesel engine increasing.

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Select the low temperature storage battery


Failing to select the storage battery as
with the capacity higher than 100 Ah according
Battery required in severe cold areas; the battery
to the working temperature of the diesel
capacity lower than 100 Ah.
engine.

See Subsection 11 of this chapter for (5) See Subsection 11 of this chapter for
Oil Supply
positions and phenomena of malfunctions troubleshooting the oil supply system. (see
System
in the oil supply system. 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 Troubleshooting

Malfunction in the oil See Subsection 11 of


supply system: failing this chapter for positions See Subsection 11 of this chapter for
to increase the power and phenomena of troubleshooting the oil supply system.(see Page 86
or rotation speed after malfunctions in the oil ~ 88)
stepping on the gas. supply system.

Malfunction in air (1) Air cleaner blockage (1) Clean the dust in the filter core of air cleaner,
intake and exhaust replace it if necessary.
systems: exhaust (2) Blockage in exhaust
temperature higher pipes or excessively long (2) Eliminate the carbon deposit in the exhaust
than the normal one connecting tubes, too pipe; and reinstall the exhaust connecting pipe with
and poor exhaust gas small turning radius and its elbows no more than 3, and the exhaust cross
color. too many elbows. section should be big enough.

(1) See Subsection 11 for troubleshooting of


“insufficient power within all ranges pf the diesel
(1) Malfunction in the oil engine”  in  the  oil  supply  system.
The performance of supply system
each rotation speed (2) Check the sealing performances of the valve
getting worse (2) Air leakage in the spring, the valve guide and the seat, examine and
valve repair them when the sealing performances are
poor and grind the valve and valve seat if
necessary.

(1) Check the coolant system, eliminate the


encrustation and test the thermostat.
(1) Overtemperature of
coolant (2) Check the capacity of engine oil, add oil in the
engine if insufficient; if the shaft bearing shell or
(2) Overtemperature of
some moving parts heat, find out the position and
Overheat of Diesel engine oil
the cause of heating, and eliminate it.
Engine (3) Overtemperature of
(3) Check the injection pressure and the
exhaust air
atomization situation of the fuel injector.
(4) Malfunction in the oil
(4) See Subsection 11 in this chapter for
supply system
troubleshooting the oil supply system. (see Page
86~88)

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(1) Air leakage in the


junction surface of the
cylinder head and the (1) Screw up the cylinder head bolt according to
Malfunction in cylinder cylinder body; loose the specified torque or replace the cylinder head
head components: cylinder head bolt or gasket.
insufficient power, damaged cylinder body
(2) Remove and check the air intake and exhaust
poor performance, air gasket.
valves, repair or grind the valve or the matching
leakage, black smoke
(2) Loose air intake and surface of the valve.
and abnormal
exhaust valves
knocking sounds. (3) Remove the fuel injector for repair, clear up and
(3) Air leakage in the fuel replace the damaged parts.
injector hole or damaged
copper gasket

Seizure between the Remove the oil pan, check whether the connecting
Malfunction in the
connecting rod small end rod big end is axially wobbling, if not, remove the
crank connecting rod
bushing and the piston piston connecting rod components for examination
mechanism
pin and repair.

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

Malfunction in the Damaged pressure


Replace the pressure sensor of high pressure oil
pressure sensor of sensor of high pressure
track
high pressure oil track oil track

Air leakage or failure in


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

4. Excessive Fuel Consumption of Diesel Engine

Part, Phenomenon and Cause of Malfunction Troubleshooting

Examine and repair, and replace the relevant parts


Fuel system Fuel leakage
in the fuel system if necessary

Blockage in the air cleaner


Air cleaner Clean or replace the air cleaner elements
elements

Fuel injector
Poor fuel injection or poor Check the fuel injector and fuel injection control
and control
controlling for fuel injection system
circuits

Compression Damaged cylinder gasket, sticky Examine and repair, and replace the cylinder
pressure piston ring 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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to the noise characteristics and combining the structure principle.

Attention: It is strictly prohibited that the engine continues operating in case of abnormal noise, stop
running immediately if abnormal noise appears, check and eliminate the malfunction, then continue to
work.

Phenomenon and Cause of Malfunction 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 (2) Replace the bush of the connecting rod small
engine, and such noise is especially clear during end, and make it within the specified clearance
idling, and sharper when you suddenly step on the scope.
gas.

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

(4) Excessive matching clearance between the (4) Remove and check the connecting rod bearing
connecting rod bearing bush and the main bearing bush, the main bearing bush, and replace them if
bush due to too much wearing, clashing noise from necessary, and keep them within the specified
the engine parts at the running crankshaft, heavy matching clearance.
and strong knocking noise during abrupt
deceleration.

(5) The valve clashing with the piston; heavy, even (5) Find out the cause; check the valve timing;
and rhythmed knocking noise from the cylinder examine and repair the relevant parts.
head during running.

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Chapter III Malfunction Diagnosis and Troubleshooting

6. Abnormal Noise from Diesel Engine


Check whether the diesel engine is adequately preheated before malfunction diagnosis.

Phenomenon Cause of Malfunctions Troubleshooting

(1) Inappropriate fuel (1) Choose the specified fuel according


to the ambient temperature.
(2) Malfunction of the fuel injector or
bad connection of the circuit (2) Replace the fuel injector and fasten
Sound of knocking the cable connection.
the diesel engine (3) Damage of the cylinder gasket,
cylinder breakage of the piston ring (3) Check the cylinder compression
pressure and replace relative parts.
(4) Wrong output signal of the coolant
temperature sensor, knocking the (4) Replace the coolant temperature
cylinder when the heater accelerates sensor.

(1) Loose connection and breakage of (1) Fasten the exhaust pipe
the exhaust pipe connection, replace the exhaust pipe.
(2) Looseness of the fuel injector (2) Fasten the fuel injector and/or the
Noise from gas and/or the glow plug glow plug, replace the gasket.
leakage
(3) Looseness of the exhaust manifold (3) Fasten the exhaust manifold pipe.
pipe
(4) Replace the cylinder gasket.
(4) Damage of the cylinder gasket

(1) Wear or damage of the water pump (1) Replace the water pump bearing.
Continual noise bearing
(2) Replace or repair the generator.
(2) Damage of the generator

(1) Looseness of the flywheel bolts (1) Fasten the flywheel bolts..
(2) Damage or wear of the crankshaft (2) Replace the crankshaft and/or the
and/or the thrust plate thrust plate.
(3) Wear of the crankshaft and the (3) Replace the crankshaft and/or the
Slapping noise
connecting rod bearing shell connecting rod bearing shell.
(4) Wear or damage of the connecting (4) Replace the connecting rod
rod bushing and the piston pin bushing and the piston pin.
(5) Wear or damage of the piston (5) Replace the piston.

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 Troubleshooting

(1) Overload of the diesel engine (1) Reduce the diesel engine load to the rated
operating range.
(2) See Chapter 11 for troubleshooting the oil
(2) Malfunction of the oil supply
supply system. (see Page 86 ~ 88)
system
(3) Check the sealing taper face, abrade the
valve seat if necessary.
(3) Leakage of the exhaust valve
Exhaust with (4) Clear and wash off the dirt and foreign
caused by bad sealing
black smoke substances in the air cleaner, and replace the
(4) Insufficient inlet airflow, filter core if necessary.
blockage of the air cleaner or the air
(5) Replace the piston ring.
inlet pipe
(6) Overhaul or replace the turbocharger.
(5) Severe wear of the cylinder hole
and the piston ring
(6) Malfunction or damage of the
turbocharger

(1) There is water in the cylinder or (1) Find out the cause of malfunction and resolve
in the diesel it.
(2) Insufficient combustion of fuel in (2) Increase the rotation speed and load of the
Exhaust with
some cylinders when the diesel diesel engine properly, and run the engine longer.
white smoke
engine is started
(3) See Chapter 11 for troubleshooting the oil
(3) Malfunction of the oil supply supply system. (see Page 86~88)
system

(1) Stuck or overly worn piston ring, (1) Check the piston ring, replace it if necessary.
insufficient elasticity; the chamfer of
piston ring is reversely installed,
leading to engine oil flowing into the (2) Increase the load properly or repair the
combustion chamber corresponding parts.
Exhaust with
(2) Long-term low load operation;
blue smoke
big clearance between the piston
(3) Examine with a dipstick and drain off the
and the cylinder hole, leading the
excessive oil.
engine oil slipping into the
combustion chamber
(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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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 Troubleshooting

(1) Applied inappropriate oil (1) Drain off the unqualified oil and fill with
specified oil.
(2) Invalidation and leakage of the
sealing gasket and the oil seal (2) Replace the sealing gasket and the oil seal.
(3) Wear of the piston ring or the (3) Replace the piston ring or the piston.
High oil ring slot
consumption (4) Replace the piston ring or the piston.
(4) Blockage of the piston ring
(5) Replace the oil seal, valve or valve guide
(5) Wear of the valve oil seal, valve pipe.
guide pipe or valve rod
(6) Repair the cylinder aperture.
(6) Wear of the cylinder

(1) Applied inappropriate oil (1) Drain off the unqualified oil and fill with
specified oil.
(2) Blockage of the safety valve
(2) Replace the safety valve.
(3) Blockage of the oil collector
(3) Wash or replace the meshy filter.
(4) Wear of the oil pump rotor
(4) Replace the oil pump assembly.
(5) Breakage, crack or connector
Too low oil looseness of the oil pipe (5) Overhaul or replace the oil pipe.
pressure
(6) Malfunction of the oil pump (6) Overhaul or replace the oil pump assembly.
(7) Over wear of the main shaft (7) Replace the main shaft bearing shell or the
bearing shell or the connecting rod connecting rod shaft bearing shell.
shaft bearing shell
(8) Overhaul or replace the oil pressure alarm
(8) Damage of the oil pressure device.
alarm device

Engine oil (1) Blockage of the oil hole on the (1) Wash or repair it.
unable to cylinder body and the cylinder head
(2) Wash or repair it.
reach the (2) Blockage of the rocker arm
valve system 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) (1) Refill coolant, check the cooling system for
leakage and repair it if necessary.
(2) Damage of the thermostat
(2) Replace the thermostat device
(3) Thermostat valve unable to be
opened (3) Replace the thermostat assembly
(4) Malfunction of the water pump (4) Overhaul or replace the water pump
assembly.
(5) Malfunction of the oil supply system
(5) See Chapter 11 for troubleshooting the oil
(6) Damage of the radiator cap or
supply system. (see Page 86~88)
blockage of the radiator core
(6) Replace the radiator cap or the wash
(7) Damage of the coolant temperature
radiator.
Overheating sensor
diesel engine (7) Replace the coolant temperature sensor.
(8) Coolant leakage caused by
damage of the cylinder gasket (8) Replace the cylinder gasket.
(9) Damage of the thermostat (9) Replace the thermostat.
(10) Blockage of the cooling system (10) Clean the cooling system.
caused by foreign materials
(11) Replace the cooling fan circuit or the fan.
(11) Open circuit of the cooling fan,
(12) Clean exhaust system.
damage of the fan
(13) Add or replace the engine oil, adjust the
(12) Blockage of the exhaust system
engine oil volume; it is recommended to use
(13) Low engine oil level or unqualified API CI-4 or better oil from Mobil Oil
engine oil Corporation.

(1) Damage of the thermostat valve or (1) Overhaul or replace the thermostat.
the thermostat valve unable to be
Too cold (2) Measure the coolant temperature and
closed
diesel engine replace the water thermometer.
(2) Malfunction of the
water——thermometer

(1) Leakage of the radiator (1) Repair or replace the radiator.


(2) Looseness of the radiator hose (2) Screw up the radiator hose connector clip
Cooling connector or damage of the hose or replace the hose.
system lack (3) Leakage of the water pump (3) Overhaul or replace the water pump
of water 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.

Too long (1) Damage of the thermostat (1) Overhaul or replace the thermostat.
preheating
(2) Damage of the thermostat device (2) Overhaul or replace the thermostat device.
time for the
diesel engine

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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 Troubleshooting

(1) Foreign materials in the oil depositing (1) Replace the engine oil, it is
at the sealing area of the turbine side recommended to use API CI-4 or better oil
from Mobil Oil Corporation, overhaul the
(2) Excessive engine oil temperature,
turbocharger.
insufficient oil supply, burning damage of
the floating bearing (2) Check the oil supply system; overhaul
the turbocharger.
(3) Blockage and deformation of the
turbocharger oil return hose, leading to oil (3) Repair or replace the fuel return hose.
leakage from the turbo and the
(4) Replace the turbocharger sealing ring.
compressor shaft end
(5) Replace the turbocharger assembly.
Insufficient (4) Damage and malfunction of the
power turbocharger sealing ring (6) Replace the turbocharger assembly.
(5) Turbo shaft rotor out of balance (7) Maintain the air cleaner; replace the
filter core.
(6) Friction and damage of the turbo
blades and the compressor blades (8) Wash, overhaul or replace the air
intake and exhaust pipe components.
(7) Blockage of the air cleaner (too dirty)
(9) Overhaul or replace the turbocharger.
(8) Too much dirt in the air intake/exhaust
pipes or leakage at the joint part
(9) Bad performance or damage of the
turbocharger

(1) Too much dirt in the air intake/exhaust (1) Overhaul the air intake and exhaust
pipes or leakage at the joint part pipes or replace the damaged parts.
High fuel
(2) Bad performance of the turbocharger (2) Wash, adjust or replace the
consumption
turbocharger.
(3) Wear of the piston ring
(3) Check or replace the piston ring.

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(continued)

Phenomenon and Cause of Malfunction Troubleshooting

(1) Wear and damage of the (1) Replace the turbocharger assembly.
turbocharger sealing ring
(2) Overhaul.
(2) Oil leakage at the end of
(3) Overhaul the oil inlet pipe, oil return hose;
High oil compressor blades
replace the gasket.
consumption (3) Looseness of screws at the joint
(4) Replace the engine oil as specified, it is
part of the oil inlet pipe and oil return
recommended to use API CI-4 or better oil
hose; damage of the gasket
from Mobil Oil Corporation.
(4) Low oil quality

(1) Too much oil dirt in the turbo end air (1) Clean or replace it.
passage, leading to obvious reduction
(2) Clean or replace it.
of the air flow
(3) Replace the turbocharger assembly.
(2) Too much oil dirt in the compressor
Abnormal
end, leading to obvious reduction of the
sounds
air flow
(3) Excessive wear of the floating
bearing; friction among the turbo, gas
compressor impeller and housing

Vibration (1) Foreign materials in (1) Clean or replace it.


caused by
(2) Excessive wear of the floating (2) Replace the turbocharger assembly.
friction
bearing
among the (3) Check, repair or replace it.
turbo, gas (3) Poor dynamic balance of the turbo
compressor shaft
impeller and
housing

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 Troubleshooting

(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 / Connecting cable / (4) Check whether the fuse / connecting cable
connector / connector is firmly connected.
(5) Diesel engine rotation speed (5) Check the diesel engine rotation speed
sensor sensor.
Diesel (6) No fuel or wrong fuel grade (6) Add the specified grade of fuel.
engine
unable to be (7) Air left in the fuel system (7) Exhaust air from the fuel system.
started (8) Blockage or leakage of the low (8) Check the low pressure oil circuit.
pressure oil circuit
(9) Check the preheat circuit (winter).
(9) Preheat circuit (winter)
(10) Check the high pressure fuel pump or the
(10) High pressure fuel pump or high high pressure fuel rail pressure control device.
pressure fuel rail pressure control
(11) Check the injector electromagnetic valve.
device
(12) Check the control unit.
(11) Injector electromagnetic valve
(12) Control unit

(1) Looseness of the fuse / connecting (1) Check whether the fuse / connecting cable
cable /connector / 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 (4) Check the low pressure oil circuit.
Diesel
the low pressure oil circuit
engine stalls, (5) Exhaust air from the fuel system.
but it can be (5) Air left in the fuel system (reignite
(6) Check the high pressure oil pump and the
restarted the low pressure oil circuit)
pressure control device.
(6) High pressure oil circuit (high
(7) Check the high pressure oil pump and the
pressure oil pump, pressure control
injector control circuit.
device)
(7) High pressure oil pump and injector
control circuit

(1) Storage battery voltage (1) Check the storage battery voltage.
(2) Starter (2) Overhaul the starter.

Difficulty in (3) Relay and starting switch (3) Overhaul the relay and the starting switch.
starting the (4) Incorrect fuel (4) Add the specified grade of fuel.
diesel engine
(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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(winter) (winter).
(8) Blockage or overlow temperature (8) Check the low pressure oil circuit.
of the low pressure oil circuit
(9) Check the high pressure oil circuit, high
(9) overlow pressure of the high pressure fuel pump and pressure control
pressure oil circuit device.
(10) High pressure fuel rail pressure (10) Check the high pressure fuel rail pressure
adjustor adjustor.
(11) Bad performance or control (11) Check or replace the fuel injector.
malfunction of the fuel injector

(continued)

Position and Phenomenon of Malfunction Troubleshooting

Diesel Accelerator pedal position sensor Check the accelerator pedal position sensor.
engine
running at a
high idle
speed

Cylinder (1) Coolant temperature sensor (1) Check the coolant temperature sensor.
knocking
(2) Fuel injector connecting circuit (2) Check the fuel injector connecting circuit.
during
warming-up (3) Malfunction of the injector (3) Check or replace the fuel injector.
or
acceleration
of the engine

(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 (3) Check low pressure oil circuit.
the low pressure oil circuit
Diesel (4) Check or replace the fuel injector.
engine (4) Bad performance of the fuel injector
(5) Check the fuel injector circuit.
wobble
(5) Fuel injector circuit
during idling (6) Overhaul the high pressure fuel rail
(6) High pressure fuel rail pressure pressure sensor, high pressure fuel rail
sensor, high pressure fuel rail pressure pressure adjustor
adjustor
(7) Check and adjust the high pressure fuel
(7) High pressure fuel pump pump.

(1) Vacuum system (1) Check whether the vacuum adjustor is


normal.
(2) Blockage of the air cleaner
(2) Maintain or replace the filter core of air
In sufficient (3) Incorrect fuel
cleaner.
power of the
(4) Blockage of overlow pressure of
diesel engine (3) Add the specified grade of fuel
the low pressure oil circuit
in all ranges (CBI9147-2009 motor diesel).
(5) Failure of the turbocharger
(4) Check the low pressure oil circuit.
(6) Wrong position of the accelerator
(5) Overhaul or replace the turbocharger.
pedal position sensor or signal

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problem (6) Adjust the position of the accelerator pedal


position sensor.
(7) Malfunction of the exhaust gas
bypass valve
(8) Leakage of the turbocharger gas (7) Overhaul the exhaust gas bypass valve.
compressor
(8) Check the sealing condition of the
(9) Coolant temperature sensor turbocharger, replace the sealer if necessary.
(10) High pressure fuel rail pressure (9) Overhaul the coolant temperature sensor.
sensor
(10) Overhaul the high pressure fuel rail
(11) Fuel injector, high pressure oil pressure sensor.
pump
(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.
Diesel
engine (3) Blockage of the low pressure oil (3) Check the low pressure oil circuit.
exhausting circuit
(4) Overhaul the preheat system.
white or blue
(4) Preheat system
smoke (5) Check the lubrication system oil level and
(5) Overhigh oil level of the lubrication drain off the excessive engine oil.
system

(1) Blockage of the air cleaner (1) Maintain or replace the filter core of the air
cleaner.
(2) Coolant temperature sensor
(2) Check the coolant temperature sensor.
Diesel (3) Malfunction of the turbocharger
engine (3) Check the turbocharger.
(4) Fuel injector and its control circuit
exhausting
(rare) (4) Check the fuel injector and its control
black smoke
circuit.
(5) Vacuum pump
(5) Check whether the vacuum system is
normal.

(1) Incorrect fuel (1) Add the specified grade of fuel.

Overheating (2) Coolant temperature sensor (2) Check the coolant temperature sensor.
diesel engine (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 Exhaust air and water from the
system fuel system.

Low pressure oil circuit Blockage or overlow pressure of Check, repair or replace the
the low pressure oil circuit; oil corresponding parts of fuel

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leakage or blockage of the fuel system.


system

Fuel injector Bad performance or blockage of Replace the fuel injector.


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 Check the high pressure fuel rail
and opening of the fuel injector 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.

Fuel injector circuit Breakage of the fuel injector Check, repair or replace wire.
circuit

Looseness of the injector circuit Fasten the fuel injector circuit.

High pressure fuel rail pressure Damage of the high pressure Replace the high pressure fuel
sensor, high pressure oil rail fuel rail pressure sensor rail pressure sensor.
pressure adjusting system
High pressure fuel rail pressure Check the metering valve and
adjusting system the oil return valve, replace the
damaged parts.

Mechanical part of the diesel Damage of the cylinder gasket, Check or replace the cylinder
engine gluing of the piston ring, gasket and the piston ring.
excessive wear of the piston ring

13. Diesel Engine Running at a High Idle Speed

Checking Item and Part Cause of Malfunction Troubleshooting

Pedal position sensor Damage of the pedal position Replace the pedal position
sensor sensor and calibrate the ECU.

14. Starter not Working, Lacking Power, and Making noise

Phenomenon and Cause of Malfunction Troubleshooting

(1) Disconnection of the control (1) Check whether the circuit is firmly connected.
circuit such as the starter switch
(2) Adjust the carbon brush spring pressure and
Starter not (2) Bad contact between the carbon clean the commutator.
working brush and the commutator
(3) Overhaul the starter.
(3) Open circuit or short circuit in the
starter

(continued)

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Phenomenon and Cause of Malfunction Troubleshooting

(1) Insufficient capacity of the (1) Charge the storage battery as specified.
storage battery
(2) Screw up the wire joints.
(2) Bad contact of the wire
(3) Polish the commutator surface or clean off the
(3) Burning damage or oil stain on oil stain.
Weak the commutator surface.
starting of (4) Replace the carbon brush or adjust the
the starter, (4) Excessive wear or insufficient carbon brush spring pressure.
unable to elasticity of the carbon brush,
(5) Polish the electromagnetic switch main contact
start the leading to its poor contact with the
with 0# non-metal abrasive paper.
diesel engine commutator
(6) Check and replace the bearing.
(5) Ablation and bad contact of the
electromagnetic switch main contact
(6) Excessive wear of the bearing,
armature rubbing the shell

Starter (1) Adhesion of the copper contact (1) Disconnect the power supply immediately;
keeping disc in the starter relay with the two check, fasten the circuit and repair the contacts.
rotating and contacts
(2) Disconnect the power supply immediately and
making
(2) Breakage or bending of the replace the starter.
sharp noise
starter armature shaft
after the (3) Disconnect the power supply immediately and
diesel engine (3) Sticking or galling of the gear repair the gear teeth face.
is started teeth face

15. Working Starter but Non-working Diesel Engine

Checking Item and Cause of Malfunction Troubleshooting


Part

(1) Looseness of the storage battery (1) Clean and/or refasten the storage
terminal due to oxidization battery terminal.
Storage battery
(2) Storage battery uncharged or (2) Recharge or replace the storage
inadequately charged battery as specified.

(1) Damage of the pinion (1) Replace the pinion.


(2) Malfunction of the electromagnetic (2) Repair or replace the
Starter switch electromagnetic switch.
(3) Damage of the electrical brush or (3) Replace the electrical brush and/or
too soft electrical brush spring the electrical brush spring.

Sticking of the piston and the Overhaul or replace the corresponding


Diesel engine crankshaft bearing or damage of other parts of diesel engine.
parts

Unable to remove the anti-theft Overhaul the anti-theft system.


Anti-theft system
protection

Main relay Damage of the main relay Replace the main relay.

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Fuse cable Looseness or bad contact of the fuse Clean and fasten the fuse cable.
connector cable

Rotation speed Damage of the rotation speed sensor Replace the rotation speed sensor.
sensor

No fuel in the fuel tank, or Add fuel or apply the motor diesel
Fuel (diesel)
inappropriate fuel (specified by CB 19147-2009).

(continued)

Checking Item and Cause of Malfunction Troubleshooting


Part

Air left in the fuel Exhaust the air in the fuel system
Fuel system not exhausted completely
system through the fuel filter.

Repair the low pressure oil circuit,


Low pressure oil Blockage or leakage of the low replace the damaged parts of low
circuit pressure oil circuit pressure oil circuit and exhaust the air
in the fuel system.

Check the high pressure fuel pump,


High pressure fuel
Unable to build up the pressure of the high pressure fuel rail and pressure
pump and high
high pressure fuel rail sensor; replace defective parts if
pressure fuel rail
necessary.

Check the working status of the fuel


Fuel injector Fuel injector electromagnetic valve not
injector electromagnetic valve and
electromagnetic valve working or bad contact
replace the fuel injector if necessary.

Replace the ECU, and input the


Electronic control Abnormal work of the electronic control
currently used injector code when
unit (ECU) unit (ECU)
replacing the ECU.

Abnormal work of the glow plug in Replace the glow plug, and check the
Preheat system
winter glow plug control unit.

16. Diesel Engine Rotating but Unable to be Started

Checking Item and


Cause of Malfunction Troubleshooting
Part

Blockage or damage of the fuel pipe; Repair or replace the fuel pipe, and
Fuel pipe system
looseness of the fuel pipe connector refasten the fuel pipe connector.

(1) Overflow valve of the fuel filter (1) Repair or replace the fuel filter
Overlow pressure of cannot be closed overflow valve.
the low pressure oil
circuit (2) Blockage of the fuel pipe or the fuel (2) Check the fuel pipe and replace the
filter element fuel filter element or the filter core.

Exhaust the air in the fuel system


Fuel system Air left in the fuel system
through the fuel filter.

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(1) Choose the qualified fuel according


(1) Applied inappropriate fuel to the ambient temperature.
Fuel (motor diesel)
(2) Water in the fuel system (2) Drain out the water in the fuel
system or replace the fuel.

(1) Looseness of the storage battery


(1) Clean the storage battery terminal
Low voltage of the wiring, corrosion of the terminal
and fasten the wiring.
storage battery (2) Storage battery inadequately
(2) Charge the storage battery.
charged

Low pressure of the Bad control of the high pressure fuel Check the high pressure fuel pump or
high pressure oil pump and high pressure fuel rail the high pressure fuel rail pressure
circuit pressure. control system.

Check the fuel injector or replace it;


Damage of the fuel injector nozzle; bad
Bad performance of when it is replaced, it is required to
performance of the electromagnetic
the fuel injector input the new injector code into the
valve
ECU.

Wrong information for the coolant


Coolant temperature Replace the coolant temperature
temperature in winter; glow plug not
sensor (winter) sensor.
working

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

When the glow plug is energized,

The indicator lamp of glow plug Damaged glow plug indicator Replace the glow plug indicator
is off. lamp lamp.

Quick start-up timer Damaged quick start-up timer Repair or replace the quick
start-up timer.

The glow plug indicator lamp is Damaged quick start-up timer Repair or replace the quick
on for 0.3 s. start-up timer.

The glow plug indicator lamp is (1) Start the diesel engine, set (1) Replace the quick start-up
on for 3.5 s. the   starting   switch   from   “ST”   to   timer.
“ON”,   and   the   glow   plug   relay  

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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.

Glow plug not energized

The glow plug indicator lamp is Blowout of the glow plug Replace the glow plug indicator
off. indicator lamp fuse lamp fuse.

Quick start-up timer Damaged quick start-up timer Replace the quick start-up timer.

The glow plug indicator lamp is (1) The glow plug relay is (1) Replace the glow plug.
on for 3.5 s. damaged. The glow plug relay is
(2) Repair or replace the glow
not connected after the starting
plug relay circuit wire.
switch  is  set  from  “OFF”  to  “ON”.
(3) Replace the fuse or wire.
(2) Damaged glow plug relay
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 Troubleshooting

(1) Improper wiring, broken wiring or poor (1) Repair the circuit.
contact of wiring
(2) Repair or replace the generator
(2) Open circuit of rotor coil assembly.
No power
(3) Damaged rectifier diode (3) Replace the diode.
generation
(4) Poor contact of carbon brush (4) Clear the dirt or replace the carbon
brush.
(5) Damaged regulator
(5) Repair or replace the regulator.

(1) Poor contact of carbon brush or oil (1) Adjust the carbon brush and clean
Undercharge of pollution on the slip ring the slip ring.
generator
(2) Damaged regulator (2) Replace the regulator.

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(3) Insufficient electrolyte in the storage (3) Add electrolyte to the required level or
battery or sulphation or ageing of polar replace the storage battery when the
plates 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 Troubleshooting

(1) Low level of electrolyte (1) Add distilled water or dilute sulphuric
acid with the density of 1.1 as required.
(2) Short circuit between polar plates
Insufficient (2) Clear the sediment and replace the
capacity of the (3) Sulphation of polar plates
electrolyte.
storage battery (4) Poor contact of circuit connectors, too
and hard to (3) Charge and discharge repeatedly to
much oxide on the terminal pole or
start the diesel clear the sulphation.
undercharge
engine (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 (1) Add electrolyte mixed up with pure
sulphuric acid and distilled water as
(2) Short circuit of the storage battery
required.
outer wire
(2) Check the part with short circuit and
(3) Short circuit of positive/negative poles
clear the malfunction.
due to electrolyte spilled out on the
storage battery surface (3) Use alkaline water or warm water to
clean the storage battery surface and
Overhigh self (4) Serious short circuit due to metal tools
pole end and keep the outer surface
discharge of the or bars left between the positive and
clean   (Don’t   get   the   alkaline   water   or  
storage battery negative poles.
warm water entered the storage battery).
(5) Short circuit of pole plates due to
(4) It is prohibited to leave metal tools or
active substance falling off from the pole
bars on the surface of storage battery.
plates and excessive sediment; short
circuit of pole plates due to damage of the (5) Repair or replace the storage battery.
baffle plate; short circuit between positive
and negative poles due to warpage of
pole plates.

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 Normal storage battery


service

Check the storage


battery Check the terminal

Disconnection of Normal connection of


terminal terminal

Clean the storage battery terminal and then Check the starter or
reconnect it starting switch

Malfunction

Repair or replace it

Connect the headlamp and the starting


switch

Headlamp off or dim Headlamp on

① Undercharge of storage battery ① Open circuit of starter


② Short circuit of starter coil ② Open circuit of starter coil
③ Malfunction of starter parts ③ Malfunction of starting switch

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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

In this case, check whether the voltage for the


Serious wear electromagnetic switch connector 3BW of
High slipping restarting relay is normal
between the pinion resistance for starter
and the gear ring

Repair or replace the Repair or replace the


starter and replace starter.
the gear ring

Normal Abnormal

Open circuit or connection Check whether there is


malfunction between the a voltage at the starting
starting switch and the switch connector of
electromagnetic switch restarting relay.

Repair it

Yes No

Connection malfunction Open circuit or connection


of the starting switch malfunction between the
starting switch and the
storage battery

Replace the Repair it


starting switch

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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 Check whether the instrument


cable indicator lamp is normal

Proper Improper Abnormal


Normal

Repair it Check whether the Open circuit or connection


connection between the malfunction between the
starting switch and the storage battery and the
Or electromagnetic switch starting switch.
terminal “s” is on
The slipping part of Open circuit or
pinion cannot move burnout of the
electromagnetic Connection Repair it
switch or the coil Check the
starter relay malfunction of
the starting
switch

Check the Replace the


Repair or replace the clutch and starting switch
starter starting switch.

The engine cannot work after the pinion is


engaged in the gear ring

Check the earthing


cable

Proper Improper

Repair or replace the


earthing cable

Connection Burnout of the Open circuit or Open circuit or Slipping


malfunction between electromagnetic damage of the damage of the pinion clutch
the electric brush and starting switch excitation coil armature coil
the rectifier

Repair or replace the


starter

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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 Terminal No.
switch key

OFF
Lock

Accessories
ON
ON

ST

All the wires except the wires above should be disconnected

Yes
No

The contact of electromagnetic switch


Replace the starter switch
is melted and cannot move or the
return spring is broken or damaged

Replace the electromagnetic


switch

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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.

Diagnosis phenomenon
Insufficient engine power

High fuel consumption of

Periodical noise from the


Too much noise from the

turbocharger turbo side


Black smoke from the

Blue smoke from the

Oil leakage from the

Oil leakage from the


compressor side
Malfunction diagnosis for the turbocharged engine
turbocharger

turbocharger
the engine
engine

engine

Possible cause Troubleshooting


Replace the filter core of
● ● ● ● ● Dirty air cleaner
the air cleaner
Blockage in the Clear the foreign matters
● ● ● ● ● ● ● compressor air intake or replace the broken
pipe components accordingly.
Blockage in the Clear the foreign matters
● ● ● compressor exhaust or replace the broken
pipe components accordingly.
Blockage in the engine Clear the foreign matters
● ● ●
air intake pipe in the air intake pipe.
Air leakage from the pipe Replace the sealer or
connecting the air tighten the fastener to

cleaner and the the required torque
compressor accordingly.
Air leakage from the pipe Replace the sealer or
connecting the tighten the fastener to
● ● ● ● ●
compressor and the the required torque
engine air intake pipe accordingly.
Air leakage from the Replace the gasket or
junction surface between tighten the fastener to
● ● ● ● ●
the engine air intake pipe the required torque
and the cylinder head accordingly.
Blockage in the engine Clear the foreign matters
● ● ● ● ● ●
exhaust pipe in the exhaust pipe.
Clear the foreign matters
Blockage in the silencer
in the exhaust pipe or
● ● ● or the exhaust pipe
replace the broken
behind
components accordingly.

● ● ● ● Air leakage from the Replace the gasket or


junction surface between tighten the fastener to

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the engine exhaust pipe the required torque


and the cylinder head accordingly.
Air leakage from the Replace the gasket or
connection between the tighten the fastener to
● ● ● ●
turbo intake port and the the required torque
engine exhaust pipe accordingly.
Clear the air leakage
Air leakage from the
● from the turbo exhaust
turbo exhaust pipe
pipe.
Blockage in the Clear the foreign matters
● ● ● ● turbocharger fuel return or replace the exhaust
hose pipe accordingly.
Clear the foreign matters
Blockage in the engine
● ● ● ● in the crankcase
crankcase respirator
respirator.
Replace the engine oil
Dirt deposit or coking in and engine oil filter core,
● ● ● ● the intermediate housing overhaul or replace the
of turbocharger turbocharger
accordingly.
Replace or adjust the
Improper control of the
high pressure fuel pump
● ● high pressure fuel pump
and relevant
or fuel injector
components accordingly.
Replace the worn
Improper timing of
● ● components and adjust
engine
the engine timing.
Blow-by resulting from Repair the engine and
● ● ● ● ● ● engine piston ring wear replace the components
or cylinder wear accordingly.
Internal malfunction of Repair the engine
● ● ● ● ● ●
engine (valve or piston) accordingly.
Clean, check and clear
Dirt deposit on the the malfunction which
● ● ● ● ● ● ● ● compressor impeller or makes the air unfiltered.
the diffuser blade Replace the engine oil or
the engine oil filter.
Find out the reason and
clear the malfunction
which results in damage.
● ● ● ● ● ● ● ● Damage of turbocharger
Overhaul or replace the
turbocharger
accordingly.

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

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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 Clean and repair the air intake
Yes
impeller is broken by foreign system or replace the turbocharger
matters

No
② Check whether the axial/radial Eliminate the factors that largen the
clearance of turbocharger is Yes turbocharger clearance or replace
largened (whether the compressor
blade has interference with its the turbocharger
housing)

No
③ Check whether the idle speed Clean the lubricating oil and avoid
Yes
time of engine is too long (more long time idling
than 20 min)

No
Yes
④ Check whether the air cleaner is Replace the filter core of air cleaner
too dirty
No

⑤ Check whether the turbocharger Eliminate the factors that throttle


air intake pipe is throttled the turbocharger air intake pipe

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

No
⑦ Check whether the lubricating Yes Clean it and clear the throttling
oil return hose of turbocharger is factor. Replace the lubricating oil
blocked and the oil return hose if necessary

No

⑧ Check whether the engine See the maintenance manual of


Yes
crankcase respirator is blocked engine manufacturer for check and
repair

⑨ Check whether there is See the maintenance manual of


malfunction in the engine (serious Yes engine manufacturer for check and
blow-by of piston or overhigh repair
pressure in the crankcase)

⑩ Check whether there is too Adjust the oil in the crankcase to a


Yes
much lubricating oil in the proper level
crankcase

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 Eliminate the factors that largen the
clearance of turbocharger is Yes turbocharger clearance or replace
largened (whether the compressor the turbocharger
blade has interference with its
housing)

No

② Check whether the idle speed Yes Clean the lubricating oil and avoid
time of engine is too long (more than long time idling
20 min)

No

③ There is too much lubricating oil Yes The redundant lubricating oil will be
added before burnt and no measures are needed

No

④ Check whether the engine Yes See the maintenance manual of


crankcase respirator is blocked engine manufacturer for check and
repair

No

⑤ Check whether the turbocharger Yes Clean it and clear the throttling
lubricating oil return hose is blocked factor, replace the lubricating oil and
oil return pipe if necessary

No
⑥ Check whether there is dirt deposit Yes Repair the engine lubrication system
or lubricating oil coking in the and replace the turbocharger
intermediate housing of turbocharger

No

⑦ Check whether there is too much Yes Adjust the oil in the crankcase to a
lubricating oil in the crankcase proper level

No

⑧ Check whether there is See the maintenance manual of


malfunction in the engine (serious Yes engine manufacturer for check and
blow-by of piston or overhigh repair
pressure in the crankcase)

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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(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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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 Disassembling the timing system ②
component and timing system
(1) Remove timing hood component I and the timing
hood. See Fig. 4-1-3.
Fuel return hose (2) Removing the timing belt: Loosen the timing tension
component pulley to make the timing belt loose and then remove it.
Fuel inlet pipe
of injector 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 (1) Equally loosen the pipe connectors located at the
fuel rail ends of the four fuel pipes of fuel injector with a spanner,
and take down the four fuel inlet pipe components of the
Fig. 4-1-4 Removing the fuel inlet pipes of fuel injector. See Fig. 4-1-4.
both fuel injector and fuel rail (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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——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 (3) Use the BOSCH or XINFENG fuel injector. Use a tool
pipe component to push out the clip, pull out the fuel return connector
from the fuel injection circuit, and then remove fuel return
hose component.
Disassembling the heater water return pipe
component ⑤
(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.

Disassembling the cylinder head cover assembly ⑥


Water outlet
Cylinder head pipe connecting (1) Remove the 2 hexagon flange bolts (M8×16)
cover pipe component 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.
Cylinder head (3) Take out the packing from the sealing groove of
cover packing cylinder cover.

Fig. 4-1-6 Removing the cylinder head cover Check the cylinder head packing and replace it if
assembly there is any damage or deformation.

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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
Fuel injector head.
assembly
Prompt: Place the removed fuel injectors carefully
according to the cylinder serial numbers 1, 2, 3 and 4,
Fig. 4-1-7 Removing the fuel injector and make corresponding marks on these fuel injectors.
assembly Protect them from being contaminated or bumped.
Water outlet pipe Disassembling the GER condenser air intake pipe,
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.
(2) Remove the 2 hexagon flange bolts (M8×20)
Exhaust manifold
pipe
connecting the EGR condenser air intake pipe to EGR
condenser.
Water inlet (3) Remove the 2 hexagon flange bolts (M8×16)
pipe connecting the EGR condenser to EGR condenser air
outlet pipe.
Fig. 4-1-8 Removing the EGR Condenser (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)
Air intake connecting EGR condenser to cylinder head, and take
manifold pipe down the EGR condenser. See Fig. 4-1-8.
Air intake
manifold pipe
gasket
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
Air outlet cylinder head. See Fig. 4-1-9.
component of EGR (2) Take down the air intake manifold pipe and its gasket
condenser
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 Check the air intake manifold pipe gasket. It must be
replaced if there is any damage or deformation.

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Disassembling the turbocharger ⑩


Turbocharger (1) Pull out the harness plug of the 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.
(3) Remove the fuel return hose connected to the
turbocharger.
Fuel return
hose Heat shield (4) Remove the fuel inlet bolts connecting the
turbocharger fuel inlet pipe to turbocharger.
(5) Remove the single bolt and the 2 fastening nuts
connecting turbocharger to exhaust manifold pipe, and
Fig. 4-1-10 Removing the turbocharger and take down the turbocharger and its gasket. See Fig.
its heat shield 4-1-10.

Exhaust Check the supercharger gasket and replace it if there


Exhaust
manifold pipe is any damage or deformation.
manifold pipe
gasket Disassembling the exhaust manifold pipe ○
11

(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 Check the exhaust manifold pipe gasket and replace
manifold pipe and gasket it if there is any damage or deformation.

Disassembling the glow plug ○


12
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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Disassembling the vacuum pump assembly ○


13

(1) Pull out the vacuum connecting hose from the


Cylinder head
vacuum pump.
(2) Remove the 3 hexagon flange bolts (M6×20)
connecting the vacuum pump to cylinder head ring
Vacuum
flange. See Fig. 4-1-13.
pump (3) Remove the vacuum pump assembly from the rear
assembly
end of the cylinder head exhaust camshaft.

Fig. 4-1-13 Removing the vacuum pump


assembly

Disassembling the camshaft bearing cap ○


14

Camshaft (1) Remove the supporting bolts for the 4 fuel injector
bearing cap ballasts.
(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 Disassembling the intake/exhaust camshaft ○


15

(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


Cylinder head is damaged.

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


camshaft

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Disassembling the hydraulic clearance adjuster ○


16

(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.
Disassembling the cylinder head ○
17

Caution: The cylinder head should not be removed


during warm-up, which may cause deformation.
Fig. 4-1-16 Removing the hydraulic (1) Gradually and evenly loosen the 10 bolts of the
clearance adjuster and rocker arm cylinder head in the order shown in Fig. 4-1-17.

Caution: If the cylinder cap bolts are not orderly


Cylinder head loosened in gradually specified order, the lower surface
bolt of the cylinder cap might be damaged.
(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 Cleaning


cylinder head in order
(1) Cylinder head bolt.
Cylinder head (2) 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.
(1) Check whether there is any leakage, rust or blow-by
Fig. 4-1-18 Checking the cylinder head and on the cylinder sealing gasket and fitting surfaces. If a
its gasket 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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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.

Attention: Do not try to weld up the cylinder head.


Fig. 4-1-19 Inspection for Cylinder Head Bolt
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.
Standard Limitation
Warp of the base plane
≤0.05  mm 0.10 mm
of cylinder head
Fig. 4-1-20 Checking the cylinder head base
plane (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 Limitation
≤0.05  mm 0.10 mm
Fig. 4-1-21 Measuring the warps of the air Reassembly
exhaust manifold pipe and the fitting surface
Reinstalling the cylinder head ○
17

(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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——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 Inlet
valve 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~
Valve spring seat
70 kPa, the blow-by flow should not excess 20 mL/min.
(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 ——Compress the valve spring with special tools to
valve lock clamp install the valve lock camp into the valve spring seat.

Valve spring compressor: 9-8523-1423-0


Cylinder head ——The valve lock clamp should be in tight contact with
bolt 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.
Cylinder head
(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
Fig. 4-1-24 Installing the cylinder head, of the cylinder head gasket onto the cylinder body fixed
tightening the bolts in order 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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Step 1 Step 2 Step 3


50 N·m±3 N·m Turn for 90° 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
rocker arm ○16

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

Reinstalling the intake and exhaust camshafts ○


15

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 Axial clearance of camshaft
camshaft
Standard 0.060~0.115 mm
Camshaft
bearing cap Reinstalling the camshaft bearing cap ○
14

Apply the
(1) Apply anaerobic plane sealant to the junction surface
sealant between the camshaft bearing cap and the cylinder head.
See Fig. 4-1-27.

LOCTTTE510 anaerobic plane sealant

Cylinder Attention: If the former cylinder head is to be used,


head clean the junction surface between the camshaft bearing
cap and the cylinder cap before applying sealant. The
Fig. 4-1-27 Installing the camshaft bearing camshaft bearing cap and the cylinder head should be
cap and applying sealant 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

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Chpter IV Mechanical System

specified order, then tighten the surrounding 6 hexagon


Camshaft flange bolts (M6×20) from the center to both sides. See
bearing cap Fig. 4-1-27.

Tightening torque for the fastening bolt of camshaft


bearing cap
9 N·m±3 N·m
(3) Install the plug cover and the front oil seal of
camshaft: apply an appropriate amount of lubricating oil
Cylinder head 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
Fig. 4-1-28 Installation for camshaft bearing corresponding holes properly without causing any oil
cap leakage.

Mobil API CI-4 lubricating oil


Cylinder head
Reinstalling the vacuum pump assembly ○
13

(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
Vacuum pump
assembly 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 (3) Fix the vacuum coupling hose to the vacuum pump.
assembly
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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Reinstalling the glow plug assembly ○


12

Cylinder head (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.

Tightening torque for glow plug


9N·m~3N·m
Heater plug (2) Check the assembled glow plugs and eliminate any
misplacement and leakage.

Fig. 4-1-30 Installing the glow plug assembly (3) Assemble the wiring harness of glow plugs and
connect the harness securely.
Reinstalling the exhaust manifold pipe ○
11
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
30N·m±3N·m
pipe
(2) Install the heat shield of exhaust manifold pipe, and
Fig. 4-1-31 Installing the air exhaust tighten the 4 hexagon flange bolts (M6×12) to the
manifold pipe specified torque. See Fig. 4-1-32.

Tightening torque for the fastening bolt of exhaust


Exhaust manifold Exhaust manifold manifold pipe heat shield
pipe gasket pipe
9 N·m±3 N·m
Reinstalling the turbocharger ⑩
(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.
Heat shield 4-1-33.

Tightening torques for the connecting bolt and


fastening nut of turbocharger
Fig. 4-1-32 Installing the heat shield of
exhaust manifold pipe 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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(3) Install the fuel inlet pipe of supercharger and fuel inlet
bolt connecting the supercharger and tighten it according
Supercharger to the required torque.

Tightening torque for supercharger fuel inlet bolt


22 N·m±3 N·m
(4) Install the heat shield of turbocharger, and tighten the
Fuel return 3 hexagon flange bolts (M6×12) to the specified torque.
hose Heat shield See Fig. 4-1-33.

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 (1) Install the air intake manifold pipe gasket and the air
gasket 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.

Air intake Tightening torque for fastening bolt and nut of air
manifold pipe intake manifold pipe
23 N·m±3 N·m
Fig. 4-1-34 Installing the air intake manifold Reinstalling GER condenser air intake pipe, EGR
pipe condenser air outlet pipe, EGR condenser ⑧
(1) Use 2 hexagon flange bolts (M10×16) to install the
Air intake Water outlet pipe EGR condenser onto the cylinder head, but do not screw
pipe down the bolts right now.
EGR condenser (2) Fit the water inlet pipe on the water pipe connector of
EGR condenser, and clamp them with a single-ear
step-less clamp.
(3) Install the EGR condenser air intake pipe and gasket
between the EGR condenser and air exhaust manifold
Exhaust pipe pipe. Do not tighten them right now. See Fig. 4-1-35.

Water inlet pipe (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.
Fig. 4-1-35 Installing the EGR Condenser
(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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4-1-36.
Air intake Water outlet pipe
pipe
Tightening torque for EGR system fastening bolt
EGR condenser
23N·m±3N·m
Reinstalling the fuel injector assembly ⑦
Exhaust
manifold pipe
(1) Tighten the supporting bolts of the fuel injector ballast
by using the required torque onto the cylinder head.

Water inlet pipe


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.
(4) Place one end of the fuel injector ballast on ballast
Fuel injector supporting bolt and the other end in fuel injector ballast
assembly groove. See Fig. 4-1-37.
(5) Install and tighten the fastening bolt washer
Fig. 4-1-37 Installing the fuel injector component of fuel injector ballast as per the required
assembly torque.

Tightening torque for fastening bolt of fuel injector


Cylinder head ballast
cover
23 N·m~35 N·m

After the installation, make sure there is no gas


leakage from the oil injector gasket.
Reinstalling the cylinder head cover assembly ⑥
Cylinder head
cover packing (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.
图 4-1-38 装配气缸盖罩密封垫 Fig. 4-1-38 (3) Install the cylinder head cover to the cylinder head,
Installing cylinder head packing 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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Water outlet pipe Reinstalling the heater water return pipe component
Cylinder head connecting pipe ⑤
cover 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 M6×16 9 N·m±3 N·m
and the water outlet pipe connecting pipe M8×16 23 N·m±3 N·m
component
(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
(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.
Fig. 4-1-40 Installing the heater water return
(2) Use BOSCH or XINFENG fuel injector. Remove the
pipe
dust cap from the upper end of the fuel injector. Install 4
short connectors of the fuel return hose into the 4 holes
Fuel return hose of at the upper end of the fuel injector, and fix them tightly
fuel injector with the spring clips. Install the other long connector to
Fuel inlet pipe the fuel return tee on the high pressure pump, and fix it
of injector
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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Reinstalling the fuel inlet pipes of fuel injector and


fuel rail ③
Timing mark (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.
Bone-line 4-1-41.
(2) Install the fuel inlet pipe of fuel rail, and tighten the
Camshaft pipe connectors at both ends of the fuel pipe to the
timing pulley specified torque. See Fig. 4-1-41.

Tightening torque for fuel inlet pipe connector of fuel


Fig. 4-1-42 Installing the camshaft timing injector and fuel rail
pulley 32 N·m±3 N·m
Timing mark of damping
pulley 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.

Damping pulley Timing mark of Reinstalling the timing system ②


timing hood
component II (1) Install the woodruff key to the exhaust camshaft,
install the timing pulley to the exhaust camshaft and
Fig. 4-1-43 Installing the timing system tighten the fastening bolt washer component to the
required torque. The camshaft timing pulley should be
pressed and installed to the right position without
Horizontal Timing mark Fuel pump pulley deflection.
bar
(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
(3) Align the timing marks on damping pulley and timing
hood II. See Fig. 4-1-43.
Fig. 4-1-44 Installing the timing system
(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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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
Timing pulley 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
Timing pin and crankshaft locking tooling, turn the crankshaft 2
tension
pulley
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
Fig. 4-1-45 Installing the timing belt 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 (7) Install the timing hood and timing hood component I.
socket head Screw down 10 hexagon flange bolts (M6×16, M10×35
spanner to adjust
the mounting
Analog notch and M10×50) to the front end of cylinder head and
hole. cylinder body by using the specified torque. See Fig.
4-1-47.
Fig. 4-1-46 Installing the timing tension
pulley 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.

Visually checked, the pulleys should be on the same


plane.
Fig. 4-1-46 Installing the timing hood
component 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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After the installation, check the generator belt. Make


sure the belt wedge-shaped teeth perfectly match the
Rotary
installation
pulley wedge slot.
position of
tension Caution: The excessive or insufficient tightening of
pulley Generator belt is not allowed.
belt

Fig. 4-1-48 Installing the engine accessories

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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 Reinstallation procedure
assembly Reinstall them in the opposite order of
dismounting.

Fig. 4-2-1 Disassembly and reassembly sequences for camshaft

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Disassembly
Disassembling the engine accessories ①
Rotary
installation (1) Remove the generator belt
position of
tension pulley Turn the tension pulley with tools until the belt is loose
Generator
belt
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

Disassembling the fuel inlet pipe component of the


Fuel return hose of fuel injector ③
fuel injector
Fuel inlet pipe of (1) Loosen evenly the pipe connectors at both ends of
injector
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:
——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
Fig. 4-2-4 Removing the fuel inlet pipe and pipe from deforming.
fuel return hose components of the fuel
injector ——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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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.

Attention: The removed fuel return hose can be


Fig. 4-2-5 Removing heater water return pipe used again and should be kept safely and cleanly.
component 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


Water outlet pipe
connecting pipe (1) Remove the 2 hexagon flange bolts (M8×16) for
Cylinder head
cover
component 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.
Cylinder head (3) Take out the packing from the sealing groove of
cover packing
cylinder cover.

Fig. 4-2-6 Removing the cylinder head cover Check the cylinder head packing and replace it if
assembly 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
(4) Take out the fuel injector assembly from the
Fuel injector
assembly mounting hole of fuel injector on the cylinder cover.

Fig. 4-2-7 Removing the fuel injector Prompt: Place the removed fuel injectors carefully
assembly 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.

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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
Camshaft (1) Remove the 22 hexagon flange bolts (M6×35 and
bearing cap
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.
(2) Remove the camshaft bearing cap from the cylinder
head.

Cylinder head

Fig. 4-2-9 Removing the camshaft bearing


cap
Disassembling the Intake/exhaust camshaft
Camshaft
assembly ⑩
(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 The parts should be adjusted, repaired or replaced if
camshaft 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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the limitation.
Outer diameters of the camshaft journals

Standard

Intake camshaft 26.947~26.960 mm

26.947~26.960 mm,
Exhaust camshaft
26.947~26.960 mm

2. Checking the height of the cam


Use a micrometer to measure the height of the cam
Fig. 4 -2-11 Measuring the outer diameter of
(H). See Fig. 4-2-12.
the camshaft journal
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


Use an inside micrometer to measure the inner
diameter of the camshaft bearing.
Fig. 4 -2-13 Measuring the radial runout of the
camshaft Inner diameters of the camshaft bearings

Standard

Intake camshaft 27.000~27.021 mm

30.000~30.021 mm,
Exhaust camshaft
27.000~27.021 mm

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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 the intake/exhaust camshaft
assemblies⑩
(1) Apply an appropriate amount of lubricating oil onto
Fig. 4-2-14 Installing the exhaust/intake
the surface of the and exhaust camshafts in the cylinder
camshaft assembly
head.
Camshaft
bearing cap Mobil API CI-4 lubricating oil
(2) Fix the intake and exhaust camshafts into the
Apply the
sealant cylinder head as shown in Fig. 4-2-14.
(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
Reassembling the camshaft bearing cap ⑨
Fig. 4-2-15 Installing the camshaft bearing
cap and applying sealant (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 ——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.
Fig. 4-2-16 Installing the camshaft bearing
cap (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

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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
Vacuum pump cylinder head exhaust camshaft and the rabbet and the
assembly rabbet round hole matched perfectly.
(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
Cylinder head
corresponding fuel injector mounting holes in the
cover packing cylinder heads 1, 2, 3 and 4.
(4) Place one end of the fuel injector ballast on ballast
supporting bolt and the other end in fuel injector ballast
groove.
Fig. 4-2-19 Installing the cylinder head cover
assembly (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

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Water outlet pipe


25 N·m~35 N·m
Cylinder head connecting pipe
cover component 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 Tightening torque for fastening bolt of cylinder
assembly head cover
9 N·m±3 N·m
Reinstalling the heater water return 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 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

Tightening torques for fastening bolts of heater


Fuel return hose water return pipe component
of fuel injector
Fuel inlet pipe of
injector 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<and tighten the 2 hexagon flange bolts
(M8×16) connecting the water outlet pipe and cylinder
head cover. See Fig. 4-2-21.

Tightening torque for fastening bolt of water outlet


Fig. 4-2-21 Installing the fuel inlet pipe and pipe connecting pipe component
return hose of fuel injector
23 N·m±3 N·m

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Reinstalling the fuel return hose component ④


(1) Use DELPHI fuel injector. Insert respectively the fuel
Timing mark return rubber hoses into 4 injector heads and position
them in place. See Fig. 4-2-22.
(2) Use BOSCH or XINFENG fuel injector. Remove the
dust cap from the upper end of the fuel injector. Install 4
Bone-line
short connectors of the fuel return hose into the 4 holes
at the upper end of the fuel injector, and fix them tight
Camshaft timing with the spring clips. Install the other long connector to
pulley the fuel return tee on the high pressure pump, and fix it
tight with a clip.
(3) Install the fuel return hose support and clamp.
Fig. 4-2-23 Installing the camshaft timing
pulley Make sure the fuel return hose is sealed properly
without leakage after installation.
Timing mark of damping
pulley Reinstalling the fuel inlet pipe component of fuel
injector③
As shown in Fig. 4-2-22, install the fuel inlet pipe of the
fuel injector and tighten evenly the pipe connectors at
both ends of the 4 fuel inlet pipes of the fuel injector
according to the specified torque.

Damping pulley Timing mark of timing Make sure the fuel inlet pipe of fuel injector is
hood component II
sealed properly without leakage after installation.

Tightening torque for fuel inlet pipe connector of


Fig. 4-2-24 Installing the timing system fuel injector
Horizontal Timing mark Fuel pump pulley 32 N·m±3 N·m
bar

Attention: When tightening the fuel inlet pipe of the


fuel injector, tighten the pipe connectors at both ends of
the pipe simultaneously and evenly to prevent the fuel
inlet pipe from deforming.
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
Fig. 4-2-25 Installing the timing system 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. 4-2-23.

Tightening torque for bolt washer component of


camshaft timing pulley
110 N·m±5 N·m

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(3) Align the timing marks on damping pulley and timing


hood II. See Fig. 4-2-24.
(4) Align the timing mark on fuel pump pulley with the
horizontal bar on water pump shell. See fig. 4-2-25.

(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,
as shown in Fig. 4-2-26.
Timing pulley
(6) Install the timing tension pulley. Fix the limit bracket
of the timing tension pulley in the place where the bowl
Timing shaped plug is installed on the cylinder head first, and
tension pulley 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,
Fig. 4-2-26 Installing the timing belt 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, as
Use a hexagon shown in Fig. 4-2-27.
socket head
spanner to adjust
Analog
the mounting hole. Notch 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. 4-2-27.
Fig. 4-2-27 Installing the timing tension pulley
Tightening torque for timing tension pulley bolt
22 N·m~26 N·m
(7) Install the timing hood and timing hood component I,
and 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. 4-2-28.

Tightening torque for fastening bolt of timing hood


45 N·m±3 N·m

Fig. 4-2-28 Installing the timing hood Tightening torque for fastening bolt of timing hood
component component I
9 N·m±3 N·m

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Reinstalling the engine accessories ①


(1) Reinstall the wedge idle wheel and tighten it
according to the required torque.
Rotary
installation
position of
Generator belt
Visually checked, the pulleys should be on the
tension pulley
same plane.

Tightening torque for wedge idle wheel


22 N·m~26 N·m
(2) Reinstall the generator belt, use a tool to turn the
tension pulley, and install it after the belt is loose
Fig. 4-2-29 Installing the engine accessories enough. See Fig. 4-2-29.
(3) After the installation, check the generator belt to
make sure the belt wedge teeth fit well with the pulley
wedge slot.
(4) Install the harness connector and make sure it is
installed firmly to the right position.

Caution: The excessive or insufficient tightening of


pulley is not allowed.

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Section III Valve, Valve Spring, Valve Oil Seal, Rocker Arm and Hydraulic
Clearance Adjuster

Camshaft installation
Intake/exhaust valve assembly
components

Dismounting procedure

① Rocker arm and hydraulic clearance adjuster

② Valve lock clamp

③ Valve spring

④ Valve

⑤ Valve oil seal


Reinstallation procedure
Reinstall them in the opposite order of dismounting.

Table 4-3-1 Dismounting and reinstalling sequences for valve, valve spring, valve oil seal, rocker arm
and hydraulic clearance adjuster

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Disassembly
Disassembling the rocker arm and hydraulic
clearance adjuster ①
(1) Take out the 16 rocker arms and hydraulic clearance
adjusters respectively from the cylinder head. See Fig.
4-3-2.
(2) Group the removed rocker arms and hydraulic
clearance adjusters according to cylinder sequence,
and make marks for the convenience of reinstallation.
Disassembling the valve lock clamp ②
Fig. 4-3-2 Removing the rocker arm and Press down the valve spring with a special tool; or
hydraulic clearance adjuster remove the valve lock clamp with a hammer, a sleeve.
See Fig. 4-3-3.

Valve spring compressor: 9-8523-1423-0


Valve lock clamp

Valve spring seat Warning: When removing, do prevent the valve


lock clamp from snapping out and hurting anyone.
Disassembling the valve spring ③
Valve spring
(1) Take out the 16 valve spring seats and valve springs
respectively from the cylinder head.
Check the valve spring and valve spring seat for
damage and deformation, and replace them if
necessary.
Fig. 4-3-3 Removing the valve lock clamp,
valve spring Disassembling the valve ④
(1) Take out the 8 intake valves and the 8 exhaust
valves respectively from the valve guide.
(2) Group the inlet/exhaust valves according to their
corresponding cylinders and make marks for the
convenience of reinstallation.
Disassembling the valve oil seal ⑤
Valve oil seal
Take out the 16 valve oil seals with a clamp or a valve
oil seal remover from the head of valve guide.
Exhaust valve
Intake valve

Valve oil seal remover: 5-8840-0373-0

Caution: Do not reuse the removed valve oil seal.


Fig. 4-3-4 Removing the valve, valve oil seal
Inspection and repair
Conduct necessary adjustment, repair and part
replacement if any excessive wear or damage is found
during inspection.

1. Valve spring

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Attention: Check the valve springs visually, and


replace them if any damage or evident abnormal wear
is found.
1.1 Checking the free height of valve spring
(1) Measure the free height of valve spring. See Fig.
4-3-5.
(2) Replace the spring if the height is below the
limitation.
The free height of valve spring

Fig. 4-3-5 Measuring the free height of valve Standard Limitation


spring
45.0 mm 44.5 mm

1.2 Checking the perpendicularity of valve spring


(1) Measure the perpendicularity of valve spring with a
steel square. See Fig. 4-3-6.
(2) Replace the valve spring if the measured value is
above the limitation. The perpendicularity limitation of
valve spring
1.2·m
1.3 Checking the tension of valve spring
(1) Press the spring down to the installation height with
a spring tester. Measure the spring tension. See Fig.
Fig. 4-3-6 Measuring the perpendicularity of 4-3-7.
valve spring (2) Replace the valve spring if the measured tension
value is below the limitation.
The tension of valve spring

Installation height Standard Limitation

32.3 mm 211 N 201 N

2. Valve guide

Attention:
(1) Take caution when clearing away the accumulated
carbon on the valve head, avoiding any damage to the
Fig. 4-3-7 Measuring the tension of valve contact surface of valve seat.
spring
(2) Check carefully for scratch or abnormal wear on the
valve stem. See Fig. 4-3-8.
(3) Replace the valve and valve guide in pairs if there is
any scratch or abnormal wear.
2.1 Checking the valve guide clearance
(1) Measure the outer diameter of valve stem with a

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micrometer. See Fig. 4-3-9.


(2) Replace the valve and valve guide in pairs if any
outer diameter of valve stem is below the limitation.
Exhaust valve The outer diameters of valve stem
Intake valve
Valve Standard

Intake valve 5.960~5.975 mm

Exhaust valve 5.945~5.960 mm

(3) Measure the inner diameter of valve guide with a


Fig. 4-3-8 Checking the valve micrometer.
(4) Subtract the measured outer diameter value of valve
stem from the measured inner diameter value of valve
guide. Replace the valve and valve guide in pairs if any
result is above the limitation
The valve guide clearances

Valve Standard

Intake valve 0.039~0.069 mm

Exhaust valve 0.064~0.096 mm

Fig. 4-3-9 Measuring the outer diameter of


valve stem

3. Valve
3.1 Cleaning the valve
(1) Scrape off the accumulated carbon at the valve end
with a gasket scraper. See Fig. 4-3-10.
(2) Clean the valve thoroughly with a steel wire brush.

Fig. 4-3-10 Cleaning the valve

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3.2 Checking the thickness of valve


(1) Measure the edge thickness of valve head. See Fig.
4-3-11.
(2) Replace the valve and valve guide in pairs if the
measured value is below the limitation.
The standard value of valve thickness

Intake valve 1.99 mm±0.10 mm

Exhaust valve 2.10±0.10 mm

Fig. 4-3-11 Measuring the edge thickness of


valve head
3.3 Checking the valve seat contact taper face angle
(1) Measure the valve seat contact taper face angle.
See Fig. 4-3-12.
(2) Replace the valve, valve guide and valve seat in
group if the measured value is above the limitation.
The standard value of valve seat contact taper face
angle on the valve
44°45’  ±75’

Fig. 4-3-12 Measuring the valve seat contact


taper face angle 3.4 Checking the valve sinkage
(1) Install the valve ① onto the cylinder head ②. See
Fig. 4-3-13.
(2) Measure the valve sinkage from the bottom surface
of cylinder head with a depth gage or a ruler and a steel
ruler. See Fig. 4-3-13.
(3) Replace the valve set if any measured valve of
sinkage is above the limitation.
The valves of sinkage

Valve Standard Limitation

Intake valve 0.73 mm 1.28 mm


Fig. 4-3-13 Measuring the valve sinkage
Exhaust valve 0.70 mm 1.20 mm

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3.5 Checking the valve contact width


(1) Check the valve contact surface for roughness or
unevenness. Ensure the valve contact surface is
smooth.
(2) Measure the valve contact width. See Fig. 4-3-14.
(3) Replace the valve seat if any valve of contact width
is above the limitation.
The valves of contact width

Valve Standard Limitation

Fig. 4-3-14 Measuring the valve contact width Intake valve 1.7 mm 2.2 mm

Exhaust valve 2.0 mm 2.5 mm

4. Valve seat
Valve guide 4.1 Removing the valve seat
(1) Conduct arc-weld inside the valve seat.
Sectional view of
cylinder head cover
(2) Cool the valve seat for several minutes. The valve
seat will contract by doing so and its removal will
become easier.
(3) Pry the valve seat with a screw driver to remove it.
Be careful lest the cylinder head be damaged.
View of intake View of exhaust (4) Carefully remove the accumulated carbon and other
valve seat valve seat foreign matters from the valve seat mounting hole in
cylinder head.
Fig 4-3-15 Removing the valve seat

4.2 Calibrating the valve seat


(1) Remove the accumulated carbon on the valve seat
surface with a gasket scraper or a steel wire brush.
(2) Treat the valve seat with a valve seat cutter (blade
of 15°, 45° and 75°) to minimize the area with scratches
or other kinds of irregularities, in order to recover the
standard value of contact width.
The valve seat angle
45°
Fig. 4-3-16 Calibrating the valve seat

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Attention:
——Cut only the uneven part and the part with
scratches. Do not cut too much. Be careful lest the
defect-free area of valve seat surface be removed.
——The valve seat cutter guide rod is not allowed to
sway inside of valve guide hole when using an
adjustable valve seat cutter guide rod.

Fig. 4-3-17 Treating the valve seat with a


milling cutter

4.3 Installing the valve seat


(1) Install carefully the accessory ① (whose outer
diameter   is   a  little  less   than   the   valve   seat’s)   onto  the  
valve seat ②. See Fig. 4-3-18.

Attention: Contact the accessory with its smooth


surface to the valve seat.
(2) Apply pressure gradually on the accessory with a
desktop press machine ③ to force the valve seat to be
in position.

Attention: The pressure applied by the desktop


Fig. 4-3-18 Installing the valve seat
press machine is not allowed to be too powerful, or the
valve seat will be damaged.
(3) Apply some grinding paste onto the surface of valve
seat.
(4) Plug the valve into the valve guide.
(5) Knock the valve up and down gently, and turn the
valve to make it match well with the valve seat. See Fig.
4-3-19.
(6) Check if the valve contact width is appropriate.
(7) Check if the surface of valve seat contacts with the
whole valve edge.
Fig. 4-3-19 Grinding the valve seat
Clean the valve and valve seat after grinding.

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4.4 Checking the valve tightness


(1) Draw 8-12 lines evenly on the valve head taper face
in the circumferential direction with a pencil. See Fig.
4-3-20.Reinstall the valve, pat the valve seat for several
times (Attention: Do not turn the valve). The valve
tightness is considered to be good if all the pencil marks
break at the ring part.
(2) Or reinstall the valve, spring etc., then inject some
kerosene through intake/exhaust passage. The
tightness is considered to be good if there is no leakage
for 3-5 min.

Fig. 4-3-20 Checking the valve tightness Reassembly


Reassembling the valve oil seal ⑤
(1) Apply a little lubricating oil to the sealing surface of
valve oil seal.

Mobil API CI-4 lubricating oil

Valve oil seal (2) Press the valve oil seal into the valve guide head
with a special tool.
Exhaust Intake valve
valve Valve oil seal installer: 5-8840-2033-0.
(3) Conduct pressure leakage test on the valve oil seal,
and the specification is as below: the air leaking amount
should be less than 20 mL/min under 50~70 kPa.
Fig. 4-3-21 Installing the valve oil seal
Attention: Do not reuse the removed valve oil
seal. Replace it with a new one.

Reassembling valve ④
(1) Apply engine oil outside the valve stem and inside
Valve lock clamp
the hole wall of valve guide before installing the valve.
Valve spring seat
Mobil API CI-4 lubricating oil
(2) There is a requirement for the matching between the
Valve spring valves with marks on heads and the valve seats after
facing up, so it is required to plug the valve into the right
place, and no misplacement is allowed. Install the valve
into the valve guide.

Fig. 4-3-22 Installing the valve, spring and The valve in the valve guide hole should be able to
lock clamp move flexibly without any seizure after the installation.
Reassembling the valve spring ③
(1) Install the valve spring onto the valve spring gasket.
(2) The valve spring should contact with the bottom
surface of valve spring seat allocating column, and it is
not allowed for the spring to be stuck to the surface of

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column.
Reassembling the valve lock clamp ②
(1) Install the valve lock clamp into the valve spring seat
with a special tool.

Valve spring compressor: 9-8523-1423-0


(2) 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
Fig. 4-3-23 Installing the rocker arm and aligned.
hydraulic clearance adjuster
(3) 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.

Caution: The installation of the valve lock clamp


must be firm enough.
Reassembling the rocker arm and hydraulic
clearance adjuster ①
(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. 4-3-23.
Fig. 4-3-24 Installing the valve rocker arm and
hydraulic clearance adjuster Mobil API CI-4 lubricating oil
(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. 4-3-23.

Make sure the hydraulic clearance adjuster will not


fall off after the installation.

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Section IV Crankshaft

Dismounting procedure
① Engine accessories
②Damping pulley assembly
③Timing system
④Cylinder head assembly
⑤Flywheel gear ring assembly
⑥ Oil pan upper and lower body assemblies and oil collector assembly
⑦ Oil pump assembly
⑧ Connecting rod assembly and piston component
⑨ Crankshaft rear oil seal
⑩ Lower cylinder body Reinstallation procedure
1
○1Crankshaft and crankshaft position signal panel Reinstall them in the opposite order of dismounting.

Fig. 4-4-1 Disassembling and reinstalling sequences for the crankshaft

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Disassembly
Disassembling the engine accessory ①
(1) Removing the generator belt: Rotate the tension
pulley with a tool to disassemble the generator belt
when it is loose enough.
(2) Remove the tension pulley. See Fig. 4-4-2.
(3) Remove the flat idle wheel assembly and the wedge
idle wheel assembly.
(4) Removing the refrigeration compressor assembly:
Unscrew the 4 hexagon flange face bolts (M8×85)
Fig.4-4-2 Removing the engine accessories fastening the refrigeration compressor to the left side of
the cylinder body, and remove the refrigeration
compressor assembly.
(5) Removing the engine bracket and the engine
assembly: Unscrew the 3 hexagon flange face bolts
(M8×30, M10×45) fastening the engine to the engine
bracket, and remove the engine; unscrew the 4
hexagon flange face bolts (M8×30, M8×35) fastening
the engine bracket to the cylinder body, and remove the
engine bracket.
(6) Removing the power steering pump assembly and
the steering pump support components: Unscrew the 3
or 4 hexagon flange face bolts (M8×30, M8×100)
fastening the power steering pump to the steering pump
Fig. 4-4-3 Removing the damping pulley support, and remove the power steering pump;
assembly unscrew the 3 hexagon flange face bolts (M8×25,
M8×30) fastening the steering pump support to the
cylinder body, and remove the steering pump support.
Disassembling the damping pulley assembly ②
(1) Remove the 4 hexagon flange face bolts (M8×20)
for fastening damping pulley at the front end of
crankshaft. See Fig. 4-4-3.
(2) Remove the damping pulley assembly from the front
end of crankshaft.
Disassembling the timing system ③
(1) Remove timing hood components I and II, the timing
hood and the rear timing hood components.
Fig. 4-4-4 Removing the timing system
(2) Removing the timing tension pulley assembly:
Loosen the combined fastening bolt of timing tension
pulley and remove the timing tension pulley. See Fig.
4-4-4.
(3) Remove the timing belt. See Fig. 4-4-4.
(4) Remove the timing idle wheel: Unscrew the
fastening bolts of timing idle wheel, and remove the
timing idle wheel. See Fig. 4-4-4.

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(5) Removing the camshaft timing pulley: Loosen the


bolt gasket component of camshaft timing pulley and
remove the camshaft timing pulley.
(6) Removing the crankshaft timing pulley: Loosen the
fastening bolt of crankshaft timing pulley and remove
the crankshaft timing pulley.
Disassembling the cylinder head assembly ④
(1) Remove the cylinder head cover component. See
Fig. 4-4-5.
(2) Remove the camshaft bearing cap.
(3) Remove the camshaft assembly.
Fig. 4-4-5 Removing the cylinder head
assembly (4) Removing the cylinder head assembly: Loosen
orderly the 10 bolts for fastening cylinder head and
cylinder body and remove the cylinder head.

Caution: If the cylinder cap bolts are not orderly


unscrewed separately, the lower surface of the cylinder
cap might be damaged.

Disassembling the flywheel gear ring assembly ⑤


(1) Install the flywheel retainer.
Crankshaft position (2) Orderly unscrew the 8 flywheel bolts fastening the
signal panel flywheel gear ring assembly to the rear end of the
crankshaft in separated times.
Flywheel gear
ring assembly (3) Remove the flywheel gear ring assembly from the
rear end of the crankshaft. See Fig. 4-4-6.

Crankshaft

Fig. 4-4-6 Removing the flywheel gear ring


assembly Disassembling the oil pan upper and lower body
assemblies and oil collector assembly ⑥
Upper body of
oil pan (1) Use a spanner to remove the 14 hexagon flange
face bolts (M6×12) fastening the lower body of oil pan in
proper order, and remove the lower body of oil pan. See
Fig. 4-4-7.
(2) Use a spanner to remove the 2 hexagon flange face
bolts (M6×16) fastening the engine oil pipe and the 2
Oil collector hexagon flange face bolts (M8×12) fastening the engine
Lower body of oil pan oil collector support, and remove the engine oil
collector.
(3) Use a spanner to remove the 15 hexagon flange
face bolts (M6×20, M6×110, M8×25 and M8×45)
Fig. 4-4-7 Removing the oil pan upper and fastening the upper body of oil pan in proper order, and
lower body assemblies and oil collector remove the upper body of oil pan from the lower
assembly cylinder body.

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Disassembling the engine oil pump assembly ⑦


(1) Remove the 10 hexagon bolts and flat ring
components fastening the engine oil pump to the
Outer rotor
cylinder body (M8×40, M8×25 and M8×20) in proper
Seal ring order, and remove the engine oil pump assembly. See
Fig. 4-4-8.
Front oil seal (2) Take out the outer rotor of oil pump and rubber seal
ring from the oil pump chamber of upper cylinder body.
See Fig 4-4-8.
(3) Take out the front oil seal of crankshaft through the
Fig. 4-4-8 Removing the oil pump assembly oil seal hole of oil pump crankshaft.

Piston Front oil seal stripper: 5-8840-2362-0.

Attention: Do not damage the mating surface of


Connecti front oil seal of crankshaft when removing it.
ng rod
(4) Check the rubber seal ring of oil pump and front oil
Crankshaft seal of crankshaft and replace them if there is any
deformation or damage.
Disassembling the connecting rod assembly and
Connecting the piston component ⑧
rod cover
(1) Unscrew and remove 8 connecting rod bolts in two
Fig. 4-4-9 Removing the connecting rod separated times following the order of cylinders 1, 4, 2
assembly and piston component and 3, and take down 4 connecting rod covers and the
lower connecting rod bearing shell. See Fig. 4-4-9.
(2) Take out the 4 piston components, the connecting
rod body and the upper connecting rod bearing shell
respectively from the upper part of the cylinder body,
and make marks on them.

Caution: Take care to avoid colliding or scratching


the connecting rod journal or the cylinder inner surface
while removing the hood.

Disassembling the crankshaft rear oil seal


assembly ⑨
(1) Take out the crankshaft rear oil seal from the
cylinder body oil sea groove. See Fig. 4-4-10.

Detacher for the rear oil seal: 5-8840-2360-0.


(2)Check the crankshaft rear oil seal and replace
Cylinder body them if there is any deformation or damage.

Rear oil seal

Fig. 4-4-10 Removing the rear oil seal of


crankshaft

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Disassembling the lower cylinder body ⑩


(1) Remove 10 main bearing cap bolts orderly.
Lower cylinder body (2) Remove the 11 hexagon flange face bolts (M8×80)
connecting the upper and the lower cylinder body in
proper order. See Fig. 4-4-11.
(3) Remove the lower cylinder body from the upper
cylinder body.
Upper cylinder body

Attention: Remove the fastening bolts of the lower


cylinder body in the order from the two sides of cylinder
body to the middle.
Fig. 4-4-11 Removing the lower cylinder body

Disassembling the crankshaft and crankshaft


position signal panel ○
11

(1) Remove the 3 hexagon lobular socket countersunk


Crankshaft position head screws for fastening the signal panel to the
signal panel crankshaft rear part. See Fig. 4-4-12.
(2) Take down the signal panel from the rear end of the
Flywheel gear crankshaft.
ring assembly
(3) Remove the crankshaft from the cylinder body.

Crankshaft

Fig. 4-4-12 Removing the crankshaft and the


signal panel

Inspection and repair


The parts should be adjusted, repaired or replaced if
any excessive worn or damage is detected during
inspection.
1. Check the thrust clearance of the
crankshaft
Install the dial indicator as per Fig 4-4-13, and measure
the thrust clearance of the crankshaft. Replace the
thrust plate in group if the thrust clearance exceeds
specified limit value.
Fig 4-4-13 Measuring the thrust clearance of Thrust clearance of the crankshaft
the crankshaft
Standard 0.10~0.28 mm

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2. Checking the clearance of crankshaft main


shaft bearing shell
(1) Remove the 10 main bearing cap bolts orderly as
per Fig. 4-4-14, and remove the lower cylinder body.
(2) Remove the crankshaft and the main shaft bearing
shell.
(3) Clean the surface of the main bearing journal of
crankshaft and the upper and the lower main shaft
bearing shells.
(4) Check the main shaft bearing shells for damage and
wear.
Fig. 4-4-14 Removing sequence for the
cylinder body bolts
Attention: Check and replace the excessively
worn or damaged main shaft bearing shell.
(5) Install the upper shaft bearing shell and the thrust
plate to their original position. And install the crankshaft
carefully.
(6) Install the lower shaft bearing shell to its original
poison of the lower cylinder body.
(7) Install the plastic gauge to the main bearing journal
of crankshaft as per Fig. 4-4-15.
(8) Install the lower cylinder body, coat the fitting
surface and the thread of its main bearing cap bolt with
engine oil, and screw down the 10 main bearing cap
Fig. 4-4-15 Installing the plastic rope bolts to specified torque in three steps.
clearance gauge
Mobil API CI-4 lubricating oil

Tightening torque for main bearing cap bolt


Step 1 Step 2 Step 3
Turn for another
40 N·m±3 N·m Turn for 90°
90°

Attention: The crankshaft should not be rotated.


(9) Remove the lower cylinder body.
(10) Measure the width of the plastic gauge, and
confirm the oil clearance (See Fig. 4-4-16).Replace the
Fig. 4-4-16 Measuring the width of the plastic
main shaft bearing shell in group and/or the crankshaft
gauge
if the oil clearance exceeds specified limit value.
(11) Remove the plastic gauge from the main shaft
bearing shell and the crankshaft.
(12) Remove the crankshaft and the main shaft bearing
shell.
Oil clearance

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Standard 0.020~0.045 mm

3. Checking the radial runout of the


crankshaft
(1) Carefully place the crankshaft on the V-block (See
Fig. 4-4-17).Slowly rotate the crankshaft and measure
the radial runout. If the value exceeds the limit value,
replace the crankshaft.
Crankshaft radial runout value

Standard 0.05~0.20 mm
Fig. 4-4-17 Measuring the radial runout of the
crankshaft (2) Measure the diameters of the crankshaft main
bearing journal and the crank pin and check them for
non-uniform wear. See Fig. 4-4-18.Replace the
crankshaft if the non-uniform wear of the crankshaft
exceeds the specified limitation.

Limitation

Main bearing journal 60.002~60.020 mm


diameter

Crank pin diameter 50.008~50.026 mm

Limitation for non-uniform 0.050 mm or less


Fig. 4-4-18 Measuring the un-uniform wear of wear
the crankshaft

4. Checking the crankshaft


(1) Check the surface of the crankshaft main bearing
journal and the crank pin for excessive wear and
damage. See Fig. 4-4-19.
(2) Check the fitting surface of the crankshaft oil seals
for excessive wear and damage.
(3) Check the oil holes of the crankshaft for blocking.

Fig. 4-4-19 Checking the crankshaft

5. Selecting the bearing shell of the


crankshaft

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While selecting or installing a new bearing shell of the


crankshaft, pay attention to the diameter dimension
marks of the journal hole in the cylinder body and the
marks of the main bearing journal of crankshaft.

Fig. 4-4-20 Installing the crankshaft Reassembly


Reinstalling the crankshaft and crankshaft position
signal panel ○11
Upper main shaft
bearing shell (1) Select the main shaft bearing shell as per Table
Upper thrust plate 4-4-1 and Table 4-4-2.Install the upper main shaft
bearing shells with oil grooves and oil holes to the
upper cylinder body, and install the lower main shaft
bearing shells without oil grooves or oil holes to the
Crankshaft lower cylinder body. See Fig. 4-4-21.Reversed installing
is no allowed! Apply an appropriate amount of
lubricating oil after the installation.
Lower main shaft
bearing shell Mobil API CI-4 lubricating oil
Lower thrust plate

Fig. 4-4-21 Installing the main shaft bearing


shell

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Table 4-4-1 Matching selection for the main shaft bearing shell of the turbocharged diesel engine
GW4D20/GW4D20B In mm

Main bearing journal of crankshaft


Color of main shaft 1 2 3
bearing shell
φ60.015~φ60.020 φ60.009~φ60.014 φ60.002~φ60.008

Shell
Shell thickness: Shell thickness:
thickness:
φ64.000~ 1.976~1.980 1.980~1.984
1 Yellow 1.976~1.980 Yellow None
φ64.006 Clearance: Clearance:
Clearance:
0.026~0.046 0.024~0.044
0.020~0.040

Main Shell
bearing Shell thickness: Shell thickness:
thickness:
aperture φ64.007~ 1.980~1.984 1.984~1.988
2 Yellow 1.976~1.980 None Blue
of φ64.012 Clearance: Clearance:
cylinder Clearance:
0.024~0.044 0.022~0.042
body 0.026~0.046

Shell
Shell thickness: Shell thickness:
thickness:
φ64.013~ 1.984~1.988 1.984~1.988
3 None 1.980~1.984 Blue Blue
φ64.018 Clearance: Clearance:
Clearance:
0.022~0.042 0.022~0.042
0.024~0.044

Table 4-4-2 Selecting the main shaft bearing shell of the turbocharged diesel engine
GW4D20/GW4D20B

Group number (1, 2 or 3) of the


cylinder body main bearing hole Main shaft bearing shell color
Fit clearance
+ group number (1, 2 or 3) of the code (number)
crankshaft main bearing journal

=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

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Attention: All the upper main bearing journals (on


the side of the upper cylinder body) have oil grooves and
oil holes, and all the lower main bearing journals (on the
side of the lower cylinder body) are without oil grooves or
oil holes. However, special attention should be paid
during installation. See Fig. 4-4-22.

Upper main shaft Lower main shaft


bearing shell bearing shell

Fig. 4-4-22 Upper and lower main shaft


bearing shells
(2) Install the crankshaft position signal panel to the 8th
crank arm of the crankshaft, and screw down the 3
hexagon lobular socket countersunk head screws
(M6×12) as per the specified torque. There should be no
Crankshaft position
deflection or improper mounting. See Fig. 4-4-23.
signal panel
Tightening torque for hexagon lobular socket
Flywheel gear countersunk head screw
ring assembly
9 N·m±3 N·m
(3) Apply an appropriate amount of lubricating oil onto the
Crankshaft
main bearing journal and into the oil hole of the
crankshaft. Install the crankshaft to the upper cylinder
body.

Fig. 4-4-23 Installing the crankshaft position Mobil API CI-4 lubricating oil
signal panel

Reinstalling the lower cylinder body ⑩


(1) Apply an appropriate amount of lubricating oil
between the crankshaft thrust plate and the crank arm
Lower cylinder body
thrust surface.

Mobil API CI-4 lubricating oil


(2) Respectively install the upper and the lower thrust
Upper cylinder body plates onto the upper and the lower cylinder body
rabbets, with the oil groove sides of them oriented to the
crank arm.

Attention: There is no positioning lip for the upper


Fig. 4-4-24 Installing the lower cylinder body thrust plate, while there is for the lower thrust plate.
(3) Evenly apply sealant to the top surface of the lower
cylinder body, and install the 10 main bearing cap bolts
(M11×1.5×87) and the 11 hexagon flange face bolts
(M8×80) of the lower cylinder body after they were
aligned to the dowel pins of the upper cylinder body, then
orderly screw down them in 3 steps as per the specified

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torque. See the Fig. 4-4-26.

LOCTITE510 anaerobic plane sealant.

Attention: Before applying the sealant to the top


surface of lower cylinder body, make sure the joint
surface between the upper and lower cylinder bodies are
clean.

Tightening torque for the fastening bolt of the main


bearing cap

Fig. 4-4-25 Installing the thrust plate Main bearing cap bolt 40 N·m±3 N·m;
(screw it down tightly by
three steps) Turn for 90°: then turn for
another 90°

Hexagon flange face bolt 23 N·m±3 N·m

Front end
Prompt: Apply a small amount of lubricating oil to the
thread while installing the main bearing cap bolts.

Mobil API CI-4 lubricating oil


Lubricate it with oil.
After installation, rotate the crankshaft manually, and
the crankshaft should be able to rotate freely without any
Fig. 4-4-26 Orderly screwing down the main seizure.
bearing cap bolts of the crankshaft in
separated times Reinstalling the rear oil seal assembly of the
crankshaft ⑨

The rear oil seal of the crankshaft ready for


installation should be clean and without any foreign
matters.
(1) Apply an appropriate amount lubricating oil to the lip
oil groove and excircle position of the oil seal assembly.

Cylinder body Mobil API CI-4 lubricating oil


Rear oil seal (2) Install the rear oil seal of the crankshaft to the cylinder
body with special tools. See Fig. 4-4-27.

Fig. 4-4-27 Installing the rear oil seal Rear oil seal installer: 5-8840-2539-0.
assembly of crankshaft
Caution: Make sure the oil seal end face does not tilt
and it is properly installed.

Reinstalling the connecting rod assembly and piston

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component ⑧
Piston (1) Carefully clear away the dirt on the back of connecting
rod bearing shell and matching surface of connecting rod
bearing seat.
Connecting
rod (2) Install the connecting rod bearing shell in the same
group to the connecting rod as per the numbers marked
during the removal. See Fig. 4-4-28.
Crankshaft
(3) Apply an appropriate amount of engine oil to the
cylinder bore, the connecting rod bearing shell and the
Connecting crank pin.
rod cover
Mobil API CI-4 lubricating oil
Fig. 4-4-28 Installing the connecting rod
assembly and piston component (4) Use the piston ring expander to install the oil ring
component, the second compression ring and the first
compression ring in proper order. See Fig. 4-4-29.Before
installation, apply an appropriate amount of engine oil to
the piston ring. The piston ring should be installed to the
piston ring groove in a correct direction with the top
marks (TOP) of the first and second compression rings
facing upwards. The piston ring moves smoothly in ring
slot without any stagnation, and the clearance meets the
requirement after installation.

Mobil API CI-4 lubricating oil

The open ends position of the three piston rings


Fig. 4-4-29 Installing the piston ring installed into the piston ring groove should be separately
staggered as per Fig. 4-4-30.
Open end of first Spiral supporting
compression spring port
ring
Prompt: Be sure to install the piston ring in proper
sequence.
(5) Use the piston ring compressor to install the piston
connecting rod to the cylinder. The front marks on the
piston and the connecting rod should face to the front end
of the diesel engine. See Fig. 4-4-31.

Open end of Open end of Piston ring compressor: 5-8840-9018-0.


oil ring second
Front end mark
compression (6) Install the cover and the bolts for the connecting rod,
ring
and screw down the bolts in two steps as per the
specified torque. The front mark on the connecting cover
Fig. 4-4-30 Inspection for open end of piston
should face to the front of the crankcase in the
ring
installation.

Tightening torque for connecting rod bolt

Step 1 Step 2

25 N·m±3 N·m Turning it for 90°±5°

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Attention: The connecting rod and the connecting


rod cover should be reinstalled as the original matching.
Reinstalling the engine oil pump assembly ⑦
Front (1) Coat the rubber seal ring with a small amount of
side
lubricating oil, and insert it fully to the bottom of the
corresponding engine oil pump housing groove. After
installation, there should be no scratch, deflection or
improper mounting.

Fig. 4-4-31 Installing the piston connecting


rod group

(2) Coat the front oil seal of the crankshaft with an


appropriate amount of lubricating oil, and insert it to the
bottom of the corresponding engine oil pump housing
Outer rotor groove. After installation, there should be no scratch,
Seal ring
deflection or improper mounting.
(3) Apply an appropriate amount of lubricating oil to the
inner surface of engine pump external rotor, and install
Front oil seal the external rotor to the engine pump cavity of the upper
cylinder body with the marks of internal and external
rotors on the same side. See Fig. 4-4-32.

Mobil API CI-4 lubricating oil


Fig. 4-4-32 Installing the oil pump assembly
(4)Install the engine oil pump assembly to the cylinder
body together, and screw down the 10 hexagon bolts and
Cylinder body flat ring components (M8×40, M8×25 and M8×20) as per
the specified torques and in proper order.

Tightening torque for fastening bolt of oil pump


23N·m±3N·m
Upper body of
oil pan There should be no stagnation when the oil pump
pulley is rotating after installation.
Reinstalling the oil pan lower body assembly, oil
collector assembly and oil pan upper body assembly

(1) Check the dowel pin of the oil pan upper body for
Fig. 4-4-33 Installing the upper body improper installation, apply rubber flat sealant to the joint
assembly of oil pan surface between the upper body of oil pan and the
cylinder body, and then install the oil pan upper body to
the cylinder body.

LOCTITE587 plane sealant.

Attention: Make sure the joint surface between the

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upper body of oil pan and the cylinder body is clean


before reapplying glue.
Screw down the 15 hexagon flange face bolts (M8×25,
M6×20, M6×110 and M8×45) as per specified torque and
in proper order. See Fig. 4-4-33 and 4-4-34.The joint face
should be firmly contacted without any looseness.

Tightening torque for fastening bolt of oil pan upper


body
M6 9 N·m±3 N·m

Fig. 4-4-34 Installing the upper body of oil M8 23 N·m±3 N·m


pan and tightening of bolts (3) Apply an appropriate amount of lubricating oil to the
oil collector sealing positions, then install the oil collector
Upper body gasket after aligning it to the oil suction hole of the oil
of oil pan pan, and screw down the 2 hexagon flange face bolts
(M6×6). See Fig. 4-4-35.

Attention: Install and fix the 2 hexagon flange face


bolts (M8×12) on the fixing oil collector bracket after
installing oil pan.
Oil collector
assembly Mobil API CI-4 lubricating oil

Tightening torque for fastening bolt of oil collector


Fig. 4-4-35 installing the oil collector
assembly M6 9 N·m±3 N·m
M8 23 N·m±3 N·m
(4) Check the joint surface between the upper body and
the lower body of the oil pan for dirt or scratch, and apply
rubber plane sealant to it. Install the lower body to the
upper body of the oil pan, and screw down the 14
hexagon flange face bolts (M6×12) as per the specified
torque and in proper order. See Fig. 4-4-36.

LOCTITE587 plane sealant.

Tightening torque for fastening bolt at lower body of


oil pan
9 N·m±3 N·m
Fig. 4-4-36 Installing the lower body of oil
pan and tightening of bolts Attention:
—— Many fastening bolts are installed on the oil pan,
and all these bolts should be tightened without any
omission. Otherwise, oil leakage may occur.
——Make sure the joint surface between the upper and
lower bodies of oil pan is clean before reapplying glue.

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Reinstalling the flywheel gear ring assembly ⑤


(1) Insert the cylindrical pin into the pin hole at the rear
Gear ring end of the crankshaft.
(2) Align the flywheel gear ring assembly to the pin hole
and fit it to the rear end of the crankshaft. Then screw
Damping down the 8 fastening bolts of flywheel as per the
pulley
specified torque and in proper order. See Fig. 4-4-37 and
Crankshaft
4-4-38.
(3) Install pressure plate dowel pin into flywheel gear ring
Flywheel
assembly.

Tightening torque for fastening bolt of flywheel gear


Fig. 4-4-37 Installing the flywheel gear ring ring assembly.
assembly
75 N·m±5 N·m

Attention: The thread fixing agent should be applied


to the thread of the flywheel bolt before being fixed.

LOCTITE 243 thread fixative.


(4) Check whether the end face runout of the flywheel is
within the range of specified values after installation.
End face runout value
Not exceed 0.12 mm
Reinstalling the cylinder head assembly ④
Fig. 4-4-38 Tightening order of fastening (1) Check the outer diameter of the cylinder head bolt. If
bolts of flywheel the cylinder head bolt is deformed, stretched or less than
the standard value in outer diameter, replace it. See Fig.
4-4-39.
(2) Check for foreign materials on the joint surface of the
cylinder head and the cylinder body, and clean it with silk.
Insert the cylinder head dowel pin sleeve into the
corresponding pin holes on the cylinder body with a
special tool and make sure they are properly assembled,
fit the fixing hole sleeve for cylinder head gasket to the
dowel pin of the cylinder body, and evenly place the
gasket to the cylinder body plane.

Make sure that the cylinder head gasket is placed


Fig. 4-4-39 Inspection for cylinder head bolt correctly in all directions after installation.

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(3) Fix the cylinder head to the cylinder body, and align
10 cylinder head bolts with the 10 screw holes, then fit
Cylinder and screw these bolts (M11×1.5×162) in three steps
head bolt orderly. See Fig. 4-4-40.

Tightening torque for cylinder head fastening bolt

Step 1 Step 2 Step 3

25 N·m±3 N·m Turning for 90° Turning for


Cylinder head 90°±5°

(4) Reinstalling the hydraulic adjuster and rocker arm


Fig. 4-4-40 Installing the cylinder head
assembly and tightening the bolts in proper ——Apply an appropriate amount of lubricating oil onto
order the globular head of hydraulic clearance adjuster, then
make it engage into the clip at the rear end of the rocker
arm, as shown in Fig. 4-4-41. Make sure it would not fall
out.
Lubrication
——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. 4-4-41.

Hydraulic clearance
Mobil API CI-4 lubricating oil
adjuster (5) Reinstalling the intake and exhaust camshafts
——Apply an appropriate amount of lubricating oil to the
Fig. 4-4-41 Installing the hydraulic clearance surface of the camshaft journal and inside the bearing
adjuster holes of the intake and exhaust camshafts in the cylinder
head.

Camshaft Mobil API CI-4 lubricating oil


——Install the intake and exhaust camshafts into the
cylinder head as shown in Fig. 4-4-42.
——Align  the  marks  “·∙”  on  the  driving  gears  of  the  intake  
and exhaust camshafts and get it in line with the upper
surface.
Axial clearance of camshaft
Cylinder head
Standard 0.060~0.0115 mm

Fig. 4-4-42 Installing the exhaust/intake (6) Reinstalling the camshaft bearing cap
camshaft ——Coat the junction surface between the camshaft
bearing cap and the cylinder head with anaerobic plane
sealant.

LOCTITE510 anaerobic plane sealant.

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Camshaft
Attention: If the former cylinder cap is to be used,
bearing clean the junction surface between the camshaft bearing
cap cap and the cylinder cap before applying the sealant.
——To install the camshaft bearing cap, screw down the
16 hexagon flange face bolts (M6×35) of camshaft
bearing cap as per specified torque and in the specified
order, then tighten the surrounding 6 hexagon flange face
bolts (M6×20) from the center to both sides.

Cylinder Tightening torque for the fastening bolt of camshaft


head bearing cap

Fig. 4-4-43 Installing the camshaft bearing 9 N·m±3 N·m


cap (7) Reinstalling the vacuum pump assembly
——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.

——Tighten the 3 hexagon flange face bolts (M6×20)


connecting the vacuum pump to the cylinder head as per
Cylinder head specified torque.
——Install the connecting hose for the vacuum pump.

There should be no deflection or misplacement after


Vacuum pump installation.
assembly

Tightening torque for vacuum pump fastening bolt


9 N·m±3 N·m
(8) Reinstalling the fuel injector
Fig. 4-4-44 Installing the vacuum pump
——Screw down the supporting bolt of fuel injector
assembly
ballast to the cylinder cap as specified torque.

Tightening torque for supporting bolt of fuel injector


ballast
23 N·m±3 N·m
——Install the copper washer and O-ring of fuel injector
to the fuel injector, and make sure only one copper
washer is installed to each fuel injector and placed
horizontally.
Fuel injector ——Plug the fuel injectors into the mounting holes on the
assembly cylinder head corresponding to cylinders 1, 2, 3 and 4
respectively according to the numbers 1, 2, 3 and 4 on
Fig. 4-4-45 Installing the fuel injector fuel injector. See Fig. 4-4-46.
——Place one end of the fuel injector ballast on ballast
supporting bolt and the other end in fuel injector ballast

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groove.
——Install and tighten the fastening bolt washer
component of fuel injector ballast as per the required
torque, without gas leakage on the injector.

Tightening torque for fastening bolt component of


fuel injector ballast
25 N·m~35 N·m
Sectional view ——Install the fuel injector harness plug.
of cylinder
head cover (9) Reinstalling the fuel return hose

Fig. 4-4-46 Installing the fuel injector ——Use DELPHI fuel injector. Insert respectively the fuel
return hose components into the 4 injector heads and
position them in place. See Fig. 4-4-47.
Fuel return
hose of fuel ——Use BOSCH or XINFENG fuel injector. Remove the
Fuel inlet injector dust cap from the upper end of the fuel injector. Install 4
pipe of short connectors of the fuel return hose into the 4 holes
injector
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 elastic clip.
——Installing the fuel return hose support and clamps.

After installation, make sure the fuel return hose and


the fuel inlet pipe components are sealed so strictly that
Fig. 4-4-47 Installing the fuel inlet pipe and
no fuel will leak from them.
return hose of the fuel injector
(10) Reinstalling the fuel inlet pipe of the fuel injector.
Install the fuel inlet pipe of the fuel injector as per Fig.
4-4-47, and evenly tighten the pipe connectors at both
ends of the fuel inlet pipe to the specified torque. After
installation, make sure the fuel pipe is sealed so strictly
that no fuel will leak from it

Tightening torque for fuel inlet pipe connector of fuel


injector
32 N·m±3 N·m

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Attention: Tighten the pipe connectors at the two


ends of the fuel inlet pipe simultaneously and evenly
when installing the fuel inlet pipe of fuel injector.
Reinstalling the timing system ③
(1) Reinstalling the camshaft timing pulleys and the
crankshaft timing pulleys.
——Install the woodruff key to the exhaust camshaft,
Timing rear hood install the timing pulley to the exhaust camshaft and
tighten the fastening bolt washer subassembly to the
required torque. The camshaft timing pulley should be
pressed and installed to the right position without
Fig. 4-4-48 Installing the timing system deflection. See Fig. 4-4-48.

Tightening torque for bolt washer component of


camshaft timing pulley
Camshaft timing 110 N·m±5 N·m
pulley
——Install the woodruff key to the crankshaft, install the
timing pulley to the crankshaft and tighten the fastening
bolt washer component to the required torque. The
Timing tension crankshaft pulley should be pressed and installed to the
pulley
right position without deflection. See Fig. 4-4-49.
Timing pulley of
crankshaft Tightening torque for fastening bolt of crankshaft
timing pulley
Fig. 4-4-49 Installing the timing pulley of 185 N·m~195 N·m
crankshaft

Attention: Use the cylindrical pin to fix the camshaft


timing pulley and the flywheel gear ring assembly when
tightening the timing pulleys of camshaft and crankshaft.
Timing mark
(2) Install the timing idle wheel assembly and screw down
the fastening bolt according to specified torque.

Bone-line Tightening torque for fastening bolt of timing idle


wheel
Camshaft
timing pulley
22 N·m~26 N·m
(3) Adjust the mark position of the scribed line on the
camshaft timing pulley till this position aligns with the
Fig. 4-4-50 Installing the timing system junction seam (on the exhaust side) which is between the
cylinder head and the camshaft bearing cap; and adjust
the mark position on the crankshaft timing belt pulley so
as to align it with the arrow mark on the engine oil pump
housing. See Fig. 4-4-50.
(4) Install the timing belt. During installation, make sure
the belts, except the timing tension pulley, are in close
contact with the pulley firmly without any looseness.
(5) Reinstalling the timing tension pulley: Embed the limit

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support of timing tension pulley into the position for


mounting the bowl-shaped plug onto the cylinder head.
After the mounting pin of the timing tension pulley is
adjusted with a hexagon socket head spanner so that it is
aligned with the notch, screw down the tension pulley
bolts to specified torque. See Fig. 4-4-51.

Use a hexagon Tightening torque for fastening bolt of timing tension


socket head pulley
spanner to adjust
the mounting hole. Analog Notch 22 N·m~26 N·m

Fig. 4-4-51 Installing the timing tension


pulley

(6) Reinstalling timing hood components I and II, the


timing hood and the rear timing hood components.
——Install the rear timing hood components and screw
down the hexagon flange face bolt (M6×16) as per the
specified torque. See Fig. 4-4-48.

Tightening torque for fastening bolt of timing rear


hood
9 N·m±3 N·m
——Clean the sealing grooves for timing hoods I and II,
and check if the sealing strip of timing hood is intact, then
Fig. 4-4-52 Checking the sealing strip of the respectively insert sealing strips I and II into the sealing
grooves of timing hoods I and II. See Fig. 4-4-52.
timing hood
——After aligning the mounting holes of the timing hood
and timing hood components I and II, screw down the 15
hexagon flange face bolts (M10×35, M10×50 and
M6×16) according to specified torques. See Fig. 4-4-53.

Tightening torque for fastening bolt of timing hood

M10×35 45 N·m±3 N·m

M6×16 9 N·m±3 N·m

Fig. 4-4-53 Installing the timing pulley and


the timing hood

Reinstalling the damping pulley assembly ②

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(1) Place the elastic cylindrical pin in the timing pulley pin
Crankshaft
hole of crankshaft
(2) Align the damping pulley with their pin holes, install
the damping pulley to the front end of crankshaft, and
screw down the 4 hexagon flange face blots (M8×20) as
per specified torque. See Fig. 4-4-54.

Timing Tightening torque for fastening bolt of damping


pulley
pulley
23 N·m±3 N·m
Damping pulley

Attention: The timing mark of the damping pulley


Fig. 4-4-54 Installing the damping pulley must face forwards.
assembly
Reinstalling the engine accessories ①
(1) Reinstall the power steering pump assembly and the
steering pump support components. See Fig. 4-4-55.
(2) Reinstall the generator support and the generator
assembly.
(3) Reinstall the refrigerating compressor assembly.
(4) Reinstall the flat idle wheel assembly and wedge idle
wheel assembly.
(5) Reinstall the tension pulley.
(6) Reinstall the generator belt: Properly install the
generator belt, making sure the belt wedge teeth fit well
with the pulley wedge slot. Turn the tension pulley with
Fig. 4-4-55 Installing the engine accessories tools until the belt is loose enough, and then embed the
flat idle wheel to the belt.
(7) Install the harness connector and make sure it is
installed firmly to the right position.

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Section V Piston and connecting rod assembly

Dismounting procedure

① Engine accessories
② Timing system
③ Cylinder head assembly
④ Oil pan upper and lower body assemblies and oil
collector assembly

⑤ Connecting rod cover


⑥ Piston and connecting rod assembly
⑦ Piston ring
⑧ Clip
⑨ Piston pin Reinstallation procedure
⑩ Piston component
Reinstall them in the opposite order of dismounting

Fig. 4-5-1 Dismounting and reinstallation procedure for piston and connecting rod assembly

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Disassembly
Disassembly precautions:
Such used parts as the piston connecting rod group,
main bearing cap and main shaft bearing shell are not
interchangeable. Thus, before removal, check if there is
cylinder sequence number or matching mark on the top
surface of piston, the side surfaces of connecting rod
and connecting rod cover, and the bottom surfaces of
main shaft bearing shell and lower cylinder body. If
there is no mark or the mark is not clear, mark up the
parts during removal to ensure the parts can be
Fig. 4-5-2 Removing the engine accessories reinstalled as the same as before.
Disassembling the engine accessories ①
(1) Remove the generator belt: turn the tension pulley
with tools until the belt is loose enough, and then
remove the generator belt. See Fig. 4-5-3.
(2) Remove the tension pulley.
(3) Remove the wedge idle wheel assembly
(4) Remove the refrigeration compressor assembly.
Disassembling the timing system ②
(1) Remove the timing hood component I and timing
Fig. 4-5-3 Removing the timing system hood. See Fig. 4-5-3.
(2) Remove the timing tension pulley assembly. See
Fig. 4-5-3.
(3) Remove the timing belt.
(4) Remove the camshaft timing pulley.
Disassembling the cylinder head assembly ③
(1) Remove the cylinder head cover component. See
Fig. 4-5-4.
(2) Remove the camshaft bearing cap.
(3) Remove the camshaft assembly.
Fig. 4-5-4 Removing the cylinder head (4) Remove the cylinder head assembly: loosen the 10
assembly bolts (M11×1.5×162) fastening the cylinder head and
cylinder body in proper order, and remove the cylinder
head.

Caution: If the cylinder head bolts are not orderly


unscrewed in separated times, the lower surface of the
cylinder head might be damaged.

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Disassembling the oil pan upper and lower body


Upper body of assemblies and oil collector assembly ④
oil pan
(1) Use a spanner to remove the 14 hexagon flange
face bolts (M6×12) fastening the upper and lower
bodies of oil pan in proper order, and remove the lower
body of oil pan. See Fig. 4-5-5.
(2) Use a spanner to remove the 2 hexagon flange bolts
(M6×16) fastening the engine oil pipe and the 2
Oil collector
hexagon flange face bolts (M8×12) fastening the oil
Lower body of oil collector support, and remove the oil collector.
pan
(3) Use a spanner to remove the 15 hexagon flange
face bolts (M6×20, M6×110, M8×25 and M8×45)
fastening the upper body of oil pan and lower cylinder
body in proper order, and remove the upper body of oil
Fig. 4-5-5 Removing the oil pan upper and pan from the lower cylinder body.
lower body assemblies and oil collector
assembly

Disassembling the connecting rod cover ⑤


Piston (1) Respectively remove the 8 connecting rod bolts
tightening the connecting rod cover under the
crankshaft, and take down the 4 connecting rod covers
Connecting and 4 lower connecting rod bearing shells. See Fig.
rod 4-5-6.

Crankshaft
(2) Place the parts removed from each cylinder orderly
and make the corresponding marks. All parts must be
reinstalled to the original positions during the
reinstallation.
Connecting rod
cover (3) Check the thread of the connecting rod bolts for
damage or stretching, and replace them if damaged.
Fig. 4-5-6 Removing the piston connecting
rod assembly
Disassembling the piston and connecting rod
assembly ⑥
(1) Before removing the piston and connecting rod
assembly, use a scraper to clear away the carbon
deposits on the cylinder wall.
(2) Move the piston to the top of the cylinder and push
the lower part of the connecting rod with a hammer
handle or something similar; take out the piston and the
connecting rod.

Caution: Do not damage the connecting rod


bearing journal and the inner surface of cylinder during
removal.
Fig. 4-5-7 Removing the piston ring
Disassembling the piston ring ⑦
(1) Use the piston ring expander to respectively remove
the second compression ring and the first oil ring. See
Fig. 4-5-7.

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(2) Place the removed piston rings properly according


to the cylinder sequence number.
Disassembling the clamping spring ⑧
(1) Use a pair of long nose pliers to pull the clamping
springs at both ends of piston pin out from the piston
ring grooves. See Fig. 4-5-8.
(2) Check the piston pin clamping spring for damage
and deformation, and replace it if necessary.

Disassembling the piston pin ⑨


Fig. 4-5-8 Removing the piston pin clamping (1) First, remove the clamping springs at both ends of
spring the piston, and then push out the piston pin.
(2) If the piston and piston pin can still be used, mark
Piston copper the cylinder sequence number and mounting position
bush
on each piston and piston pin.
Piston

Disassembling the piston component ⑩


(1) Remove the piston copper bushes from both ends of
Piston copper Clamping
spring
the piston. See Fig. 4-5-9.
bush
Piston (2) Place the removed piston in groups according to the
Piston pin cylinder sequence number and make the corresponding
Clamping spring marks. Prevent them from being bumped.
(3) Use a wood chip to remove the carbon deposits on
Fig. 4-5-9 Removing the piston the piston. Alternatively, clean the carbon deposits off
with carbon tetrachloride.

Inspection and repair


1. Piston
1.1 Cleaning the piston
Piston
Use a wood chip or a gasket scraper to carefully
remove the carbon deposits on the piston top and
Connecting rod piston ring groove. Alternatively, clean the carbon
body
deposits off with carbon tetrachloride.

Connecting rod Attention:


cover
—— Do not use a metal brush to clean the piston.
Otherwise, the piston may be damaged.
Fig. 4-5-10 Checking the piston —— Visually check each piston for crack, bruise or
other traces of heavy wear. Replace the piston in case
of the above traces.
1.2 Checking the cylinder bore
Use an inside dial indicator to measure the cylinder
bore at the measurement point ① along the trust
direction ②-② and the crankshaft axial direction ③-③.

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See Fig. 4-5-11.

Height of measurement 20mm


point ①

If the measured value exceeds the limitation, go to the


Great Wall Authorized Service Station for overhaul.
Cylinder bore group

Mark Cylinder  bore  size  (φ)

1 83.09~83.10mm
Fig. 4-5-11 Measurement for cylinder bore
2 83.10~83.11mm

3 83.11~83.12mm

1.3 Checking the piston outer diameter


Use a screw micrometer to measure the piston outer
diameter at the piston group position. See Fig. 4-5-12.
Piston group

Mark Piston  group  size  (φ)

0.081
1 83.1 0.090 mm
Fig. 4-5-12 Measurement for piston outer
diameter 0.071
2 83.1 0.080 mm

0.061
3 83.1 0.070 mm

Cylinder clearance: 0.071~0.090mm.


2. Piston
2.1 Checking the clearance of piston ring open end
Install the piston ring in the cylinder and use a feeler
gauge to check the clearance of piston ring open end.
See Fig. 4-5-13.
Fig. 4-5-13 Measurement for clearance of Clearance of piston ring open end
piston ring open end
Piston ring Standard

First compression 0.20~0.40mm


ring
Compression
ring
Second 0.65~0.85mm
compression ring

Oil ring 0.25~0.50mm

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2.2 Checking the axial clearance between the piston


ring and the piston ring groove
Use a feeler gauge to measure the axial clearance
between the piston ring and the piston ring groove. See
Fig. 4-5-14.
Replace the piston if the axial clearance exceeds the
limitation.
Axial clearance between the piston ring and the piston
ring groove

Piston ring Standard


Fig. 4-5-14 Measurement for the clearance First compression
between the piston ring and the piston ring 0.055~0.100mm
ring
groove with a feeler gauge Compression
ring
Second
0.035~0.080mm
compression ring

Oil ring 0.030~0.070mm

3. Piston
Visually check the piston pin for crack, bruise or other
damage, and replace it if necessary.
3.1 Checking the piston pin outer diameter
Use a screw micrometer to measure the piston pin outer
diameter at three different positions in two directions.
See Fig. 4-5-15.
Fig. 4-5-15 Measurement for piston pin outer
diameter Replace the piston pin if the measured value exceeds
the limitation.
Piston pin outer diameter

Standard 28.007~28.010mm

3.2 Checking the inner diameter of connecting rod


small end hole
Use an inside dial indicator to measure the inner
diameter of the connecting rod small end hole. See Fig.
4-5-16.
Replace the connecting rod/bushing and the piston pin
if the clearance between the connecting rod small end
Fig. 4-5-16 Measurement for inner diameter hole and the piston pin is not in accordance with the
of connecting rod small end hole specified value.
Clearance between the connecting rod small end hole
and the piston pin

Standard 0.010~0.024mm

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3.3 Checking the clearance between the piston pin


and the pin hole
Insert the piston pin into the piston pin hole and rotate it.
See Fig. 4-5-17.
If the piston pin moves smoothly, the clearance is
normal.
If the clearance is large or the surface is uneven,
measure the clearance.
Replace the piston or piston pin if the clearance
exceeds the limitation.
Clearance between the piston pin and the pin hole

Fig. 4-5-17 Installing the piston pin Standard 0.005~0.012mm

4. Bushing
Removal: Use a suitable wood punch or a copper bar to
knock the piston pin out from the piston pin hole.
Alternatively, use a bench press for disassembly.
Installation: Use a suitable wood punch or a copper bar
to gently knock the piston pin into the piston pin hole.
Alternatively, use a bench press for assembly.

Attention:
——The connecting rod bushing should be aligned with
the oil hole on the connecting rod small end.
Fig. 4-5-18 Replacing the connecting rod ——After installing the new connecting rod bushing,
bushing use a pin hole grinder to grind the bushing hole.
5. Connecting rod
5.1 Checking the axis error of connecting rod big &
small end holes
Use a connecting rod calibrator to check the axis error
of connecting rod big & small end holes. See Fig.
4-5-19.
Replace the connecting rod if the bending or torsion
exceeds the limitation.
Bending and torsion of connecting rod

Connecting rod Standard


Fig. 4-5-19 Checking the axis error of
connecting rod big & small end holes Bending 0.05mm or less

Torsion 0.06mm or less

5.2 Checking the axial clearance of connecting rod


Use a feeler gauge to measure the thrust clearance at

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the connecting rod big end. See Fig. 4-5-20.


Replace the connecting rod if the measured value
exceeds the limitation.
Axial clearance of connecting rod
Standard 0.15~0.32mm
5.3 Checking the oil clearance between the
connecting rod bearing shell and crank pin
(1) Remove the connecting rod cover bolts and the
connecting rod covers.
(2) Place the removed connecting rod covers properly
Fig. 4-5-20 Measurement for axial clearance according to the cylinder sequence number.
of connecting rod
(3) Clean the surfaces of connecting rod bearing shells
and crank pins.
(4) Carefully check the connecting rod bearing shells for
damage. Replace all connecting rod bearing shells
even if only one bearing shell is damaged or heavily
worn.
(5) Install the connecting rod bearing shells to their
original positions.
(6) Place the plastic precision clearance gauge on the
crank pin.
(7) Install the connecting rod covers to their original
positions.
Fig. 4-5-21 Measurement for oil clearance
Screw down the connecting rod cover bolts as per the
between the connecting rod and the
specified torque by two steps.
crankshaft
Step 1 (touching torque) Step 2 (final torque)
25N·m±3N·m Turning angle 90°

Attention: The crankshaft should not rotate when


you screwing down the connecting rod cover bolts.
(9) Remove the connecting rod covers.
(10) Measure the width of plastic precision clearance
gauge and determine the oil clearance. See Fig.
4-5-22.Replace the connecting rod bearing shell in
group if the clearance exceeds the limitation.
(11) Remove the plastic precision clearance gauge from
the crank pin.
Oil clearance between the connecting rod bearing shell
Fig. 4-5-22 Measurement for width of plastic and crank pin
precision clearance gauge and determination
of oil clearance Standard 0.020~0.048mm

Reassembly
Reinstalling the piston component ⑩

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Install the piston on the connecting rod; the forward


mark on the piston top should be on the same side with
the connecting rod forward mark. See Fig. 4-5-23.
Forward mark
Attention: Do not change the combination of
piston and piston pin when the piston connecting rod
combination is not replaced.
Reinstalling the piston pin ⑨
(1) Coat the piston with an appropriate amount of
Forward mark lubricating oil, and install it into the piston pin hole and
connecting rod small end hole.

Fig. 4-5-23 Installing the piston pin and Mobil API CI-4 lubricating oil
clamping spring (2) Install the piston pin into the piston pin hole. After the
installation, the piston pin should move smoothly
without any seizure.
The side marked (TOP) Clearance between the piston pin and the pin hole
upwards First compression ring

Standard 0.005~0.012mm
Second Taper face
compression ring Clearance between the connecting rod small end hole
and the piston pin

Oil ring 0.010~0.024mm

Reinstalling the clamping spring ⑧


Install the clamping springs to both ends of the piston
pin. The clamping spring should be completely installed
into the clamping spring groove and be able to move
Fig. 4-5-24 Piston ring installation procedure
around. Do not leave any part of the clamping spring at
the outside or on the upper part of the groove. It should
be at the bottom of the groove.

Caution: The piston pin clamping spring must be


firmly fixed.
Reinstalling the piston ring ⑦
Install the piston ring in the piston ring groove in the
correct direction. The marks (TOPs) on the first &
TOP mark
second compression rings should be upwards (see Fig.
(compression 4-5-24 and Fig. 5-5-25). The piston ring should move
ring) smoothly in the piston ring groove without any seizure.
The clearance should meet the requirements.

Fig. 4-5-25 Installing the piston ring Attention:


——The two compression rings are not
interchangeable.
——The piston ring should not tilt.
——No defect or foreign material in the piston ring
groove is acceptable.

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Table 4-5-1 Clearance for the piston ring of the turbocharged diesel engine GW4D20/GW4D20B

Clearance between the piston Clearance of piston ring open


ring and the piston ring groove end
First compression ring 0.055~0.100mm 0.200~0.400mm
Second compression ring 0.035~0.080mm 0.650~0.850mm
Oil ring component 0.030~0.070mm 0.250~0.500mm

Reinstalling the piston and connecting rod assembly ⑥


(1) Matching select the connecting rod bearing shell according to Table 4-5-2 and Table 4-5-3.
Table 4-5-2 Matching selection for the main shaft bearing shell of the turbocharged diesel engine
GW4D20/GW4D20B Unit: mm

Connecting rod bearing journal of crankshaft


Color code of connecting rod 1 2 3
shaft bearing shell
Φ50.021~φ50.026 Φ50.015~φ50.020 Φ50.008~φ50.014
Shell Shell Shell
thickness: thickness: thickness:
Φ53.000~ Yellow 1.473~1.477 Yellow 1.473~1.477 None 1.477~1.481
1
φ53.006 (1) (1) (2)
Clearance: Clearance: Clearance:
0.020~0.040 0.026~0.046 0.024~0.044
Shell Shell Shell
Connecting thickness: thickness: thickness:
rod big end Φ53.007~ Yellow 1.473~1.477 None 1.477~1.481 Blue 1.481~1.485
2
hole φ53.012 (1) (2) (3)
diameter Clearance: Clearance: Clearance:
0.026~0.046 0.024~0.044 0.022~0.042
Shell Shell Shell
thickness: thickness: thickness:
Φ53.013~ None 1.477~1.481 Blue 1.481~1.485 Blue 1.481~1.485
3
φ53.018 (2) (3) (3)
Clearance: Clearance: Clearance:
0.024~0.044 0.022~0.042 0.028~0.048

Table 4-5-3 Matching selection for the connecting rod bearing shell of the turbocharged diesel engine
GW4D20/GW4D20B

Connecting rod big end hole


diameter group number + Main shaft bearing shell color
Fit clearance
connecting rod bearing shell code (number)
group number
=2-3 Yellow (1) 0.020~0.046 mm

=4 None (2) 0.024~0.044 mm

=5-6 Blue (3) 0.022~0.048 mm

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Open end of first Spiral supporting (2) Apply some lubricating oil to the surface of cylinder
compression ring spring port bore, connecting rod bearing shell, crank pin, piston
ring and piston.

Mobil API CI-4 lubricating oil


(3) Stagger the open ends of piston rings. After the
installation, check the positions of the open ends of
piston rings, as shown in Fig. 4-5-26.
Open end of Open end of second (4) Use the piston ring compressor to install the piston
oil ring compression ring
Front end and connecting rod assembly in each cylinder. See Fig.
mark
4-5-27.

Fig. 4-5-26 Checking the open end of piston Piston ring compressor: 5-8840-9018-0.
ring
Piston cylinder clearance
0.07~0.09mm

Attention: The frond end mark on the piston top


should face the front of diesel engine.

Reinstalling the connecting rod cover ⑤

Attention:
——Before the installation, check the connecting rod
Front side

bolts for any distortion, stretching or thread slipping. If


necessary, replace them.
——Reinstall the connecting rods and connecting rod
covers as the same as before.
(1) During the installation, the forward mark on the
connecting rod cover should face the front of
crankshaft.
Fig. 4-5-27 Installing the piston connecting (2) Install the connecting rod cover and connecting rod
rod group bolts, and screw down the bolts as per the specified
torque by two steps. See Fig. 4-5-28.

Tightening torque for connecting rod bolt

Step 1 (touching torque) Step 2 (final torque)

25N·m±3N·m Turning angle 90°±5°

Forward mark Clearance between connecting rod big end and


crankshaft crank
0.22~0.37mm

Fig. 4-5-28 Installing the connecting rod cover

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Reinstalling the oil pan upper and lower body


Forward mark assemblies and oil collector assembly ④
on piston
(1) Check if the dowel pin of the oil pan upper body is
installed correctly. Coat the junction surface between
the oil pan and the lower cylinder body with silicone
plane sealant. Install the oil pan upper body on the
lower cylinder body.

LOCTITE 587 plane sealant.

Attention: Make sure the junction surface between


the oil pan upper body and the lower cylinder body is
Fig. 4-5-29 Mark on piston connecting rod clean before reapplying glue.
(2) Screw down the 15 hexagon flange face bolts
(M8×25, M6×20, M6×110 and M8×45) fastening the oil
pan upper body and lower cylinder body as per the
specified order and torque. The junction surfaces
should cling tightly. See Fig. 4-5-30.

Tightening torque for fastening bolt of oil pan


upper body

M6 9N·m±3N·m

M8 23N·m±3N·m

Fig. 4-5-30 Installing the upper body of oil pan (3) Coat the sealing part of oil collector with an
and tightening of bolts appropriate amount of lubricating oil. After that, align
the oil suction holes of oil pan and install a gasket. Use
4 hexagon flange face bolts (M8×12 and M6×16) to fix
it. See Fig. 4-5-31.

Attention: Install and fix the 2 hexagon flange face


bolts (M8×12) fastening the oil collector bracket after
installing the oil pan upper body.

Mobil API CI-4 lubricating oil

Tightening torque for fastening bolt of oil collector

M6 9N·m±3N·m

M8 23N·m±3N·m

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(4) Check the junction surface between the upper and


Upper body lower bodies of oil pan for dirt and scratch. Evenly coat
of oil pan the junction surface with silicone plane sealant. Install
the oil pan lower body on the oil pan upper body. Screw
down the 14 hexagon flange face bolts (M6×12) as per
the specified order and torque. See Fig. 4-5-32.

Oil collector Attention:


Lower body ——Fix the oil pan lower body with 14 hexagon flange
of oil pan face bolts. All the bolts should be tightened (see Fig.
4-5-32). All the bolts the bolts should be tightened.
Otherwise, oil leakage may occur.

Fig. 4-5-31 Installing the oil pan upper and ——Before applying sealant again, make sure the
lower body assemblies and oil collector junction surface of upper and lower bodies of oil pan is
assembly clean.

LOCTITE 587 plane sealant

Tightening torque for fastening bolt of oil pan lower


body
9N·m±3N·m

Reinstalling the cylinder head assembly ③


(1) Check for foreign materials on the junction surface
of the cylinder head and the cylinder body, and clean it
with silk.
Fig. 4-5-32 Installing the lower body of oil pan
Insert the cylinder head dowel pin sleeves into the
corresponding pin holes on the cylinder body with a
special tool, and make sure they are properly
assembled. Fit the fixing hole sleeve for cylinder head
Cylinder
head bolt gasket to the dowel pin of the cylinder body, and evenly
place the gasket to the cylinder body plane.

Make sure the cylinder head gasket is in the right


direction after the installation.
(3) Install the cylinder head to the cylinder body, align
the 10 screw holes, and then install and screw down the
Cylinder head 10 cylinder head bolts (M11×1.5×162) as per the
specified sequences by 3 steps. See Fig. 4-5-33.
Fig. 4-5-33 Installing the cylinder head
Tightening torque for fastening bolt of cylinder
head

Step 1 Step 2 Step 3

Turning angle
50N·m±3N·m Turning angle 90°
120°

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Lubrication Attention: Check the cylinder head bolt before


installation and replace it when there is any
deformation, stretching or thread slipping.
(4) Reinstall the hydraulic adjuster and rocker arm.
——Coat the ball head of the hydraulic clearance
adjuster with an appropriate amount of lubricating oil.
See Fig. 4-5-34.
Hydraulic clearance ——Fix the ball head of the hydraulic clearance
adjuster
adjuster into the clip at the rear of rocker arm. Make
sure the tappet will not fall off after the installation.
Fig. 4-5-34 Installing the hydraulic clearance
adjuster and rocker arm ——Coat 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 on the cylinder head, with the other side of the
rocker arm overlapping on the valve. See Fig. 4-5-34.

Mobil API CI-4 lubricating oil

(5) Reinstall the intake and exhaust camshafts.


Camshaft ——Install the intake and exhaust camshafts into the
cylinder head. See Fig. 4-5-35.
——Align  the  marks  “·∙”  on  the  driving gears of exhaust
and intake camshafts and get them in line with the
upper surface.
Axial clearance of camshaft

Standard 0.060~0.0115mm
Cylinder head
(6) Reinstall the camshaft bearing cap.
Fig. 4-5-35 Installing the exhaust/intake ——Apply the anaerobic plane sealant to the junction
camshaft surface between the camshaft bearing cap and the
cylinder head.

Camshaft LOCTITE 510 anaerobic plane sealant


bearing cap
——Screw down the 16 hexagon flange face bolts
(M6×35) fastening the camshaft bearing cap as per the
specified order and torque, and then screw down the 6
hexagon flange face bolts (M6×20) around them
according to the requirements. See Fig. 4-5-36.

Tightening torque for fastening bolt of camshaft


bearing cap
Cylinder head
9N·m±3N·m

Fig. 4-5-36 Installing the camshaft bearing (7) Reinstall the vacuum pump assembly.
cap ——The vacuum pump is installed at the rear of
exhaust camshaft. The flat bump on the shaft should be

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inserted into the axle neck groove at the rear of exhaust


camshaft. The rabbet and rabbet round hole should
Cylinder head match well.
——Align the vacuum pump with the corresponding
flange on the cylinder head. Tighten the 3 hexagon
flange face bolts (M6×20) connecting the vacuum pump
Vacuum and the cylinder head. See Fig. 4-5-37.
pump
assembly
Tightening torque for fastening bolt of vacuum
pump
9N·m±3N·m

Fig. 4-5-37 Installing the vacuum pump ——Install the vacuum connecting hose.
assembly
There should be no deflection or misplacement
after the installation.
(8) Reinstall the fuel injector assembly.
——Screw down the supporting bolt of fuel injector
ballast to the cylinder head as per the specified torque.

Tightening torque for supporting bolt of fuel


injector ballast
Fuel injector 23N·m±3N·m
assembly
——Install the copper washer and O-ring of fuel injector
to the fuel injector, and make sure only one copper
Fig. 4-5-38 Installing the fuel injector washer is installed to each fuel injector and each
assembly copper washer is placed horizontally. See Fig. 4-5-38.
——According to the fuel injector numbers 1, 2, 3 and
4, respectively insert the fuel injectors to the fuel
injector mounting holes on cylinder heads 1, 2, 3 and 4.
——Place one end of the fuel injector ballast on the
ballast supporting bolt and the other end in the fuel
injector ballast groove.

——Install the fastening bolt component as per the


Fuel return hose specified torque. There should be no air leakage at the
of fuel injector fuel injector gasket.
Fuel inlet pipe
of fuel injector
Tightening torque for fastening bolt component of
fuel injector ballast
25N·m~35N·m

(9) Reinstall the fuel return hose.


——For the DELPHI fuel injector: Insert respectively
the fuel return hose components into the 4 fuel return
Fig. 4-5-39 Installing the fuel inlet pipe and hoses of fuel injector and place them properly. See Fig.
fuel return hose of fuel injector 4-5-39.

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(2) For the BOSCH or XINFENG fuel injector: Remove


the dust cap from the upper end of the fuel injector.
Install the 4 short connectors of the fuel return hose in
Timing mark the 4 holes at the upper end of the fuel injector, and fix
them tightly with clamping springs. Install the other long
connector to the fuel return tee on the high pressure
pump, and fix it tightly with a small steel belt spring clip.
Bone-line

Make sure the fuel return hose is sealed properly


Camshaft without leakage after the installation.
timing pulley
(10) Reinstall the fuel inlet pipes of fuel injector and the
fuel inlet pipe component of fuel rail.

Fig. 4-5-40 Installing the camshaft timing ——Install the fuel inlet pipes of fuel injector and evenly
pulley tighten the connectors at both ends of the 4 fuel inlet
pipes of fuel injector as per the specified torque. See
Timing mark of damping Fig. 4-5-39.
pulley ——Install the fuel inlet pipe component of fuel rail and
tighten the connectors at both ends of the fuel inlet pipe
component of fuel rail as per the specified torque.

Make sure the fuel pipe is sealed without oil


leakage after the installation.

Timing mark of Tightening torque for fuel inlet pipe connectors of


Damping pulley
timing hood fuel injector and fuel rail
component II
32N·m±3N·m
Fig. 4-5-41 Installing the timing system
Attention: During the installation, make sure the
Horizontal connectors at both ends of the fuel inlet pipe of fuel
bar Timing mark Fuel pump pulley injector and the fuel inlet pipe component of fuel rail are
evenly tightened at the same time. Otherwise, the fuel
pipe may be distorted.
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 as per the
specified torque. The camshaft timing pulley should be
pressed and installed to the right position without
deflection.
Fig. 4-5-42 Installing the timing system (2) Adjust the scale mark on the camshaft timing pulley
to align it with the bone-line (at exhaust side) between
the cylinder head and the camshaft bearing cap. See
Fig. 4-5-40.

Tightening torque for bolt washer component of


camshaft timing pulley
110N·m±5N·m
(3) Align the timing marks on the damping pulley and

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timing hood II. See Fig. 4-5-41.


(4) Align the timing mark on fuel pump pulley with the
horizontal bar on water pump housing. See Fig. 4-5-42.

(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. 4-5-43.
Timing pulley
(6) Install the timing tension pulley. Fix the limit bracket
of the timing tension pulley in the place where the bowl
shaped plug is installed on the cylinder head, and then
use a hexagon socket head spanner to turn the
Timing
tension pinhole-mounting position clockwise until it is slightly
pulley 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,
Fig. 4-5-43 Installing the timing pulley camshaft pulley dowel pin and crankshaft locking
tooling, turn the crankshaft for 2 circles clockwise with
the spanner to make sure the damping pulley, camshaft
timing pulley and fuel pump pulley align with the
corresponding timing marks and the belt fits properly. If
any pulley is not aligned properly, loosen the fasting
bolts of timing tension 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
Use a hexagon valve timing is accurate. See Fig. 4-5-44.
socket head
spanner to
adjust the Arm Notch
mounting hole. indicator Attention: If the pulley mark is not aligned, it is required
to turn the vehicle or not to turn the vehicle
Fig. 4-5-44 Installing the timing tension pulley anticlockwise when inspecting. See Fig. 4-5-44.

Tightening torque for timing tension pulley bolt


22N·m~26N·m
(7) Install the timing hood and timing hood component I,
screw down the 10 hexagon flange face bolts (M6×16,
M10×35 and M10×50) to the front ends of cylinder head
and cylinder body as per the specified torque. See Fig.
4-5-45.

Tightening torque for fastening bolt of timing hood


45N·m±3N·m

Fig. 4-5-45 Installing the timing hood


Tightening torque for fastening bolt of timing hood
component
component I
9N·m±3N·m

Reinstalling the engine accessories ①

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(1) Reinstall the wedge idle wheel and tighten it as per


the specified torque.

Visually check the pulleys to ensure they are on the


Rotary
installation same plane.
position of Generator
tension belt Tightening torque for wedge idle wheel
pulley
22N·m~26N·m
(2) Reinstall the generator belt, use a tool to turn the
tension pulley, and install it after the belt is loose
enough. See Fig. 4-5-46.
Fig. 4-5-46 Installing the generator belt (3) After the installation, check the generator belt to
make sure the belt wedge-shaped teeth perfectly match
the pulley wedge slots.

Caution: The excessive or insufficient tightening of


pulley is not allowed.

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Section VI Engine oil pump assembly

Dismounting procedure
① Engine accessories
② Damping pulley assembly
③ Timing system
④ Oil pan lower body assembly Reinstallation procedure
⑤ Engine oil pump assembly Reinstall them in the opposite order of
dismounting.

Fig. 4-6-1 Disassembling and reinstallation procedure for engine oil pump assembly

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Disassembly
Disassembling the engine accessories ①
(1) Remove the generator belt:Turn the tension pulley
with tools until the belt is loose enough, and then
remove the generator belt.
(2) Remove the tension pulley. See Fig. 4-6-2.
(3) Remove the flat idle wheel assembly and wedge idle
wheel assembly.
(4) Remove the refrigeration compressor assembly:
Loosen the 4 hexagon flange face bolts (M8×85)
Fig. 4-6-2 Removing the engine accessories fastening the refrigeration compressor and the left side
of cylinder body, and remove the refrigeration
Crankshaft compressor.
(5) Remove the power steering pump assembly and its
bracket component: loosen the 3 or 4 hexagon flange
face bolts (M8×30 and M8×100) fastening the power
steering pump and its bracket, and remove the power
steering pump; loosen the 3 hexagon flange face bolts
Timing (M8×25 and M8×30) fastening the steering pump
pulley bracket and the cylinder body, and remove the steering
pump bracket.
(6) Remove the generator assembly and generator
Damping pulley bracket: loosen the 3 hexagon flange face bolts (M8×30
and M10×45) fastening the generator and its bracket,
Fig. 4-6-3 Removing the damping pulley and remove the generator; loosen the 4 hexagon flange
assembly face bolts (M8×30 and M8×25) fastening the generator
bracket and the cylinder body, and remove the
generator bracket. See Fig. 4-6-2.

Disassembling the damping pulley assembly ②


(1) Remove the 4 hexagon flange face bolts (M8x20)
fastening the damping pulley and the front end of
crankshaft. See Fig. 4-6-3.
(2) Remove the damping pulley assembly from the front
end of crankshaft.

Disassembling the timing system ③


Fig. 4-6-4 Installing the timing hood (1) Remove the 15 hexagon flange face bolts (M16×16,
component M10×35 and M10×50) fastening the timing hood
component I, timing hood component II and timing hood
from the front end of engine. Remove the timing hood
component I, timing hood component II and timing hood
from the front ends of cylinder head and cylinder body.
See Fig. 4-6-4.

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(2) Remove the timing tension pulley assembly: loosen


the combined fastening bolt of timing tension pulley and
remove the timing tension pulley. See Fig. 4-6-5.
(3) Remove the timing belt.
(4) Remove the timing idle wheel assembly: loosen the
fastening bolts of timing idle wheel, and remove the
timing idle wheel.

Timing belt

Fig. 4-6-5 Removing the timing system

Disassembling the lower body assembly of oil pan



(1) Use a spanner to remove the 14 hexagon flange
face bolts (M6×12) fastening the lower body of oil pan in
Upper body of oil proper order. See Fig. 4-6-6.
pan
(2) Take off the oil pan lower body from the oil pan
Lower body of oil upper body.
pan

Disassembling the engine oil pump assembly ⑤


(1) Orderly remove the 10 hexagon bolt and plain
washer components (M8×40, M8×25 and M8×20)
Fig. 4-6-6 Removing the lower body assembly fastening the engine oil pump and the cylinder body, as
of oil pan well as the 4 hexagon flange face bolts (M8×25 and
M8×45) connecting the engine oil pump and the oil pan
upper body, and then remove the engine oil pump
assembly. See Fig. 4-6-7.
Outer rotor (2) Take out the outer rotor of engine oil pump and the
Seal ring
rubber seal ring from the engine oil pump cavity of
upper cylinder body. See Fig 4-6-7.
(3) Take out the front oil seal of crankshaft through the
Front oil seal crankshaft oil seal hole of engine oil pump.

Front oil seal remover: 5-8840-2362-0.

Fig. 4-6-7 Removing the engine oil pump Inspection and repair
assembly
(1) Replace the engine oil pump assembly if the rotor of
engine oil pump is damaged or heavily worn.
(2) Replace the engine oil pump assembly if the
pressure limiting valve is seized. See Fig. 4-6-8.

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Reassembly
Reinstalling the engine oil pump assembly ⑤
(1) Coat a small amount of lubricating oil to the seal ring
of engine oil pump, and install the seal ring into the
corresponding groove on the engine oil pump housing.
There should be no scratch, deflection and
misplacement.(2) Coat the front oil seal of crankshaft
with lubricating oil, and install it into the front oil seal
hole of the engine oil pump housing. After the
installation, there should not be scratch, deflection or
misplacement.
(3) Apply an appropriate amount of lubricating oil to the
Fig. 4-6-8 Checking the rotor and pressure inner surface of engine oil pump external rotor, and
limiting valve of engine oil pump install the external rotor into the engine oil pump cavity
of the upper cylinder body, with the marked side facing
the bottom of pump cavity of cylinder body. See Fig.
4-6-8.
Engine oil
pump
assembly Mobil API CI-4 lubricating oil
(4) Assemble the engine oil pump assembly and
cylinder body. Tighten the 10 hexagon bolt and plain
Cylinder body washer components (M8×40, M8×25 and M8×20) as
well as the 4 hexagon flange face bolts (M8×25 and
M8×45) as per the specified order and torque. See Fig.
4-6-9.

Fig. 4-6-9 Installing the engine oil pump Tightening torque for fastening bolt of engine oil
assembly pump
23N·m±3N·m

There should be no stagnation when the engine oil


pump pulley is rotating after the installation.

Reinstalling the lower body assembly of oil pan ④


(1) Check the junction surface between the upper and
lower bodies of oil pan for dirt and scratch. Evenly coat
the junction surface with silicone plane sealant.
Install the oil pan lower body on the oil pan upper body.
Screw down the 14 hexagon flange face bolts (M6×12)
as per the specified order and torque. See Fig. 4-6-10.

LOCTITE 587 plane sealant.

Tightening torque for fastening bolt at lower body


of oil pan
Fig. 4-6-10 Installing the lower body of oil pan
and tightening of bolts 9N·m±3N·m

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Attention:
——Many fastening bolts are installed on the oil pan,
and all the bolts should be tightened. Otherwise, oil
leakage may occur.
——Make sure the junction surface between the upper
and lower bodies of oil pan is clean before reapplying
glue.

Reinstalling the timing system ③


(1) Reinstall the timing idle wheel assembly.
Fig. 4-6-11 Installing the timing system
(2) Reinstall the timing belt. See Fig. 4-6-11.
Crankshaft (3) Reinstall the timing tension pulley. See Fig. 4-6-11.
(4) Reinstall the timing hood component I, timing hood
component II and timing hood. See Fig. 4-6-11.

Reinstalling the damping pulley assembly ②


Timing
(1) Place the elastic cylindrical pin in the timing pulley
pulley
pin hole of crankshaft.
(2) Align the damping pulley pin holes, install the
Damping pulley damping pulley to the front end of crankshaft, and
screw down the 4 hexagon flange face bolts (M8×20)
as per the specified torque. See Fig. 4-6-12.
Fig. 4-6-12 Installing the damping pulley
assembly
Tightening torque for fastening bolt of damping
pulley
23N·m±3N·m

Attention: After the installation, the timing mark of


the damping pulley should be set forward.
Reinstalling the engine accessories ①
(1) Reinstall the power steering pump assembly and its
bracket component.
(2) Reinstall the generator bracket and the generator
assembly. See Fig. 4-6-13.
Fig. 4-6-13 Installing the engine accessories (3) Reinstall the flat idle wheel assembly and wedge
idle wheel assembly.
(4) Reinstall the refrigeration compressor assembly.
(5) Reinstall the tension pulley.
(6) Reinstall the generator belt:Turn the tension pulley
with tools until the belt is loose enough, and then install
the generator belt. Make sure the belt wedge-shaped
teeth perfectly match the pulley wedge slots.

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Section VII Cylinder body assembly

Dismounting procedure
① Engine
② accessories
Damping pulley assembly
③ Timing system
④ Cylinder head assembly
⑤ Water pump assembly
⑥ Flywheel gear ring assembly
⑦ Thermostat assembly and thermostat cap
⑧ Heater water return connecting hose and heater water
return pipe component
⑨ Oil filter assembly and oil cooler assembly
⑩ Oil pan upper and lower body assemblies and oil
collector assembly

11 Engine oil pump assembly

12 Connecting rod assembly and piston component

13 Crankshaft rear oil seal

14 Lower cylinder body

15 Crankshaft and crankshaft position signal panel Installation procedure

16 Cooling nozzle assembly Install them in the opposite order of
removal.

Fig. 4-7-1 Disassembling and reinstallation procedure for cylinder body assembly

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Disassembly
Disassembling the engine accessories ①
(1) Remove the generator belt assembly: rotate the
tension pulley with tools until the belt is loose enough,
and then remove the generator belt.
(2) Remove the tension pulley. See Fig. 4-7-2.
(3) Remove the flat idle wheel assembly and wedge idle
wheel assembly.
(4) Remove the refrigeration compressor assembly:
loosen the 4 hexagon flange face bolts (M8×85)
fastening the refrigeration compressor and the left side
Fig. 4-7-2 Removing the engine accessories of the cylinder body, and remove the refrigeration
compressor.
(5) Remove the power steering pump and its bracket
component: loosen the 3 or 4 hexagon flange face bolts
(M8×30 and M8×100) fastening the power steering
pump and its bracket, and remove the power steering
pump; loosen the 3 hexagon flange face bolts (M8×25
and M8×30) fastening the steering pump bracket and
the cylinder body, and remove the steering pump
bracket.
(6) Remove the generator assembly and generator
bracket: loosen the 3 hexagon flange face bolts (M8×30
and M10×45) fastening the generator and its bracket,
and remove the generator; loosen the 4 hexagon flange
Fig. 4-7-3 Removing the damping pulley face bolts (M8×30 and M8×25) fastening the generator
assembly bracket and the cylinder body, and remove the
generator bracket. See Fig. 4-7-2.
Disassembling the damping pulley assembly ②
(1) Remove the 4 hexagon flange face bolts (M8×20)
fastening the damping pulley and the front end of
crankshaft. See Fig. 4-7-3.
(2) Remove the damping pulley assembly from the front
end of the crankshaft.
Disassembling the timing system ③
(1) Remove the timing hood component I, timing hood
component II and timing hood from the front end of
engine, and the rear timing hood component from the
front end of cylinder head. See Fig. 4-7-4.
Fig. 4-7-4 Removing the timing system (2) Remove the timing tension pulley assembly: loosen
the fastening bolt of timing tension pulley and take off
the timing idle wheel. See Fig. 4-7-4.
(3) Remove the timing belt.
(4) Remove the timing idle wheel assembly: loosen the
fastening bolt of timing idle wheel and take off the timing
idle wheel.
(5) Remove the camshaft timing pulley: loosen the bolt

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washer component of camshaft timing pulley and take


Cylinder off the camshaft timing pulley.
head cover
(6) Remove the crankshaft timing pulley: loosen the
fastening bolt of crankshaft timing pulley and take off
the crankshaft timing pulley.

Disassembling the cylinder head assembly ④


Camshaft bearing
cap (1) Remove the cylinder head cover component. See
Fig. 4-7-5.
Cylinder head
(2) Remove the camshaft bearing cap.
(3) Remove the camshaft assembly.
Fig. 4-7-5 Removing the cylinder head
assembly (4) Remove the cylinder head assembly: loosen the 10
cylinder head bolts (M11x1.5x162) in proper order, and
remove the cylinder head and cylinder head gasket
from the cylinder body.

Disassembling the water pump assembly ⑤


(1) Remove the 6 hexagon flange face bolts (M8x25,
M8x30 and M10x25) fastening the water pump
assembly and the cylinder body, and take off the water
pump assembly. See Fig. 4-7-6.
(2) Remove the water pump gasket.
Water pump
gasket Check the water pump gasket for damage and
deformation, and replace it if necessary.
Water pump
assembly

Disassembling the flywheel gear ring assembly ⑥


Fig. 4-7-6 Removing the water pump
assembly (1) Install the flywheel retainer.
(2) Remove the 8 flywheel bolts fastening the flywheel
gear ring assembly and the rear end of crankshaft in
proper order.
(3) Remove the flywheel gear ring assembly from the
Crankshaft position
signal panel rear end of crankshaft. See Fig. 4-7-7.

Flywheel gear ring


assembly Disassembling the thermostat assembly and
thermostat cap ⑦
(1) Remove the 2 hexagon flange face bolts (M6X20)
fastening the thermostat cap and the cylinder body, and
Crankshaft take off the thermostat cap. See Fig. 4-7-8.
(2) Take out the thermostat and rubber seal ring from
Fig. 4-7-7 Removing the flywheel gear ring the thermostat seat on the cylinder body.
assembly (3) Take out the thermostat shield from the thermostat
chamber at the left side of cylinder body.

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Check the thermostat rubber seal ring for aging,


Thermostat Thermostat deformation and damage, and replace it if necessary.
shield
Thermostat cap
Disassembling the heater water return connecting
hose and heater water return pipe component ⑧
(1) Loosen the clamp and the single-hole clip for the
heater water return connecting hose.
(2) Loosen the 3 hexagon flange face bolts (M8x16 and
M6x16) fastening the heater water return pipe
component, and take off the heater water return pipe
Fig. 4-7-8 Removing the thermostat cap and
component and heater water return connecting hose.
thermostat
See Fig. 4-7-9.

Water return
connecting Water return
hose of heater pipe
component of
heater

Fig. 4-7-9 Removing the heater water return


connecting hose and heater water return pipe
component

Disassembling the oil filter assembly and oil cooler


assembly ⑨
(1) Use a spanner to unscrew the oil filter, and take off
the oil filter and its seal ring.
Oil cooler

Spanner for the oil filter: 5-8840-0020-0.


Oil filter
Pipe (2) Use a spanner to unscrew the pipe connector
connector
connecting to the cylinder body, and take off the pipe
connector and oil cooler. See Fig. 4-7-10.
(3) Remove the oil cooler seal ring from the oil cooler.
Fig. 4-7-10 Removing the oil filter and oil Disassembling the oil pan upper and lower body
cooler assemblies and oil collector assembly ⑩
(1) Use a spanner to remove the 14 hexagon flange
face bolts (M6x12) fastening the oil pan upper and
lower bodies in proper order, and take off the oil pan
lower body. See Fig. 4-7-11.
(2) Use a spanner to remove the 2 hexagon flange face
bolts (M6x16) fastening the engine oil pipe and the 2
hexagon flange face bolts (M8×12) fastening the oil
collector support, and take off the oil collector.

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(3) Use a spanner to remove the 15 hexagon flange


Upper body of
oil pan
bolts (M6×20, M6×10, M8×25 and M8×45) fastening the
oil pan upper body and the lower cylinder body in
proper order, and take off the oil pan upper body from
the lower cylinder body.

Disassembling the engine oil pump ○


11
Oil collector
(1) Remove the 10 hexagon bolt and plain washer
Lower body of oil subassemblies (M8x40, M8x25 and M8x20) fastening
pan
the engine oil pump assembly and the cylinder body,
and take off the engine oil pump assembly. See Fig.
4-7-12.
Fig. 4-7-11 Removing the oil pan upper and (2) Take out the outer rotor of engine oil pump and the
lower body assemblies and oil collector rubber seal ring from the engine oil pump cavity of
assembly upper cylinder body.
(3) Take out the front oil seal of crankshaft through the
crankshaft oil seal hole of engine oil pump.

Outer rotor Front oil seal remover: 5-8840-2362-0.


Seal ring
Caution: Do not damage the mating surface of
front oil seal of crankshaft when removing it.
Front oil seal
(4) Check the rubber seal ring of engine oil pump and
the front oil seal of crankshaft for damage and
deformation, and replace them if necessary.

Fig. 4-7-12 Removing the engine oil pump Disassembling the connecting rod assembly and
assembly piston component ○
12

(1) Loosen and remove the 8 connecting rod bolts by


Piston two steps according to the cylinder sequence numbers
of 1, 4, 2 and 3, and respectively take off the 4
connecting rod covers and the lower connecting rod
Connecting
bearing shells. See Fig. 4-7-13.
rod (2) Respectively take out the 4 piston components, the
connecting rod bodies and the upper connecting rod
Crankshaft bearing shells from the cylinder body, and make the
corresponding marks.

Connecting rod Caution: Do not damage or scratch the connecting


cover rod bearing journal and the inner surface of cylinder.

Fig. 4-7-13 Removing the connecting rod


assembly and piston component

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Disassembling the rear oil seal of crankshaft ○


13

Use a rear oil seal remover to take out the rear oil seal
of crankshaft from the oil seal groove of cylinder body.
See Fig. 4-7-14.
Rear oil seal
Signal panel Rear oil seal remover: 5-8840-2360-0.

Crankshaft
Disassembling the lower cylinder body ○
14
Front oil seal
(1) Remove the 10 main bearing cap bolts and the 11
hexagon flange face bolts (M8x80) connecting the
upper and lower cylinder bodies in proper order. See
Fig. 4-7-14 Removing the rear oil seal and Fig. 4-7-15.
position signal panel of crankshaft
(2) Remove the lower cylinder body from the upper
cylinder body.
Lower cylinder
body Attention: Orderly remove the fastening bolts of
lower cylinder body from both sides of cylinder body to
the center.

Upper cylinder Disassembling the crankshaft and crankshaft


body position signal panel ○
15

(1) Remove the 3 hexagon lobular socket countersunk


head bolts (M6x12) fastening the signal panel and the
rear end of crankshaft.
Fig. 4-7-15 Removing the lower cylinder body
(2) Take off the signal panel from the rear end of
crankshaft. See Fig. 4-7-14.
Cylinder body (3) Remove the crankshaft from the cylinder body.

Disassembling the cooling nozzle assembly ○


16

Remove the 4 hexagon socket head cap head screws


(M6x12) fastening the 4 cooling nozzles, and take out
the 4 cooling nozzles from the upper cylinder body. See
Fig. 4-7-16.
Cooling nozzle
Inspection and repair
If necessary, adjust, repair or replace the parts heavily
Fig. 4-7-16 Removing the cooling nozzle
worn or damaged.
assembly
(1) Remove the foreign materials adhered on the
packing or the upper surface of cylinder body.

Attention:
——Do not drop any foreign materials into the cylinder
body by accident.
——Do not scratch the upper surface of cylinder body.

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(2) Clean the surface of cylinder body.


Measuring the cylinder bore
Use an inside dial indicator to measure the cylinder
bore at the measurement point ① along the trust
direction ②-② and the crankshaft axial direction ③-③.
See Fig. 4-7-17.

Height of measurement
20mm
point ①

Attention: If the measured value exceeds the


Fig. 4-7-17 Measurement for cylinder bore limitation, go to the Great Wall Authorized Service
Station for overhaul.
Cylinder bore

Standard 83.09~83.12mm

Cylinder body Reassembly


Reinstalling the cooling nozzle assembly ○
16

Install the cooling nozzle and screw down the hexagon


socket head cap head screws (M6x12) fastening the
cooling nozzle onto the upper cylinder body as per the
specified torque. See Fig. 4-7-18.

Tightening torque for fastening bolt of cooling


Cooling nozzle nozzle

9 N·m ± 3 N·m
Fig. 4-7-18 Installing the cooling nozzle
assembly Reinstalling the crankshaft and crankshaft position
signal panel ○15

(1) Install the upper bearing shell with oil groove and oil
hole on the upper cylinder body and the lower bearing
Crankshaft shell without oil groove and oil hole on the lower
position signal cylinder body. Do not install them reversely. After the
panel installation, apply an appropriate amount of lubricating
Flywheel gear ring oil.
assembly
(2) Install the crankshaft position sensor signal panel on
the 8th crank arm, and screw down the 3 hexagon
lobular socket countersunk head screws (M6x12) as per
Crankshaft
the specified torque. After the installation, there should
be no deflection or misplacement. See Fig. 4-7-19.

Fig. 4-7-19 Installing the crankshaft position Tightening torque for hexagon lobular socket
sensor signal panel countersunk head screw

9 N·m ± 3 N·m

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(3) Coat the main bearing journal of crankshaft and the


Crankshaft
oil hole with an appropriate amount of lubricating oil,
and install the crankshaft in the upper cylinder body.
Crankshaft axial clearance

Lower cylinder 0.10~0.28mm


body

Mobil API CI-4 lubricating oil.


Reinstalling the lower cylinder body ○
14

(1) Coat an appropriate amount of lubricating oil


between the crankshaft thrust plate and crank arm
Fig. 4-7-20 Installing the crankshaft thrust surface.

Mobil API CI-4 lubricating oil。


Lower cylinder
body (2) Install the upper thrust plate in the rabbet of upper
cylinder body, with the side with oil groove facing crank
arm. Install the lower thrust plate in the rabbet of lower
cylinder body, with the side with oil groove facing crank
arm.
Upper cylinder
body Attention: There is no positioning lip on the upper
thrust plate. The lower thrust plate has a positioning lip.
(3) Evenly coat sealant on the top surface of lower
cylinder body. Align the lower cylinder body with the
Fig. 4-7-21 Installing the lower cylinder body location sleeve of upper cylinder body, and install the
lower cylinder body. Install the 10 main bearing cap
bolts (M11x1.5x87) and tighten them by 3 steps as per
the specified order and torque. Install the 11 hexagon
flange face bolts (M8x80) fastening the upper and lower
cylinder bodies, and tighten them as per the specified
torque. See Fig. 4-7-20.

LOCTITE510 anaerobic plane sealant

Attention: Before applying sealant on the lower


cylinder body, make sure the junction surface between
the upper and lower cylinder bodies is clean.

Tightening torque for fastening bolt of main


bearing cap and lower cylinder body

40 N·m ± 3 N·m
Main bearing cap bolt
Turning for 90° and
(tightening by 3 steps)
turning for another 90°

Hexagon flange face bolt 23 N·m ± 3 N·m

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After the installation, rotate the crankshaft by hand


and there should be no stagnation.
Reinstalling the rear oil seal of crankshaft ○
13

The rear oil seal of crankshaft to be installed


should be clean and without foreign materials.
(1) Coat an appropriate amount of lubricating oil on the
Cylinder body
oil groove and cylindrical surface on the lip of oil seal
Rear oil seal assembly.

Fig. 4-7-22 Installing the rear oil seal of Mobil API CI-4 lubricating oil
crankshaft (2) Use a special tool to install the rear oil seal of
crankshaft to the cylinder body.

Piston Rear oil seal installer: 5-8840-2539-0.

Caution: Make sure the oil seal end face does not
Connecting tilt and it is properly installed.
rod
Reinstalling the connecting rod assembly and
Crankshaft piston component ○12

(1) Install the connecting rod bearing shell on the


connecting rod. See Fig. 4-7-23.
Connecting rod
cover (2) Coat an appropriate amount of engine oil on the
cylinder bore, the connecting rod bearing shell and the
crank pin.
Fig. 4-7-23 Installing the connecting rod
assembly and piston
Mobil API CI-4 lubricating oil
(3) Check the open end of piston ring.
(4) Use the piston ring compressor to install the piston
connecting rod in the cylinder.
Front side

Piston ring compressor: 5-8840-9018-0.

Attention: The forward marks on the piston and


connecting rod should face the front of engine. See Fig.
4-7-24.
(5) Install the bolts of connecting rod cover and
connecting rod, and tighten them by 2 steps as per the
Fig. 4-7-24 Installing the piston connecting specified torque. During the installation, the forward
rod assembly mark on the connecting rod cover should face the front
of crankcase.

Tightening torque for connecting rod bolt

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Step 1 Step 2

25 N·m ± 3 N·m Turning angle: 90° ± 5 N·m


Outer rotor

Seal ring Reinstalling the engine oil pump assembly ○


11

(1) Install the seal ring of engine oil pump into the
corresponding groove on the engine oil pump housing.
Front oil seal It should be installed to the bottom of the groove. There
should be no scratch, deflection and misplacement.
(2) Coat the front oil seal of crankshaft with lubricating
oil, and install it to the front oil seal hole of the engine oil
pump housing. After the installation, there should not be
Fig. 4-7-25 Installing the engine oil pump
scratch, deflection or misplacement.
assembly
Front oil seal installer: 5-8840-2361-0.
(3) Apply an appropriate amount of lubricating oil to the
inner surface of engine oil pump external rotor, and
install the external rotor to the engine oil pump cavity of
the upper cylinder body, with the side with the marks of
internal and external rotors on the same side.

Mobil API CI-4 lubricating oil


(4) Assemble the engine oil pump assembly and
cylinder body. Tighten the 10 hexagon bolt and plain
washer subassemblies (M8×40, M8×25 and M8×20) as
per the specified order and torque. See Fig. 4-7-25.

Tightening torque for fastening bolt of engine oil


pump
23N·m±3N·m

There should be no stagnation when the engine oil


pump pulley is rotating after the installation.

Reinstalling the oil pan upper and lower body


assemblies and oil collector assembly ⑩
(1) Check if the dowel pin of the oil pan upper body is
installed correctly. Coat the junction surface between
the oil pan and the cylinder body with silicone plane
sealant. Install the oil pan upper body on the cylinder
body.

LOCTITE 587 plane sealant

Attention: Make sure the junction surface


between the oil pan upper body and the cylinder body is
Fig. 4-7-26 Installing the upper body of oil pan clean before reapplying glue.
and tightening of bolts
(2) Install the oil pan upper body. Screw down the 15
hexagon flange face bolts (M8x25, M6x20, M6x110 and

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Chpter IV Mechanical System

M8x45) connecting the oil pan upper body and the


Upper body of lower cylinder body as per the specified order and
oil pan
torque. The junction surfaces should cling tightly. See
Fig. 4-7-26.

Tightening torque for fastening bolt of oil pan


upper body
Oil collector M6 9N·m±3N·m
Lower body of M8 23N·m±3N·m
oil pan
(3) Coat the sealing part of oil collector with an
appropriate amount of lubricating oil. After that, align the
oil suction holes of oil pan and install a gasket. Use 4
Fig. 4-7-27 Installing the oil pan upper and hexagon flange face bolts (M8×12 and M6×16) to fix it.
lower body assemblies and oil collector See Fig. 4-7-27.
assembly

Attention: Install and fix the 2 hexagon flange


face bolts (M8×12) fastening the oil collector bracket
after installing the oil pan upper body.

Mobil API CI-4 lubricating oil

Tightening torque for fastening bolt of oil collector


M6 9N·m±3N·m
M8 23N·m±3N·m
(4) Check the junction surface between the upper and
Fig. 4-5-28 Installing the lower body of oil pan lower bodies of oil pan for dirt and scratch. Evenly coat
and tightening of bolts the junction surface with silicone plane sealant. Install
the oil pan lower body on the oil pan upper body. Screw
Cylinder body
down the 14 hexagon flange face bolts (M6×12) as per
the specified order and torque. See Fig. 4-7-28.

Attention:
——Fix the oil pan lower body with 14 hexagon flange
face bolts (see Fig. 4-5-28). All the bolts should be
tightened. Otherwise, oil leakage may occur.
——Make sure the junction surface between the upper
Oil filter body and the lower body of oil pan is clean before
reapplying glue.

Fig. 4-7-29 Installing the oil filter LOCTITE 587 plane sealant

Tightening torque for fastening bolt of oil pan lower


body assembly
9N·m±3N·m

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Reinstalling the oil filter assembly and oil cooler


assembly ⑨
(1) Check if the seal ring of oil cooler is installed
correctly. Align the location notch on the oil cooler with
the installation mark on the cylinder body, and then
install the oil cooler on the oil filter seat of cylinder body.
(2) Insert the pipe connector of oil filter into the hole on
the oil cooler assembly and screw it into the cylinder
body. After the installation, the oil cooler should be tight
without oil leakage at the seal ring.
Water return (3) Check if the seal ring of oil filter assembly is installed
connecting
hose of Water return correctly. Screw the oil filter onto the pipe connector and
heater pipe turn it for another 3/4~1 circle when the seal ring
component of touches the oil cooler.
heater
After the installation, there should be no oil
leakage at the seal ring of oil filter.

Fig. 4-7-30 Installing the heater water return Spanner for the oil filter: 5-8840-0020-0.
connecting hose and heater water return pipe Reinstalling the heater water return connecting
component hose and heater water return pipe component ⑧
(1) Insert the heater water return conencting hose into
the pipe connector and fasten it with single-ear stepless
clips. Fix it on the cylidner body with clamps and
Thermostat Thermostat shield
hexagon flange face bolts (M8x16). See Fig. 4-7-30.
Thermostat cap (2) Use single-ear stepless clips to connect one end of
the heater water return pipe component with the heater
water return conencting hose. Fix the other end on the
vacuum adjuster seat.
Reinstalling the thermostat assembly and
thermostat cap ⑦
(1) Install the thermostat shield in the thermostat
chamber properly.
Fig. 4-7-31 Installing the thermostat cap and (2) Check if the rubber seal ring of thermostat assembly
thermostat is installed correctly. Place the thermostat assembly in
the thermostat shield of cylinder body. See Fig. 4-7-31.
(3) Install the thermostat cap on the thermostat seat.
Screw down the 2 hexagon flange face bolts (M6x20) to
the cylinder body as per the specified torque.
Crankshaft
position signal After the installation, the pipe opening of the
panel thermostat cap should face the lower part of the front
end of diesel engine, and there should be no water
Flywheel gear
ring assembly dripping at the joint.

Tightening torque for fastening bolt of thermostat


cap
Crankshaft
9N·m±3N·m
Reinstalling the flywheel gear ring assembly ⑥
(1) Install the cylindrical pin in the pin hole of the flange
Fig. 4-7-32 Installing the flywheel gear ring
at the rear of crankshaft.
assembly

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(2) Align the pin holes, install the flywheel gear ring
Cylinder body assembly on the crankshaft, and screw down the 8
fastening bolts of flywheel as per the specified order
Water pump Water pump
assembly and torque. See Fig. 4-7-32.
gasket
(3) Install the dowel pin of pressure plate in the flywheel
gear ring assembly.

Tightening torque for fastening bolt of flywheel


75N·m±5N·m

Attention: Thread fixing agent should be applied


to the thread of the flywheel bolt before fitting the bolt.
Fig. 4-7-33 Installing the water pump LOCTITE 243 thread fixing agent
assembly
Check whether the end face runout is within the
specified range. This value should be or less than 0.12.
Reinstalling the water pump assembly ⑤
(1) Fit the location sleeve of water pump in the cylinder
body dowel pin hole.
(2) Install the water pump gasket.
(3) Install the water pump assembly on the cylinder
body and screw down the 6 hexagon flange face bolts
(M8x25, M8x30 and M10x25) as per the specified
torque. See Fig. 4-7-33.

Tightening torque for fastening bolt of water pump


assembly
Cylinder head
bolt M8 23N·m±3N·m
M10 45N·m±3N·m

There should be no stagnation when the water


pump pulley is rotating after the installation.
Reinstalling the cylinder head assembly ④
(1) Check for foreign materials on the jhunction surface
Cylinder
of the cylinder head and the cylinder body, and clean it
head
with silk.
Fig. 4-7-34 Installing the cylinder head (2) Insert the cylinder head dowel pin sleeves into the
assembly corresponding pin holes on the cylinder body with a
special tool, and make sure they are properly
assembled; fit the fixing hole sleeve for cylinder head
gasket to the dowel pin of the cylinder body, and evenly
place the gasket to the cylinder body plane.

Make sure the cylinder head gasket is in the right


direction after the installation
(3) Install the cylinder head to the cylinder body, align
the 10 screw holes, and then install and screw down the
10 cylinder head bolts (M11×1.5×162) as per the
specified order by 3 steps. See Fig. 4-7-34.

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Tightening torque for fastening bolt of cylinder


head
Step 1 Step 2 Step 3
Turning angle: Turning angle:
50N·m±3N·m
90° 120°

Attention: Check the cylinder head bolt before


installation and replace it when there is any
deformation, stretching or thread slipping.
Reinstalling the timing system ③
(1) Reinstall the timing idle wheel assembly, camshaft
Fig. 4-7-35 Installing the timing system timing pulley and crankshaft timing pulley. See Fig.
4-7-35.
Crankshaft (2) Reinstall the timing belt.
(3) Reinstall the timing tension pulley.
(4) Reinstall the timing hood component I, timig hood
component II and rear timing hood.
Reinstalling the damping pulley assembly ②
Timing (1) Place the elastic cylindrical pin in the timing pulley
pulley pin hole of crankshaft.
(2) Align the damping pulley pin holes, install the
damping pulley assembly and screw down the 4
Damping pulley hexagon flange face bolts (M8x20) to the front end of
crankshaft as per the specified torque. See Fig. 4-7-36.

Fig. 4-7-36 Installing the damping pulley Tightening torque for fastening bolt of damping
assembly pulley assembly
23N·m±3N·m

Attention: The timing mark must face forwards


after the installation.
Reinstalling the engine accessories ①
(1) Reinstall the generator assembly and generator
bracket. See Fig. 4-7-37.
(2) Reinstall the power steering pump assembly and its
bracket component.
(3) Reinstall the refrigeration compressor assembly.
(4) Reinstall the flat idle wheel assembly and wedge idle
wheel assembly.
(5) Reinstall the tension pulley.
(6) Reinstall the generator belt: turn the tension pulley
Fig. 4-7-37 Installing the engine accessories
with tools until the belt is loose enough, and then install
the generator belt. Make sure the belt wedge-shaped
teeth perfectly match the pulley wedge slots.

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Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine

Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine

Section I General

GW4D20 / GW4D20B turbocharged diesel engine


employs four-in-line, 16-valve and double overhead
camshaft (DOHC) technologies to increase the opening
area of the valve and improve volumetric efficiency so
as to boost the rated power and provide larger power at
high speed.
GW4D20 / GW4D20B turbocharged diesel engine
adopts DELPHI, BOSCH or XINFENG high-pressure
common rail system. It mainly consists of various
sensors, ECU actuators and connecting wires. The
max. fuel supply pressure is 1600 bar~1800 bar. And
the fuel supply process is automatically controlled by
electronic control unit (ECU).
Fig. 5-1-2 Right view of GW4D20
turbocharged diesel engine GW4D20 / GW4D20B turbocharged diesel engine uses
electronically-controlled exhaust gas recirculation
(EGR) technique. The opening height of EGR valve is
driven by the motor to achieve more precise control of
EGR rate so as to control the density of NOx in
emissions. At the same time, the
electronically-controlled EGR valve is equipped with
self-cleaning function which prevents the seizure of the
valve to a grate degree.
GW4D20 / GW4D20B turbocharged diesel engine is
mainly used for Hover and Fengjun models of Great
Wall Motor Company Limited and similar models of
other complete vehicle manufacturing enterprises.
GW4D20 turbocharged diesel engine has a rated
power of 110 kW / 4000 r / min, a max. torque of 310
N·m /(1800~2800)r / min and a min. fuel consumption
rate of 210 g / kW·h.
Fig. 5-1-3 Top view of GW4D20 turbocharged GW4D20 turbocharged diesel engine is equipped with
diesel engine DELPHI fuel supply system and variable geometry
exhaust turbocharger (VGT).
GW4D20B turbocharged diesel engine has a rated
power of 100 kW / 4000 r / min, a max. torque of 310
N·m /(1800~2800)r / min and a min. fuel consumption
rate of 210 g / kW h.
GW4D20B turbocharged diesel engine is optionally
installed with BOSCH, DELPHI or XINFENG fuel supply
system and equipped with WGT turbocharger.

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Section II Engine Assembly

Removal procedure
① Transmission assembly and clutch assembly
② Radiator assembly
③ Air intake pipe and air flow sensor
④ Air cleaner
⑤ Harness
⑥ Fuel hose
⑦ Oil pressure switch wire
⑧ Refrigerating compressor assembly
⑨ Power steering pump assembly
⑩ Catalytic converter pipe
11 Fastening nut of engine bracket

○ Engine assembly
12

Installation procedure
Reinstall them in the opposite order of
dismounting.

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Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine

Removal
Preparation
(1) Disconnect the earthing cable of storage battery.
See Fig. 5-2-2.
(2) Drain coolant of the cooling system.
(3) Drain the lubricating oil of the transmission.

Warning: hot oil (lubricating oil) may cause burn,


handle the used oil properly and protect the
environment.

Fig. 5-2-2 Removing the earthing cable of


storage battery
Removing transmission assembly and clutch
assembly ①
Lift the vehicle and support it with appropriate safety
rack.
(1) Transmission assembly
——Remove the drive shaft on the flange yoke.
——Remove the rotation speed sensor connector.