Name: Great Wall GW4D20
Brand: Great Wall
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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

长城内燃机

GREAT WALL ENGINES

Table of Contents5
Chapter I Introduction11
Section I How to Use this Manual11
Section II Main Contents of Civilized Production for Maintenance14
Section III Fire Control Measures for Maintenance Workshop14
Section IV Dress Security Requirements for Maintenance Personnel15
Section V Main Contents of Maintenance Process Regulation15
Section VI Identification Marks15
Section VII General Repair Instructions16
Section VIII Precautions for Maintenance Operation18
Chapter II Technical Information of Engine19
Section I Structure of Engine19
Cylinder Head and Cylinder Body19
Crank and Connecting Rod Mechanism19
Valve Actuating Mechanism and Intake/Exhaust System19
Turbocharging System20
Fuel Supply System20
Lubrication System21
Cooling System21
Startup Device21
Section II View of Engine22
Front View of Engine22
Rear View of Engine23
Left View of Engine24
Right View of Engine25
Vertical View of Engine26
Section III Main Performance Indexes of Engine27
Power Performance Index27
Economical Efficiency Index27
Reliability and Durability Index28
Low Public Hazard Index28
Section IV Engine Property Curves29
Section V Technical Data and Specifications of Engine31
Technical Parameters of Engine31
Various Temperature and Pressure Ranges of Engine33
Specifications of Main Engine Accessories34
Specifications of Main Parts of Fuel Supply System35
Section VI Maintenance Standard for Engine36
Tightening Torque of Main Fasteners of Engine36
Fit Clearance of Main Parts of Engine38
Section VII Running-In of Engine42
Preparation before Running-In42
Running-In42
Precautions for Running-In43
Technical Maintenance after Running-In43
Precautions for Usage of New Vehicles43
Section VIII Technical Maintenance for Engine44
Technical Maintenance Cycle44
Technical Maintenance Contents47
Technical Maintenance for Air Cleaner50
Technical Maintenance for Oil Supply System51
Technical Maintenance for Fuel Lubrication System53
Technical Maintenance for Cooling System56
Additional Maintenance in Severe Driving Conditions58
Technical Maintenance During Storage58
Precautions in Technical Maintenance58
Section IX Repair Process for Diesel Engine58
Repair Process for Diesel Engine58
Engine Handover and Repair Class Identification59
Exterior Washing for the Engine60
Section X Technical Requirements for Engine Removal and Reinstallation61
General Technical Requirements for Assembling61
General Technical Requirements for Removal63
Section XI Special Tools and Instruments for Repair64
Section XII Repair Operation for Engine66
Model Mark66
Air Cleaner66
Lubrication System67
Fuel System68
Cooling System69
Engine Control71
Great Wall Baoding Internal Combustion Engine71
Quick Start-Up System72
Section XIII Engine Parts and Tightening Torques73
Engine Bracket Mounting Assembly73
Cylinder Body Mounting Assembly74
Cylinder Body Component75
Cylinder Head Mounting Assembly --176
Cylinder Head Mounting Assembly --277
Cylinder Head Mounting Assembly --378
Piston Connecting Rod Mounting Assembly79
Crankshaft Flywheel and Clutch Mounting Assembly80
Air Intake and Exhaust Systems Mounting Assembly --181
Air Intake and Exhaust Systems Mounting Assembly --282
Oil Pan and Engine Oil Collector Mounting Assembly83
Engine Oil Pump Mounting Assembly84
Engine Oil Cooler and Cooling Pipelines Mounting Assembly85
Timing Mechanism Mounting Assembly --186
Timing Mechanism Mounting Assembly --287
Fuel Supply System Mounting Assembly --1①88
Fuel Supply System Mounting Assembly --2①89
Fuel Supply System Mounting Assembly --3①90
Turbocharger Mounting Assembly --1①91
Turbocharger Mounting Assembly --2①92
EGR System Mounting Assembly93
Electronic Control System Sensor94
Generator Mounting Assembly95
Throttle Mounting Assembly96
Thermostat and Water Pump Mounting Assembly97
Engine and Compressor Mounting Assembly98
Vacuum Pump and Steering Pump Mounting Assembly99
Chapter III Malfunction Diagnosis and Troubleshooting100
Section I Troubleshooting100
Failure to Start the Diesel Engine101
Difficulty in Starting the Diesel Engine at a Low Temperature101
Insufficient Power in the Diesel Engine102
Excessive Fuel Consumption of Diesel Engine103
Abnormal Noise During the Diesel Engine Running103
Abnormal Noise from Diesel Engine105
Abnormal Smoke from Diesel Engine105
Heavy Oil Consumption and Low Pressure of the Diesel Engine Lubrication System106
Abnormal Coolant Temperature, Lack of Coolant in the Diesel Engine Cooling System108
Malfunction of the Diesel Engine Turbocharging System109
Malfunction of the Diesel Engine Oil Supply System110
Diesel Engine Wobble During Idling113
Diesel Engine Running at a High Idle Speed114
Starter Not Working, Lacking Power, and Making Noise114
Working Starter but Non-Working Diesel Engine115
Diesel Engine Rotating but Unable to be Started116
Difficulty in Starting Due to Malfunction in the Quick Start-Up System117
No Power Generation, Undercharge or Overhigh Charging Current of Generator118
Insufficient Capacity, Difficulty in Starting or Overhigh Self Discharge of the Storage Battery119
Section II Malfunction Diagnosis120
Start-Up System Malfunction Diagnosis120
Turbocharging System Malfunction Diagnosis124
Chapter IV Mechanical System129
Section I Cylinder Head129
Section II Camshaft147
Section III Valve, Valve Spring, Valve Oil Seal, Rocker Arm and Hydraulic Clearance Adjuster158
Section IV Crankshaft167
Section V Piston and Connecting Rod Assembly188
Section VI Engine Oil Pump Assembly206
Section VII Cylinder Body Assembly211
Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine225
Section I General225
Section II Engine Assembly226
Section III Engine Brackets235
Section IV Air Intake Manifold Pipe245
Section V Exhaust Manifold Pipe250
Section VI Cylinder Cover256
Section VII Camshaft263
Section VIII Rocker Arms and Hydraulic Clearance Adjusters273
Section IX Valve Oil Seal and Valve Spring283
Section X Cylinder Head Assembly and Cylinder Head Gasket296
Section XI Timing Pulley308
Section XII Oil Filter and Oil Cooler313
Section XIII Primary Shaft Front Bearing of the Flywheel and Transmission316
Section XIV Oil Pump Assembly320
Section XV Oil Pan Assembly328
Section XVI Piston and Connecting Rod Assembly333
Section XVII Front Oil Seal of Crankshaft347
Section XVIII Rear Oil Seal of Crankshaft352
Section XIX Crankshaft356
Section XX Cylinder Body Assembly374
Chapter VI Fuel System394
Section I General394
Components of Fuel Supply System394
Components of High Pressure Common Rail System396
Section II On-Board Maintenance410
Fuel Filter Assembly410
Fuel Injector Assembly413
High-Pressure Fuel Pump Assembly417
Chapter VII Cooling System421
Section I General421
Water Pump421
Thermostat422
Radiator422
Antifreeze Fluid422
Section II On-Board Maintenance424
Water Pump Assembly424
Thermostat430
Radiator434
Chapter VIII Lubrication System438
Section I General438
Section II On-Board Repair439
Oil Filter439
Engine Oil Pump442
Oil Collector449
Oil Pan452
Chapter IX Turbocharging System456
Section I General456
Turbocharging System Composition456
Turbocharger Structure456
Section II On-Board Maintenance459
Section III Inspection and Repair464
Checking the Working Condition of the Exhaust Outlet464
Checking the Working Condition of the Turbocharger465
Checking the Axial Clearance of the Impeller Shaft465
Checking the Axial Clearance of the Rotor465
Checking the Clearance between the Impeller Shaft and the Bearing466
Checking the Radial Clearance of the Rotor466
Chapter X Electronic Control EGR System467
Section I General467
Section II On-Board Maintenance468
Chapter XI Electrical System472
Section I Storage Battery472
Storage Battery Performance Parameters472
Preparing Electrolyte473
Charging the Storage Battery474
Checking the Storage Battery Remaining Capacity476
Section II Starting System478
General478
On-Board Maintenance480
Section III Charging System483
Generator483
Diagnosis485
On-Board Maintenance487
Chapter XII Exhaust System491
Section I General491
Section II On-Board Maintenance491
Section III Front Exhaust Pipe492
Appendix496
Appendix I Engine Malfunction Code496
Appendix II Conversion Table of Common Measurement Units for Engines509

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General

Brand	Great Wall
Model	GW4D20
Category	Engine
Language	English

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