GW4D20 Eng

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
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.

Manufacturing Company Limited
III
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

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

V
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

VI Manufacturing Company Limited
Table of Contents
7. Quick start-up system ................................................................................................................ 62

Section XIII Engine Parts and Tightening Torques................................................................................... 63
1. Engine Bracket Mounting Assembly .......................................................................................... 63
2. Cylinder Body Mounting Assembly ............................................................................................ 64
3. Cylinder Body Component ......................................................................................................... 65
4. Cylinder Head Mounting Assembly ——1 ................................................................................. 66
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
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

VII
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

VIII Manufacturing Company Limited
Table of Contents
Section XII Oil Filter and Oil Cooler ....................................................................................................... 303

Section XIII Primary shaft front bearing of the flywheel and transmission ............................................ 306
Section XIV Oil pump assembly ............................................................................................................. 310
Section XV Oil pan assembly ................................................................................................................. 318
Section XVI Piston and connecting rod assembly ................................................................................. 323
Section XVII Front oil seal of crankshaft ................................................................................................ 337
Section XVIII Rear Oil Seal of Crankshaft ............................................................................................. 342
Section XIX Crankshaft .......................................................................................................................... 346
Section XX Cylinder Body Assembly...................................................................................................... 364
Chapter VI Fuel System ....................................................................................................................... 384
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
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 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
1. Turbocharging system composition ......................................................................................... 446

IX
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
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 III Front Exhaust Pipe ................................................................................................................ 482
Appendix ............................................................................................................................................... 486
Appendix I Engine Malfunction Code ..................................................................................................... 486
Appendix II Conversion Table of Common Measurement Units for Engines......................................... 499

X Manufacturing Company Limited
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:

1
(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.

2 Manufacturing Company Limited
“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;;

3
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.

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

5
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.

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.

7
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.

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,

9
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.

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.

11
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

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

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

13
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

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

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

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

15
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

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

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.

17
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.

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.

19
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)

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.

21
(Continued)
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.

Table 2-5-2 Technical Parameters of Main Parts of GBWD20/GW4D20B Turbocharged Diesel

Engine Electric System
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)
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

23
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.

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.

25
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

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.

27
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.

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
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.

29
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

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

and lower cylinder body sealant
Joint surface between upper Silicon rubber flat

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

pressure alarm assembly fixing sealant
Threaded section of water Anaerobic thread

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

31
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
Not over the rated Max. rotation speed of diesel

＞1501~2500 Full load
engine

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
＞101~250
＞251~450
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.

33
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.

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

35
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

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.

37
(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

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.

39
(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

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.

41
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:

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

43
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

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.

45
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.

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.

47
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.

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.

49
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

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

51
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.

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.

53
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

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.

55
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

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.

57
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

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

59
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

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

61
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

Section XIII Engine Parts and Tightening Torques

1. Engine Bracket Mounting Assembly
Cylinder body assembly

63
2. Cylinder Body Mounting Assembly
Cylinder body component
Sectional view of the

upper cylinder body

3. Cylinder Body Component
Upper cylinder body
Crankshaft
Lower cylinder body
Step 1 Step 2 Step 3

Turn for 90° Turn for 90° again

65
4. Cylinder Head Mounting Assembly ——1
DELPHI cylinder
cover assembly
BOSCH or XINFENG
cylinder cover assembly
BOSCH or XINFENG
cylinder head

DELPHI camshaft
bearing cap
BOSCH or XINFENG
camshaft bearing cap
Cylinder head assembly

67
Step 1 Step 2
Turn for 90° ± 5°
Step 3
Turn for 120° ± 5°
Step 1 Step 2
Step 3
Turn for 120° ± 5°
Camshaft bearing cap
Cylinder head
Cylinder head gasket

7. Piston Connecting Rod Mounting Assembly
Step 1 Step 2

69
8. Crankshaft Flywheel and Clutch Mounting Assembly

9. Air Intake and Exhaust Systems Mounting Assembly ——1
DELPHI air intake

manifold pipe
BOSCH or XINFENG air

intake manifold pipe

71
10. Air Intake and Exhaust Systems Mounting Assembly ——2
Cylinder head mounting

assembly
Air intake manifold pipe

11. Oil Pan and Engine Oil Collector Mounting Assembly

73
12. Engine Oil Pump Mounting Assembly
Engine oil pump mounting

assembly

13. Engine Oil Cooler and Cooling Pipelines Mounting Assembly
Upper cylinder body
Engine oil filter mounting assembly
Engine oil cooler mounting assembly

75
14. Timing Mechanism Mounting Assembly ——1

15. Timing Mechanism Mounting Assembly ——2
BOSCH or XINFENG
crankshaft timing belt
pulley component
DELPHI crankshaft
timing belt pulley
component

77
①
16. Fuel Supply System Mounting Assembly ——1
Note: ① DELPHI fuel supply system mounting assembly.

17. Fuel Supply System Mounting Assembly ——2①
Note: ① BOSCH fuel supply system mounting assembly.

79
18. Fuel Supply System Mounting Assembly ——3①
Note: ① XINFENG fuel supply system

mounting assembly.

19. Turbocharger Mounting Assembly ——1①
Note: ① VGT turbocharger mounting assembly.

81
20. Turbocharger Mounting Assembly ——2①
Note: ① WGT turbocharger mounting assembly.

21. EGR System Mounting Assembly
Cylinder head

83
22. Electronic Control System Sensor
Crankshaft position
sensor (XINFENG)

23. Generator Mounting Assembly
Generator belt

85
24. Throttle Mounting Assembly
Exported AT vehicle
model
Common vehicle model

25. Thermostat and Water Pump Mounting Assembly
Thermostat shield

87
26. Engine and Compressor Mounting Assembly
Lower cylinder body

27. Vacuum Pump and Steering Pump Mounting Assembly

89
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.

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
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.

91
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.
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)

(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

93
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.
(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.

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.

95
(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) 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.

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.
(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

97
9. Abnormal Coolant Temperature, Lack of Coolant in the Diesel Engine Cooling

System
(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
(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

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
(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)
(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.

99
(continued)
(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.

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

101
(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.
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
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
pedal position sensor or signal

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

103
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
(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)

(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.

105
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.

(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

107
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
(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.

(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
(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.

109
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

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

111
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

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

113
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.
● ● ● 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

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.
● ● ● ● 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

115
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)

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

117
(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.

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

119
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.

——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.
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.

121
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.
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.

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

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

123
Disassembling the vacuum pump assembly ○

13
(1) Pull out the vacuum connecting hose from the

Cylinder head
vacuum pump.
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

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

125
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

——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

127

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

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.

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

129
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

(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.

131
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
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
Tightening torque for fastening bolt of cylinder head

cover
9 N·m±3 N·m

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
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

133
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

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.

135
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

Section II Camshaft
Dismounting procedure
② Timing system
③ Fuel inlet pipe component of
fuel injector
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

137
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
(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.

Disassembling the fuel return hose component ④

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
connecting the heater water return pipe component to
the cylinder head cover.
(2) Remove the 1 hexagon flange bolt (M8×16)
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.
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
(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.

139
Disassembling the vacuum pump assembly⑧

Cylinder head (1) Pull out the vacuum connecting hose from the
vacuum pump.
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

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

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
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

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
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
30.000～30.021 mm，
Exhaust camshaft
27.000～27.021 mm

141
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.
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

9 N·m±3 N·m
Cylinder head Reassembling the vacuum pump assembly⑧
(1) Install the vacuum pump to 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

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
ballast
Cylinder head
cover 23 N·m±3 N·m
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.
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

143
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
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
⑤
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.

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
23 N·m±3 N·m

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,
tighten the fastening bolt washer component to the
Fig. 4-2-25 Installing the timing system pressed and installed to the right position without
deflection.

110 N·m±5 N·m

145

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

connected with the pulley firmly without any looseness,
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
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.

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


(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.

147
Section III Valve, Valve Spring, Valve Oil Seal, Rocker Arm and Hydraulic
Clearance Adjuster
Camshaft installation
Intake/exhaust valve assembly
components
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

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 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
Conduct necessary adjustment, repair and part
replacement if any excessive wear or damage is found
during inspection.
1. Valve spring

149
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

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

151
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

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

153
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.

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.
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
(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

155
column.
Reassembling the valve lock clamp ②
(1) Install the valve lock clamp into the valve spring seat
with a special tool.

(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
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.

Section IV Crankshaft
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

157
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.
(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.

(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.

159
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

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

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

161
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
Tightening torque for main bearing cap bolt

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

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
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

163
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

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

165
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.

(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

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.

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

167
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
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.
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°

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.

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
⑥
(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

169
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.
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.

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.

171
(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.
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
hole, with the other side of the rocker arm overlapping on
the valve. See Fig. 4-4-41.
Hydraulic clearance
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.
Cylinder head
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.

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 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.

Vacuum pump installation.
assembly

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

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

173
groove.
——Install and tighten the fastening bolt washer
component of fuel injector ballast as per the required
torque, without gas leakage on the injector.

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
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

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
Fig. 4-4-48 Installing the timing system deflection. See Fig. 4-4-48.

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

175
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

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
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.
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

(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
(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.

177
Section V Piston and connecting rod assembly
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

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.
(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.
Disassembling the cylinder head assembly ③
Fig. 4-5-4.
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.

179
Disassembling the oil pan upper and lower body

Upper body of assemblies and oil collector assembly ④
oil pan
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
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.

(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.

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.

181
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

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
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

183
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
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

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

Replace the connecting rod if the measured value
Axial clearance of connecting rod
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

185
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
Second Taper face
compression ring Clearance between the connecting rod small end hole
and the piston pin
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.

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）
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）
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

187
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.

(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.
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

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.

bolts (M8×12) fastening the oil collector bracket after
installing the oil pan upper body.
M6 9N·m±3N·m
M8 23N·m±3N·m

189
(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
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.
Tightening torque for fastening bolt of cylinder
head
Turning angle
50N·m±3N·m Turning angle 90°
120°

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.
adjuster and rocker arm ——Coat the surfaces of the rocker arm and the
hole on the cylinder head, with the other side of the
rocker arm overlapping on the valve. See Fig. 4-5-34.
(5) Reinstall the intake and exhaust camshafts.

Camshaft ——Install the intake and exhaust camshafts into the
——Align the marks “·∙” on the driving gears of exhaust
and intake camshafts and get them in line with the
upper surface.
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

191
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.
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
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
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.

(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
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
tighten the fastening bolt washer component as per the
specified torque. The camshaft timing pulley should be
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.

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

193
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.

See Fig. 4-5-43.
Timing pulley
Timing
tension pinhole-mounting position clockwise until it is slightly
pulley over 30° past the vertical direction and the tension
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.

22N·m~26N·m
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.

45N·m±3N·m

component
component I
9N·m±3N·m

(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
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.


195
Section VI Engine oil pump assembly
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

Disassembly
(1) Remove the generator belt:Turn the tension pulley
with tools until the belt is loose enough, and then
remove the generator belt.
(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.

(1) Remove the 4 hexagon flange face bolts (M8x20)
fastening the damping pulley and the front end of
end of crankshaft.

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.

197
(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.
(4) Remove the timing idle wheel assembly: loosen the
fastening bolts of timing idle wheel, and remove the
timing idle wheel.
Timing belt
Disassembling the lower body assembly of oil pan

④
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.
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.

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.
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
(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

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
and tightening of bolts 9N·m±3N·m

199
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.

(1) Reinstall the timing idle wheel assembly.
(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.

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.
(1) Reinstall the power steering pump assembly and its
bracket component.
(2) Reinstall the generator bracket and the generator
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.
(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.

Section VII Cylinder body assembly
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

201
Disassembly
(1) Remove the generator belt assembly: rotate the
tension pulley with tools until the belt is loose enough,
and then remove the generator belt.
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.
fastening the damping pulley and the front end of
end of the crankshaft.
(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.
(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

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
Disassembling the cylinder head assembly ④

Camshaft bearing
cap (1) Remove the cylinder head cover component. See
Fig. 4-7-5.
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.

203
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
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
collector support, and take off the oil collector.


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.
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

205
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
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

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
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
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.

(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
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
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

207
(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

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

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
crank pin.
Fig. 4-7-23 Installing the connecting rod
assembly and piston
(3) Check the open end of piston ring.
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.

209
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.
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.

(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

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

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.

M6 9N·m±3N·m
M8 23N·m±3N·m
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

211
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

(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
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

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
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.

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.

213

head
Turning angle: Turning angle:
50N·m±3N·m
90° 120°
Attention: Check the cylinder head bolt before

deformation, stretching or thread slipping.
(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.
Timing (1) Place the elastic cylindrical pin in the timing pulley
pulley pin hole of crankshaft.
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

(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.
(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.

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.

215
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
Reinstall them in the opposite order of
dismounting.

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.
——Remove the fastening bolts connecting the
transmission and clutch in proper order, and remove the
transmission assembly.
(2) Clutch assembly
Fig. 5-2-3 Removing the clutch assembly
Attention: Do not leave any liquid on the clutch
surface, and clean it immediately.
——Remove the pressure plate assembly.
——Remove the driven disc assembly.
——Use guide centering device to prevent the clutch
from falling off the driven disc assembly freely.
Guide centering device: 5-5821-3001-0.

——Make a mark on the flanges of flywheel and
pressure plate to facilitate the alignment during the
installation.
Fig. 5-2-4 Removing the radiator assembly ——Loosen the fixing bolts of clutch pressure plate
(for reference only) assembly, and remove the clutch assembly, as shown in
Fig. 5-2-3.

217
Removing the radiator assembly ②

(1) Loosen the clip of upper / lower hose for the radiator,
and remove the upper hose.
Air flow sensor
(2) Remove the hose for overflow tank.
(3) Remove the upper mounting support of radiator, and
remove the radiator assembly, as shown in Fig. 5-2-4.
Removing air intake pipe and air flow sensor ③

(1) Loosen the clip that fixes the air intake pipe and take
Fig. 5-2-5 Removing air intake pipe and air down the air intake pipe, as shown in Fig. 5-2-5.
flow sensor (2) Loosen the clip that fixes the air flow sensor and
take down the air flow sensor.
Attention: The air flow sensor is a precision part,

and its state has a direct influence on the operation of
the diesel engine. Remove and install with care; do not
collide and keep it clean. Apply special storage after
removal.
Removing the air cleaner ④

(1) Remove 3 hexagon bolts fastening the air cleaner
assembly to the frame. See Fig. 5-2-6.
(2) Remove the clamp at the air intake port of the air
cleaner and take down the air cleaner. See Fig. 5-2-6.
Air intake pipe
Fig. 5-2-6 Removing the air cleaner
Removing the harness ⑤

Remove the harness connectors from electronic control
unit (ECU), fuel injector, high-pressure fuel pump, glow
plug, turbocharger, EGR valve, electromagnetic valve of
A/C compressor and various sensors, etc. respectively.
(2) Loosen the harness clamp and the harness bracket,
and remove the harness. See Fig. 5-2-7.
Attention: Harness connectors are equipped with

the self-locking devices. Hold the harness connector
stably when pulling it out. It is strictly forbidden to
directly remove the harness with violence.
Fig. 5-2-7 Removing the engine harness

Removing the fuel hose ⑥

(1) Remove the clamp that fixes the fuel inlet hose and
the fuel return hose.
(2) Remove the fuel inlet hose and the fuel return hose
respectively.
The fuel hose should be added with a label before

being removed, for the purpose of easy recognition
upon the latest connection.
Fig. 5-2-8 Removing the wire of engine oil

pressure switch
Removing the wire of engine oil pressure switch ⑦
Remove the wire connector that connects the engine oil
pressure switch, as shown in Fig. 5-2-8.
Warning: Pull the plug connector instead of the

harness (the wire) when separating the connector.
Refrigeration
compressor
Removing the refrigeration compressor assembly
Cylinder body ⑧
(1) Turn the tension pulley with tools until the generator
belt is loose enough, and then remove the generator
Fig. 5-2-9 Removing the refrigeration belt.
compressor assembly (2) Remove the wire connector of electromagnetic
clutch.
(3) Remove 4 hexagon flange bolts (M8×85) fastening
the refrigeration compressor to the left side of the
cylinder body, and take off the refrigeration compressor
Removing the power steering pump assembly ⑨

of the power steering pump.
(2) Remove 3 or 4 hexagon flange bolts (M8×30,
M8×100) fastening the power steering pump to the
bracket of power steering pump, and then take off the
Cylinder body bracket of power steering pump. See Fig. 5-2-10.
(3) Remove 3 hexagon flange bolts (M8×25, M8×30)
fastening the bracket of power steering pump to the
cylinder body, and then take off the bracket of power
steering pump. See Fig. 5-2-10.
Fig. 5-2-10 Removing the power steering

Pump Assembly

219
Removing the catalytic converter pipe ⑩

(1) Remove the fixing bolts and nuts of catalytic
converter from the turbocharger or the exhaust elbow.
See Fig. 5-2-11.
(2) Remove the fixing bolts and nuts from the front
exhaust pipe.
(3) Remove the catalytic converter pipe and the sealing
gaskets on both ends.
(4) Check the sealing gasket, and replace those
damaged or deformed ones.
Fig. 5-2-11 Removing the catalytic converter
pipe
Removing the fastening nuts of engine bracket ○

11
(1) Use a crane to hitch the engine hook, but don't lift
the engine.
(2) Loosen 2 fastening nuts that fix the left / right engine
bracket to the frame studs (as shown in Fig. 5-2-12) so
as to separate the engine from the frame.
Fig. 5-2-12 Removing the fastening nuts of

engine bracket
Engine hook Removing the engine assembly ○

12
(1) Connect the hook to the crane to lift the engine

carefully, as shown in Fig. 5-2-13.
(2) After being raised, the head of the engine should be
higher than the tail.
(3) Place the engine steady on the maintenance rack for
repair, removal and reinstallation.
Attention: When taking out the engine assembly,

do not damage the oil pipe, the sensor or electric
elements, etc.
Fig. 5-2-13 Removing the engine assembly

Installation
Installing the engine assembly
Use a crane to hitch the engine hook, and rest the
engine steady at the mounting position of the frame.
Installing fastening nuts of engine brackets ○
11
After installing the engine, tighten 2 nuts that fix the left /
right bracket to the frame studs to specified torques so
as to fix the engine to the frame. See Fig. 5-2-14.
Tightening torques for fastening nuts of left / right

Fig. 5-2-14 Installing fastening nuts of engine engine bracket
brackets
95N·m±10N·m
Installing the catalytic converter pipe ⑩

Connect the catalytic converter pipe to the turbocharger
or the front exhaust pipe, install the sealing gaskets on
both ends, and tighten the fastening bolts and nuts of
catalytic converter pipe to specified torques. See Fig.
5-2-15.
Tightening torques for fastening bolts and nuts of

catalytic converter pipe
23N·m±3N·m
Fig. 5-2-15 Installing the front exhaust pipe
Installing the power steering pump assembly ⑨

(1) Install the power steering pump, and tighten 3 or 4
Steering pump hexagon flange bolts (M8×100, M8×30). See Fig.
bracket
5-2-16.
Steering pump Tightening torques for fastening bolts of power

steering pump
23N·m±3N·m
(2) Install the fuel inlet hose and the fuel return hose of
the power steering pump.
Fig. 5-2-16 Installing the power steering pump Installing the refrigeration compressor assembly ⑧
assembly
(1) Install the refrigeration compressor assembly to the
cylinder body, and tighten 4 hexagon flange bolts
(M8×85) as per specified torque. See Fig. 5-2-17.
Tightening torques for fastening bolts of the

refrigeration compressor

221
23N·m±3N·m
(2) Install the wire connector of electromagnetic clutch.
(3) Install the generator belt, use a tool to turn the
enough. After the installation, check the generator belt
Refrigeration for any excessive tension or any insufficient tension.
compressor
Cylinder body
Fig. 5-2-17 Installing the refrigeration

compressor
Installing the wire of engine oil pressure switch ⑦

Connect the wire connector of engine oil pressure
switch.
Installing the fuel hose ⑥

(1) Connect the fuel inlet hose and the fuel return hose
(see Fig. 5-2-18).Then tighten the clamp firmly.
(2) After installation, check connectors of the fuel inlet
hose and the fuel return hose, and make sure they are
sealed firmly without any fuel leakage.
Fig. 5-2-18 Installing the fuel hose

Installing harness ⑤
(1) Insert various sensor plugs on the engine harness to
the corresponding sensors respectively. Connect plugs
of fuel injector, high-pressure fuel pump, ECU, glow
plug, turbocharger, EGR valve, and electromagnetic
valve of A/C compressor, etc. See Fig. 5-2-19.
(2) Check all connectors of the harness for any incorrect
insertion.
(3) Install the harness bracket, and fasten the harness
clamp.
Fig. 5-2-19 Installing the engine harness Attention: Harness connectors are equipped with
the self-locking devices. Hold the harness connectors
stably during installation and make sure they are
properly installed.

Installing the air cleaner ④

(1) Install the air cleaner assembly to the frame, and
tighten 3 hexagon bolts as per specified torque. See
Fig. 5-2-20.
Tightening torques for fastening bolts of the air

cleaner
Air intake pipe
23N·m±3N·m
(2) Install the intake pipe of air cleaner and tighten the
Fig. 5-2-20 Installing the air cleaner clamp, as shown in Fig. 5-2-20.
Installing air intake pipe and air flow sensor ③

Tighten the fastening clamp after connecting the air
Air flow sensor
intake pipe and the air flow sensor. See Fig. 5-2-21.
Attention: The air flow sensor has a mounting

direction with the arrow mark toward the air intake port
of the turbocharger.
Caution: Keep the air flow sensor clean, and

prevent dirt or dust from getting into it.
Fig. 5-2-21 Installing air intake pipe and air
flow sensor
Installing the radiator assembly ②

(1) Install the radiator assembly. See Fig. 5-2-22.
(2) Connect upper / lower hose for the radiator.
(3) Connect the hose for overflow tank.
After installation, check connectors of upper / lower

hose for the radiator and make sure they are sealed
firmly without any coolant leakage.
Installing the transmission assembly and the clutch

assembly ①
Fig. 5-2-22 Installing the radiator assembly
(for reference only) Clutch
(1) Driven disc assembly
——Grease the spline of the clutch driven disc hub with
molybdenum disulfide grease.
——Install the driven disc assembly by guide centering
device. See Fig. 5-2-23.

223
(2) Pressure plate assembly

——Tighten 9 bolts that fix the clutch pressure plate
assembly to specified torques in proper order as shown
in Fig. 5-2-24.
Tightening torques for fixing bolts of the clutch

pressure plate assembly
23N·m±3N·m
——Remove the guide centering device.
Attention: If a new pressure plate is installed, the

Fig. 5-2-23 Installing the clutch assembly wire for protecting the diaphragm spring must be
removed after the fixing bolts of the pressure plate are
tightened to specified torques.

——Fit 2 transmission dowel pins into the back end face
of the cylinder body by a special tool; there should be no
——Install the transmission assembly. Screw down the
fastening bolts connecting the transmission and clutch
in proper order and as per specified torque. See Fig.
5-2-25.
Fig. 5-2-24 Installing the clutch pressure plate ——Install the drive shaft.
assembly
After the installation, please carry out the following
operations.
Transmission
(1) Connect the earthing cable of storage battery.
Clutch assembly
(2) Fill coolant into the cooling system.
(3) Fill the lubricating oil into the transmission.
(4) Start the engine, and check the cooling system for
leakage and the engine for abnormal working.
Fig. 5-2-25 Installing the transmission and the

clutch assembly

Section III Engine Brackets
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
12 Engine assembly
○
13 Left / right engine bracket
○

225
Removal
Preparation
See Fig. 5-3-2.
(2) Drain coolant of the cooling system.
(3) Drain the lubricating oil of the transmission.
Warning: Risk of burn from the hot engine oil.

Properly handle the waste engine oil and protect the
environment.

storage battery
Removing the transmission assembly and the
clutch assembly ①
Lift the vehicle and support it with appropriate safety
rack.
——Remove the drive shaft on the flange yoke.
——Remove the fastening bolts connecting the
transmission and clutch in proper order, and remove the
transmission assembly.
(2) Clutch assembly

——Remove the pressure plate assembly. See Fig.
5-3-3.
——Use guide centering device to prevent the clutch

——Make a mark on the flanges of flywheel and
Fig. 5-3-4 Removing the radiator assembly installation.
(for reference only)
——Loosen the fastening bolts of the clutch pressure
plate assembly, and remove the clutch assembly, as
Removing the radiator assembly ②
(1) Loosen the clip of upper / lower hose for the radiator,

and remove the upper and lower hoses.

(2) Remove the hose for overflow tank.
(3) Remove the upper mounting support of radiator, and
Air flow sensor
remove the radiator assembly, as shown in Fig. 5-3-4.
Attention: Remove the radiator carefully so as not

to scratch the core.
Removing the air intake pipe and the air flow sensor
③
(1) Loosen the clip that fixes the air intake pipe and take
Fig. 5-3-5 Removing the air intake pipe and down the air intake pipe, as shown in Fig. 5-3-5.
the air flow sensor (2) Loosen the clip that fixes the air flow sensor and
take down the air flow sensor.
Attention: The air flow sensor is a precision part,

and its state has a direct influence on the operation of
the diesel engine. Remove and install with care; do not
collide and keep it clean. Apply special storage after
removal.
Removing the air cleaner ④

(1) Remove 3 hexagon bolts fastening the air cleaner
assembly to the frame. See Fig. 5-3-6.
(2) Remove the clamp at the air intake port of the air
cleaner and take off the air cleaner. See Fig. 5-3-6.
Air intake pipe
Fig. 5-3-6 Removing the air cleaner
Removing the harness ⑤

Remove the harness connectors from electronic control
unit (ECU), fuel injector, high-pressure fuel pump, glow
plug, turbocharger, EGR valve, electromagnetic valve of
A/C compressor and various sensors, etc.
(2) Loosen the harness clamp and the harness bracket,
and remove the harness. See Fig. 5-3-7.
Attention: Harness connectors are equipped with

the self-locking devices. Hold the harness connector
stably when pulling it out. It is strictly forbidden to
directly remove the harness with violence.
Fig. 5-3-7 Removing the engine harness

227
Removing the fuel hose ⑥

(1) Remove the clamp that fixes the fuel inlet hose and
the fuel return hose.
respectively, as shown in Fig. 5-3-8.
The fuel hose should be added with a label before

being removed, for the purpose of easy recognition
upon the latest connection.
Removing the wire of engine oil pressure switch ⑦

Remove the wire connector that connects the engine oil
Fig. 5-2-8 Removing the fuel hose pressure switch.
Warning: Pull the plug connector instead of the


Refrigeration
⑧
compressor (1) Turn the accessory tension pulley with tools until the
generator belt is loose enough, and then remove the
Cylinder body generator belt.
(2) Remove the wire connector of electromagnetic
clutch.
Fig. 5-3-9 Removing the refrigeration (3) Remove 4 hexagon flange bolts (M8×85) fastening
compressor assembly the refrigeration compressor to the left side of the
cylinder body, and take off the refrigeration compressor
Removing the power steering pump assembly ⑨

of the power steering pump.
(2) Remove 1 hexagon flange nut and 1 hexagon flange
bolt (M8×30) fastening the power steering pump to the
bracket of power steering pump, and then take off the
Cylinder bracket of power steering pump. See Fig. 5-3-10.
body
fastening the bracket of power steering pump to the
cylinder body, and then take off the bracket of power
steering pump. See Fig. 5-2-10.
Fig. 5-3-10 Removing the power steering
pump assembly

Removing the catalytic converter pipe ⑩

(1) Remove the fixing bolts and nuts of catalytic
converter from the turbocharger or the exhaust elbow.
See Fig. 5-3-11.
(2) Remove the fixing nuts from the front exhaust pipe.
(3) Remove the catalytic converter pipe and the sealing
gaskets.
(4) Check the sealing gaskets, and replace those

pipe (for reference only)
Removing the fastening nuts of engine bracket ○
11
(1) Use a crane to hitch the engine hook, but don't lift
the engine.
(2) Loosen 2 fastening nuts that fix the left / right engine
bracket to the frame studs (as shown in Fig. 5-3-12) so
as to separate the engine from the frame.
Fig. 5-3-12 Removing the fastening nuts of

engine bracket
Removing the engine assembly ○
12
Engine hook
repair, removal and reinstallation.
Attention: When removing the engine assembly,

do not damage the oil pipe, the brake pipe, the sensor
or electric elements, etc.

229
Removing left / right engine bracket ○

13
Cylinder
body (1) Remove 3 hexagon bolts (M10×1.25×25) fixing the
left bracket to the cylinder body and the spring washer
and plain washer subassembly, and remove the left
(2) Remove 3 hexagon bolts (M10×1.25×25) fixing the
Engine
bracket
right bracket to the cylinder body and the spring washer
and plain washer subassembly, and remove the right
Installation
Fig. 5-3-14 Removing and installing the Installing the engine assembly ○
13
engine brackets
(1) Install the right bracket to the right side of the
cylinder body. Fix it with 3 hexagon bolts
(M10×1.25×25) and the spring washer and plain washer
subassembly as per specified torque. See Fig. 5-3-14.
(2) Install the left bracket to the right side of the cylinder
body. Fix it with 3 hexagon bolts (M10×1.25×25) and
the spring washer and plain washer subassembly as

engine bracket
45N·m±10N·m
Fig. 5-3-15 Installing the fastening nuts of left / Installing the engine assembly ○
12
right engine bracket
Use a crane to hitch the engine hook, and rest the
engine steady at the mounting position of the frame.
Installing the fastening nuts of engine bracket ○
11
After installing the engine, tighten 2 nuts that fix left /

right bracket to the frame studs to specified torques, as

engine bracket
95N·m±10N·m
Installing the catalytic converter pipe ⑩
Fig. 5-3-16 Installing the front exhaust pipe Connect the catalytic converter pipe to the turbocharger
or the front exhaust pipe, install the sealing gaskets on
both ends, and tighten the fastening bolts and nuts of
catalytic converter pipe to specified torques. See Fig.
5-3-16.
Tightening torques for fastening bolts and nuts of

catalytic converter pipe
23N·m±3N·m

Installing the power steering pump assembly ⑨
Steering pump
(1) Install the power steering pump, and tighten 3 or 4
bracket hexagon flange bolts (M8×100, M8×30). See Fig.
5-3-17.
Steering pump
Tightening torques for fastening bolts of the power
steering pump
23N·m±3N·m
(2) Install the fuel inlet hose and the fuel return hose of
the power steering pump.
Fig. 5-3-17 Installing the power steering pump

assembly
Installing the refrigeration compressor assembly ⑧

(1) Install the refrigeration compressor assembly to the
cylinder body and the oil pan, align the mounting holes,
and tighten 4 hexagon flange bolts (M8×85) as per
Refrigeration
compressor Tightening torques for fastening bolts of the
23N·m±3N·m
Cylinder body
(2) Install the wire connector of electromagnetic clutch.
Turn the accessory tension pulley with tools until the
Fig. 5-3-18 Installing the refrigeration belt is loose enough, and then install the generator belt.
compressor After the installation, check the generator belt for any
excessive tension or any insufficient tension.
Installing the wire of engine oil pressure switch ⑦

Connect the wire connector of engine oil pressure
switch. See Fig. 5-3-19.
Fig. 5-3-19 Installing engine oil pressure

switch

231
Installing the fuel hose ⑥

(1) Connect the fuel inlet hose and the fuel return hose
(see Fig. 5-3-20).Then tighten the clamp firmly.
(2) After installation, check connectors of fuel inlet hose
and fuel return hose and make sure they are sealed
firmly without any fuel leakage.
Fig. 5-3-20 Installing the fuel hose

Installing harness ⑤
(1) Insert various sensor plugs on the engine harness
into corresponding sensors respectively. Connect plugs
of fuel injector, high-pressure fuel pump, ECU, glow
plug, turbocharger, EGR valve, and electromagnetic
valve of A/C compressor, etc.
(2) Check all connectors of the harness for incorrect
insertion.
(3) Install the harness bracket, and fix the harness to
the harness clamp, as shown in Fig. 5-3-21.
Fig. 5-3-21 Installing the engine harness Attention: Harness connectors are equipped with
the self-locking devices. Hold the harness connectors
stably during installation and make sure they are
self-locked after installation.
Installing the air cleaner ④

(1) Install the air cleaner assembly to the frame, and
tighten 3 hexagon bolts as per specified torque. See
Fig. 5-3-22.
Tightening torques for fastening bolts of the air

cleaner
Air intake pipe
23N·m±3N·m
(2) Install the intake pipe of air cleaner and tighten the
clamp, as shown in Fig. 5-3-22.
Fig. 5-3-22 Installing the air cleaner

Installing air intake pipe and air flow sensor ③

Tighten the fastening clamp after connecting air intake
pipe and air flow sensor. See Fig. 5-3-23.
Air flow sensor
Attention: The air flow sensor has a mounting
direction with the arrow mark toward the air intake port
of the turbocharger.
Caution: Keep the air flow sensor clean, and

prevent dirt or dust from getting into it.
图 5-3-23 装配进空气导管及空气流量传感器
Fig. 5-3-23 Installing intake pipe and air flow Installing the radiator assembly ②
sensor
(1) Install the radiator assembly. See Fig. 5-3-24.
(2) Connect upper / lower hose for the radiator.
(3) Connect the hose for overflow tank.
After installation, check connectors of upper / lower

hose for the radiator and make sure they are sealed
firmly without any coolant leakage.

(for reference only) Installing the transmission assembly and the clutch
assembly ①
Clutch
——Install the driven disc assembly by guide centering
device. See Fig. 5-3-25.
Fig. 5-3-25 Installing the clutch assembly

233

in Fig. 5-3-26.
Tightening torques for fixing bolts of clutch

23N·m±3N·m
——Remove the guide centering device.

Fig. 5-3-26 Installing the clutch pressure plate wire for protecting the diaphragm spring must be
assembly removed after the fixing bolts of the pressure plate are
tightened to specified torques.
Transmission
Clutch assembly (3) Transmission assembly

——Fit the 2 transmission dowel pins into the back end
face of the cylinder body by a special tool; there should
be no deflection or improper mounting.
——Install the transmission assembly. Screw down the
in proper order and as per specified torque. See Fig.
5-3-27.
——Install the drive shaft.
Fig. 5-3-27 Installing the transmission and the
clutch assembly
operations.
(1) Connect the earthing cable of storage battery. See
Fig. 5-3-28.
(3) Fill the lubricating oil into the transmission.
Start the engine, check its working condition and check
the cooling system for leakage.
Fig. 5-3-28 Connecting the earthing cable of

storage battery

Section IV Air Intake Manifold Pipe
Removal procedure
① Air intake connecting hose
② Intercooler port
③ EGR valve and air outlet pipe of
EGR condenser
④ Fuel inlet pipe of high-pressure
fuel rail
⑤ Turbocharger pressure
sensor
⑥ Air intake manifold pipe
Install them in the opposite order
of removal.
Fig. 5-4-1 Installation and removal procedures of air intake manifold pipe

235
Removal
Preparation
Disconnect the earthing cable of storage battery.
Removing the air intake connecting hose ①

(1) Loosen the clip connecting the air intake connecting
hose and intercooler connector.
(2) Remove the air intake connecting hose from the
intercooler connector. See Fig. 5-4-2.
Fig. 5-4-2 Removing the air intake connecting
hose (for reference only) Removing the intercooler port ②
Air intake fastening the intercooler port to air intake manifold pipe.
manifold pipe (2) Remove the intercooler port and throttle gasket from
Intercooler air intake manifold pipe. See Fig. 5-4-3.
port
(3) Check the throttle gasket and replace it if there is
any damage or deformation.
Throttle gasket
Removing the EGR valve and air outlet pipe of EGR
condenser ③
(1) Remove the 2 hexagon flange bolts and 2 hexagon
Fig. 5-4-3 Removing the intercooler connector flange nuts (M8×25, M8×30, M8×1.25) on air outlet pipe
of EGR condenser and EGR condenser. See Fig. 5-4-4.
(2) Remove the 2 hexagon flange bolts (M8×20) on air
outlet pipe of EGR condenser and EGR valve
EGR valve assembly.
assembly
(3) Pull out the plug connecting harness and EGR
valve.
Air outlet pipe of
EGR condenser (4) Remove the 2 hexagon flange nuts connecting the
EGR valve and air intake manifold pipe, and then
remove the EGR valve. See Fig. 5-4-4.
Removing the fuel inlet pipe of high-pressure fuel

rail ④
Fig. 5-4-4 Removing the air outlet pipe (1) Loosen the fastening bolt on fuel inlet pipe clamp of
component of EGR condenser high-pressure fuel rail, and then remove the fuel inlet
pipe clamp of high-pressure fuel rail.
(2) Loosen evenly the pipe connector at both ends of
fuel inlet pipe of high-pressure fuel rail, and then
remove the fuel inlet pipe of high-pressure fuel rail. See
Fig. 5-4-5.

Fuel inlet pipe of Attention:

high-pressure
fuel rail (1) Loosen evenly the pipe connectors at both ends of
the fuel inlet pipe of high-pressure fuel rail to avoid
deformation of fuel pipe.
(2) Use a clean plug cover to block the fuel pipe after
High-pressure removing the fuel inlet pipe of high-pressure fuel rail.
fuel rail
Removing the turbocharger pressure sensor ⑤

(1) Pull out the connector between harness and
turbocharger pressure sensor.
Fig. 5-4-5 Removing the fuel inlet pipe of
high-pressure fuel rail (2) Remove the 2 hexagon flange bolts (M6×10)
fastening the turbocharger pressure sensor bracket,
and then remove the bracket. See Fig. 5-4-6.
(3) Remove the turbocharger pressure sensor from
exhaust manifold pipe.
Removing the air intake manifold pipe ⑥

(1) Remove the 7 hexagon flange bolts (M8×105,
M8×25) and 2 hexagon flange nuts (M8×1.25)
connecting air intake manifold pipe and cylinder head.
See Fig. 5-4-6.
(2) Remove the air intake manifold pipe and air intake
manifold pipe gasket from the air intake side of cylinder
head.
Air intake
manifold pipe
Check the air intake manifold pipe gasket and
replace it if there is any damage or deformation.
Fig. 5-4-6 Installing and removing the air
intake manifold pipe
Installation
Installing the air intake manifold pipe ⑥
Turbocharger
pressure sensor (1) Check whether the 2 double end studs on cylinder
head are in proper condition.
(2) Install the air intake manifold pipe gasket. See Fig.
5-4-6.
(3) Tighten the 7 hexagon flange bolts (M8×25,
M8×105) and 2 hexagon flange nuts fastening the air
intake manifold pipe to cylinder head to their specified
torques.
Fig. 5-4-7 Installing the turbocharger pressure Tightening torque for fastening bolt and nut of air
sensor intake manifold pipe
23N·m±3N·m

237
Installing the turbocharger pressure sensor ⑤

Fuel inlet pipe of (1) Check whether the O-ring on turbocharger pressure
high-pressure
sensor is installed properly.
fuel rail
Install the turbocharger pressure sensor to the sensor
hole of constant pressure chamber of air intake
manifold pipe.
High-pressure
fuel rail
fastening the turbocharger pressure sensor bracket
according to the specified torque. See Fig. 5-4-7.
(3) Connect the harness connector of turbocharger
pressure sensor.
Fig. 5-4-8 Installing the fuel inlet pipe of
high-pressure fuel rail Tightening torque for fastening bolt of turbocharger
pressure sensor
9N·m±3N·m
EGR valve
assembly
There should be no air leakage after installation.
Installing the fuel inlet pipe of high-pressure fuel
Air outlet pipe of rail ④
EGR condenser
(1) Install the fuel inlet pipe of high-pressure fuel rail
and tighten evenly the pipe connectors at both ends of
the fuel inlet pipe of high-pressure fuel rail according to
the specified torque. See Fig. 5-4-8.
(2) Tighten the hexagon flange bolt (M6×12) fastening
the fuel inlet pipe of high-pressure fuel rail according to
Fig. 5-4-9 Installing the air outlet pipe of EGR the specified torque.
condenser
Attention: There are 2 rubber pads in the fuel inlet
pipe clamp of high-pressure fuel rail. Don’t forget to
install them.
Tightening torque for fastening bolt of fuel inlet

pipe connector and clamp
Fuel inlet pipe connector 23N·m±3N·m

of high-pressure fuel rail
Fuel inlet pipe clamp of 9N·m±3N·m

high-pressure fuel rail
Installing the EGR valve and air outlet pipe of EGR

condenser ③
(1) Install the EGR valve and air outlet port gasket of
EGR valve to the air intake manifold pipe and tighten
the 2 hexagon flange nuts according to the specified
torque.

(2) Install the EGR condenser gasket and air outlet pipe
of EGR condenser and tighten the 4 hexagon flange
Air intake bolts (M8×20, M8×25, M8×30) according to the
manifold pipe specified torque. See Fig. 5-4-9.
Intercooler
port (3) Connect the EGR valve harness connector.
Tightening torque for fastening bolt and nut of EGR

valve
Throttle gasket
23N·m±3N·m
Installing the intercooler port ②
(1) Install the intercooler port throttle gasket and
Fig. 5-4-10 Installing the intercooler connector intercooler port to the air intake manifold pipe. See Fig.
5-4-10.
fastening the intercooler port according to the specified
Tightening torque for fastening bolt of intercooler

port
9N·m±3N·m
Installing the air intake connecting hose ①
(1) Install the air intake connecting hose and tighten the
clip connecting the air intake connecting hose and
Fig. 5-4-11 Installing the air intake connecting intercooler connector. See Fig. 5-4-11.
hose (for reference only)
(2) There should be no air leakage of the air intake
connecting hose seal.
operations.
Fig. 5-4-12.
(2) Start the engine, check its working condition and
make sure the air intake system and fuel system are in
normal operation.

storage battery

239
Section V Exhaust Manifold Pipe
Filter core
Removal procedure
① Air cleaner and turbocharger air
intake hose
② Catalytic converter pipe
③ Turbocharger fuel inlet bolt
④ Turbocharger assembly
⑤ Air intake pipe of EGR condenser
⑥ Heat shield of exhaust manifold pipe
and exhaust manifold pipe
Install them in the opposite order of
removal.
Fig. 5-5-1 Installation and removal procedures of exhaust manifold pipe

Removal
Preparation
Filter core
Removing the air cleaner and turbocharger air

intake hose ①
Turbocharger (1) Loosen the clip connecting the turbocharger air
intake hose
intake hose and turbocharger compressor casing. See
Fig. 5-5-2.
(2) Pull out the harness connector of air cleaner.
Fig. 5-5-2 Removing the air cleaner and
turbocharger air intake hose (3) Remove the turbocharger air intake hose
(4) Remove the 3 hexagon bolts fastening the air
cleaner casing and take off the air cleaner. See Fig.
5-5-2.
Remove the catalytic converter pipe ②

(1) Remove the fixing bolts of catalytic converter from
the turbocharger or the exhaust elbow.
(2) Remove the fixing nuts from the front exhaust pipe.
(3) Take out the catalytic converter pipe and the gaskets
at the both ends. See Fig. 5-5-3.

pipe (for reference only) Check the packing and replace it if there is any
damage or deformation.
Fuel inlet bolt

Removing the turbocharger fuel inlet bolt ③
(1) Remove the fuel inlet bolt and fuel inlet bolt gasket
Fuel inlet pipe at the turbocharger end.
assembly Check the turbocharger fuel inlet bolt gasket and
replace it if there is any damage or deformation.
Removing the turbocharger assembly ④

(1) Pull out the harness connector of the turbocharger.
(2) Remove 3 hexagon flange bolts (M6×12) fastening
Fig. 5-5-4 Removing the turbocharger fuel
the turbocharger heat shield, and take off the heat
inlet bolt
shield (VCT turbocharger). See Fig. 5-5-5.
(3) Remove the fuel return hose components and fuel
return hose which are connected to the turbocharger.
(4) Remove 1 connecting bolt and 2 fastening nuts
fixing the turbocharger assembly, and take off the

241
turbocharger assembly and the turbocharger gasket.
Turbocharger Check the turbocharger gasket and replace it if

there is any damage or deformation.
Fuel return
hose Heat shield
Fig. 5-5-5 Removing the turbocharger heat

shield and turbocharger
Removing the air intake pipe of EGR condenser ⑤

(1) Remove the 2 hexagon flange bolts (M8×1.25) on
Air intake pipe of air intake pipe of EGR condenser and exhaust manifold
condenser pipe. See Fig. 5-5-6.
connecting the air intake pipe of EGR condenser and
EGR condenser components. See Fig. 5-5-6.
(3) Remove the air intake pipe, air intake pipe gasket
condenser and air intake port gasket of EGR condenser.
Check the sealing gasket and replace it if there is

any damage or deformation.
Fig. 5-5-6 Removing the air intake pipe of
EGR condenser
Removing the heat shield of exhaust manifold pipe
Exhaust and exhaust manifold pipe ⑥
manifold pipe Exhaust
gasket manifold pipe (1) Remove the 4 hexagon flange bolts (M6×12)
fastening the heat shield of exhaust manifold pipe, and
take off the heat shield of exhaust manifold pipe. See
Fig. 5-5-7.
Heat shield
Fig. 5-5-7 Removing the heat shield of

exhaust manifold pipe

Exhaust
manifold pipe (2) Remove the 8 hexagon flange bolts fastening the
gasket exhaust manifold pipe, and then take off the exhaust
manifold pipe and exhaust manifold pipe gasket. See
Fig. 5-5-8.
(3) Check the exhaust manifold pipe gasket and replace
it if there is any damage, deformation or burnout.
Exhaust
manifold pipe
Fig. 5-5-8 Removing the exhaust manifold

pipe and gasket component
Installation
Cylinder head
assembly Installing the heat shield of exhaust manifold pipe
and exhaust manifold pipe ⑥
(1) Install the exhaust manifold pipe gasket to the
cylinder head exhaust manifold pipe.
(2) Install the exhaust manifold pipe and tighten the 8
hexagon flange nuts according to the specified torque.
Exhaust See Fig. 5-5-9.
manifold pipe
Tightening torque for fastening bolt of exhaust
manifold pipe
Fig. 5-5-9 Installing the exhaust manifold pipe
and gasket component 30N·m±3N·m
(3) Install the heat shield to the exhaust manifold pipe

Exhaust manifold
Exhaust and tighten the 4 hexagon flange bolts (M6×12)
pipe gasket according to the specified torque. See Fig. 5-5-10.
manifold pipe
Tightening torque for fastening bolt of heat shield

of exhaust manifold pipe
9N·m±3N·m
Installing the air intake pipe of EGR condenser ⑤
Heat shield
(1) Install the air intake pipe and air intake port gasket of
EGR condenser.
(2) Install the air intake pipe of EGR condenser and
Fig. 5-5-10 Installing the heat shield of tighten the 2 hexagon flange bolts (M8×20) connected
exhaust manifold pipe with EGR condenser component and 2 hexagon flange
nuts (M8×1.25) at the air intake pipe of EGR condenser
and exhaust manifold pipe. See Fig. 5-5-11.
Tightening torque for fastening bolt and nut of air

intake pipe of EGR condenser

243
23N·m±3N·m
Installing the turbocharger assembly ④
Air intake pipe of
condenser (1) Install the turbocharger gasket and turbocharger and
tighten the connecting bolt and 2 fastening nuts
Tightening torque for fastening bolt and nut of

turbocharger
condenser
45N·m±3N·m
(2) Install the turbocharger heat shield and tighten the 3
hexagon flange bolts (M6×12) according to the
Fig. 5-5-11 Installing the air intake pipe of specified torque.
EGR condenser
heat shield
Turbocharger 9N·m±3N·m
(3) Install the fuel inlet pipe of turbocharger and fuel
inlet bolt connecting the turbocharger and tighten it
Fuel return Tightening torque for turbocharger fuel inlet bolt

Heat shield
hose
22N·m±3N·m
(4) Install the turbocharger fuel return hose component
and tighten the 2 hexagon flange bolts (M6×16)
Fig. 5-5-12 Installing the turbocharger heat according to the specified torque.
shield and turbocharger
heat shield
Fuel inlet bolt
9N·m±3N·m
(5) Connect the turbocharger harness plug.
Fuel inlet pipe
assembly
Installing the turbocharger fuel inlet bolt ③
Install the fuel inlet bolt and gasket at turbocharger and
tighten it according to the specified torque. See Fig.
5-5-13.
Fig. 5-5-13 Installing the turbocharger fuel

inlet bolt

Attention:
(1) There is a fuel inlet bolt gasket on the upper / lower
end of turbocharger fuel inlet pipe ball head. See Fig.
5-5-13.
Check the turbocharger fuel inlet bolt gasket and repair
or replace it if there is any damage.
Tightening torque for turbocharger fuel inlet bolt

22N·m±3N·m
Fig. 5-5-14 Installing the catalytic converter Installing the catalytic converter pipe②
pipe
Connect the catalytic converter pipe and turbocharger
or front exhaust pipe, install the sealing gasket at the
both ends and tight the fixing bolt and nut to the
Filter core
Tightening torque for fixing bolt and nut of catalytic
converter
23N·m±3N·m
Turbocharger
intake hose Installing the air cleaner and turbocharger air intake
hose ①
(1) Install the air cleaner casing to the frame and fix it
Fig. 5-5-15 Installing the air cleaner and with 3 hexagon flange bolts. See Fig. 5-5-15.
turbocharger air intake hose (2) Install the turbocharger air intake hose and fasten it
with a clip.
(3) Connect the harness connector of air cleaner.
Check the turbocharger air intake hose connector

for leakage after installation.

operations.
Fig. 5-5-16.
(2) Start the engine and check the working condition of
exhaust system.
storage battery

245
Section VI Cylinder Cover
Removal procedure
① Injector harness connector
② Fuel return hose component
③ Fuel inlet pipe of fuel injector
④ Crankcase vent hose
subassembly
⑤ Water outlet pipe connecting
pipe component
⑥ Vacuum control valve (VGT
turbocharger)
⑦ Water return pipe
component of heater
⑧ Camshaft position
sensor
⑨ Oil filler cover
⑩ Cylinder cover
○11 Cylinder cover packing
Install them in the
opposite order of
removal.
Fig. 5-6-1 Installation and removal procedures of cylinder cover

Removal
Removal preparation
(1) Remove the earthing cable of storage battery. See
Fig. 5-6-2.
(2) Drain out the coolant from the engine and the
radiator.
Warning: The coolant is poisonous, thus must be

stored in the original container to avoid the direct touch
from human.

storage battery Removing the injector harness connector ①
Pull out the harness connector self-locking device, and
Fuel inlet pipe then remove the fuel injector harness connector.
of injector
Fuel inlet Removing the fuel return hose component ②

pipe of fuel
rail (1) Remove the fuel return hose bracket and clamp.
return hoses connected with fuel injector, and then take
off the fuel return hose component. See Fig. 5-6-3.
Fuel
Fuel return hose injector (3) Use the BOSCH or XINFENG fuel injector. Use a
component tool to push out the clip, pull out the fuel return
connector from the fuel injection circuit, and then
Fig. 5-6-3 Removing the fuel inlet pipe and remove fuel return hose component.
Removing the fuel inlet pipe of fuel injector ③

(1) Remove the connectors connecting the 4 injector
fuel inlet pipes and fuel injector. See Fig. 5-6-3.
(2) Loosen the pipe connector connecting the fuel inlet
Crankcase pipe of fuel injector and high-pressure fuel rail but don’t
vent hose remove the pipe connector.
Attention:
Cylinder cover
(1) When loosening the fuel inlet pipe of fuel injector,
loosen evenly and simultaneously the connectors at
both ends of the fuel pipe.
Fig. 5-6-4 Removing the crankcase vent hose (2) After removing the fuel inlet pipe of fuel injector, use
subassembly clean plug covers to block the fuel inlet and fuel inlet
pipe port of fuel injector.

247
Removing the crankcase vent hose subassembly ④

Water outlet
Cylinder cover pipe connecting (1) Remove the single-ear stepless clip fastening the
pipe component connection between crankcase vent hose subassembly
and forced-draught pipe.
(2) Remove the crankcase vent hose subassembly
from the cylinder cover. See Fig. 5-6-4.
Removing the water outlet pipe connecting pipe
component ⑤
Cylinder cover
packing
(1) Pull out the vacuum connecting pipe from vacuum
control valve.
Fig. 5-6-5 Removing the connecting pipe (2) Remove 2 hexagon flange bolts (M8×16) fixing the
component of water pipe ⑤ connecting water outlet pipe, and take off the
connecting water outlet pipe from the cylinder cover.
See Fig. 5-6-5.
Vacuum Removing the vacuum control valve (VGT

control valve turbocharger) ⑥
Connecting (1) Remove the 2 hexagon flange bolts (M6×16)
rubber hose fastening vacuum control valve and pull out the 2
connecting rubber hoses. See Fig. 5-6-6.
fastening the vacuum control valve bracket component,
Connecting
and then remove the vacuum control valve bracket
rubber hose component.
Bracket
component Attention: Only the engine with VGT turbocharger
is equipped with the vacuum control valve.
Fig. 5-6-6 Removing the vacuum control valve
(VGT turbocharger)
Removing the heater water return pipe component
⑦
(1) Remove 1 hexagon flange bolt (M6×16) connecting
the heater water return pipe component to the cylinder
(2) Take off the heater water return pipe component
Water return pipe from the cylinder head.
component of
heater
Removing the camshaft position sensor ⑧
(1) Pull out the camshaft position sensor harness
connector.
Fig. 5-6-7 Removing the heater water return
pipe component (2) Remove 1 hexagon flange bolt (M6×12) fastening
the camshaft position sensor. See Fig. 5-6-8.
(3) Remove the camshaft position sensor from the
cylinder cover.

Removing the oil filler cover ⑨

Camshaft Cylinder cover
position sensor Remove the oil filler cover from the oil filler screw hole
of cylinder cover. See Fig. 5-6-8.
Remove the cylinder cover ⑩

fastening the cylinder cover to cylinder head.
Cylinder head (2) Remove the cylinder cover from the cylinder head.
See Fig. 5-6-9.
Fig. 5-6-8 Removing the camshaft position

Remove the cylinder cover packing○
11
sensor
(1) Take out the packing from the sealing groove of
Oil filler cover cylinder cover. See Fig. 5-6-9.
Check the cylinder cover packing and replace it if there
Cylinder cover is any damage or deformation.
Installation
Installing the cylinder cover packing
Packing
(1) Check whether the cylinder cover packing is in good
condition.
(2) Clean the cylinder cover packing groove.
Fig. 5-6-9 Installing and removing the cylinder (3) Install the cylinder cover packing into the cylinder
cover and packing cover packing groove and make sure the rubber strip is
set in position. See Fig. 5-6-9.
Cylinder cover Installing the cylinder cover ⑩

Install the cylinder cover assembly to the top of cylinder
head and tighten the 6 hexagon flange bolts (M6×20) to
the cylinder head according to the specified torque and
sequence. See Fig. 5-6-9 and 5-6-10.

cover
9N·m±3N·m
Oil filler cover
Removing the oil filler cover ⑨

Fig. 5-6-10 Tightening sequence of cylinder
cover bolt Install the oil filler cover to the oil filler screw hole of
cylinder cover and tighten it. See Fig. 5-6-10.
Installing the camshaft position sensor ⑧

(1) Check whether the O-ring on camshaft position
sensor is in good condition.

249
(2) Install the camshaft position sensor to cylinder cover

Camshaft Cylinder cover and tighten the 2 hexagon flange bolts (M6×12) to the
position sensor specified torque. Make sure the sensor installing
surface fits well with the cylinder cover installing surface
after installation. See Fig. 5-6-11.
Tightening torque for the fastening bolt of

camshaft position sensor
9N·m±3N·m
Cylinder head
(3) Connect the camshaft position sensor harness
connector.
Fig. 5-6-11 Installing the camshaft position
sensor Installing the heater water return pipe component
⑦
vacuum control valve bracket and tighten the 2
hexagon flange bolts (M6×16) at the heater water return
pipe and cylinder cover according to the specified
torque.
Water return pipe
component of Tightening torque for fastening bolt of vacuum
heater pump control valve bracket
9N·m±3N·m
Fig. 5-6-12 Installing the heater water return (2) Tighten a hexagon flange bolt (M8×16) connecting
pipe component the heater water return pipe to the cylinder head
Vacuum
control valve
Tightening torque for fastening bolt of heater water
Connecting
rubber hose
M8×16 23N·m±3N·m
Connecting Installing the vacuum control valve (VGT

rubber hose
turbocharger) ⑥
Bracket
component (1) Installing the vacuum control valve and tighten the 2
hexagon flange bolts (M6×16). See Fig. 5-6-13.
Fig. 5-6-13 Installing the vacuum control valve
Tightening torque for fastening bolt of vacuum
control valve
9N·m±3N·m
(3) Install the 2 connecting rubber hose to the vacuum
control valve. See Fig. 5-6-13.

Installing the water outlet pipe connecting pipe

Water outlet pipe
connecting pipe
component ⑤
component (1) Install the connecting pipe component of water
outlet pipe to the cylinder head and tighten the 2
hexagon flange bolts (M8×16) according to the
Tightening torque for the fastening bolt of water

Cylinder cover outlet pipe connecting pipe
23N·m±3N·m
(2) Connect the vacuum connecting pipe.
Fig. 5-6-14 Installing the water outlet pipe
connecting pipe component ⑤
Installing the crankcase vent hose subassembly ④
Install the crankcase vent hose subassembly, tighten
the single-ear stepless clip fastening the crankcase
vent hose subassembly and forced-draught pipe. See
Fig. 5-6-15.
Crankcase
vent hose
Installing the fuel inlet pipe of fuel injector ③
(1) Remove the dust boot at both ends of the fuel inlet
Cylinder cover pipe of fuel injector.
(2) Install the fuel inlet pipe of fuel injector and tighten
evenly the pipe connector at both ends of the 4 fuel inlet
pipes of fuel injector. See Fig. 5-6-16.
Fig. 5-6-15 Installing the crankcase vent hose
subassembly
Make sure the fuel inlet pipe of fuel injector is
Fuel return hose
component Tightening torque for fuel inlet pipe connector of
Fuel inlet pipe
of injector fuel injector
32N·m±3N·m
Attention: When tightening the fuel inlet pipe

connector, make sure to tighten evenly and
simultaneously the both ends of fuel pipe to avoid
deformation and damage.

fuel return hose components of the fuel Installing the fuel return hose component ②
injector (1) In case of DELPHI fuel injector, insert respectively
the fuel return rubber hoses into 4 injector heads and
(2) In case of BOSCH or XINFENG fuel injector, install
4 short connectors of the fuel return hose in 4 holes at
the upper end of the fuel injector, and tighten them with
the spring clips. Install the other long connector to the

251
fuel return tee on the high pressure pump, and tighten it

with a single-ear stepless clip.
(3) Installing the fuel return hose support and clamps.
After installation, make sure the fuel return hose is

sealed so strictly that no fuel will leaks from it.
Installing the injector harness connector ①
Plug the fuel injector harness connector on engine
harness to the 4 fuel injectors respectively. See Fig.
5-6-17.
Fig. 5-6-17 Installing the fuel injector harness Attention: Don’t plug it into the wrong position.
connector
operations.
(2) Fill the engine cooling system with coolant.
make sure the cylinder cover is sealed properly.

Section VII Camshaft
Removal procedure
② Timing system
⑤ Water outlet pipe connecting pipe component
⑥ Heater water return pipe component
⑦ Cylinder cover assembly
⑧ Fuel injector assembly
⑨ Camshaft bearing cap Installation procedure
⑩ Intake/exhaust camshaft assembly Install them in the opposite order of removal.
Fig. 5-7-1 Installation and removal procedures of camshaft

253
Removal
Preparation
Rotary
installation (2) Drain out the coolant from the engine and the
position of Generator radiator.
tension belt
pulley
from human.
Removing the engine accessories ①
Fig. 5-7-2 Removing the engine accessories (1) Remove the generator belt
Turn the tension pulley with tools until the belt is loose
enough, and then remove the generator belt.
(2) Removing the wedge idle wheel assembly
then remove the wedge idle wheel assembly. See Fig.
5-7-2.
Removing the timing system ②
(2) Remove the tension pulley assembly. See Fig.
5-7-3.
Fuel return hose
Fuel inlet component Removing the fuel inlet pipe component of fuel
pipe of injector ③
injector
(1) Loosen evenly the pipe connectors fastening the 4
fuel injector fuel inlet pipes with spanner.
Attention:
Fig. 5-7-4 Removing the fuel inlet pipe and injector, loosen the pipe connectors at both ends of the
fuel return hose components of the fuel fuel pipe simultaneously and evenly to prevent the fuel
injector pipe from deforming.
——After removing the fuel inlet pipe of the fuel injector,
use clean 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.

Removing the fuel return hose component ④

Water outlet pipe
connecting pipe (1) Remove the fuel return hose bracket and clamp.
component
(2) Use the DELPHI fuel injector. Uninstall respectively
the 4 fuel return hoses connecting to the fuel injector,
and take off the components of fuel return hoses. See
Fig. 5-7-4.
Cylinder cover tool to push out the clip, pull out the fuel return
remove fuel return hose component.
Fig. 5-7-5 Removing the water outlet pipe component ⑤
connecting pipe component
(1) Uninstall the vacuum connecting pipe.
(2) Remove 2 hexagon flange face bolts (M8×16) fixing
the connecting water outlet pipe, and take off the
See Fig. 5-7-5.

⑥
the cylinder cover.
(2) Remove the 1 hexagon flange face bolt (M6×16)
the cylinder cover. See Fig. 5-7-6.
from the cylinder head.
Fig. 5-7-6 Removing the heater water return Removing the cylinder cover assembly ⑦
pipe component
fastening the cylinder cover to the cylinder head, and
take off the cylinder cover. See Fig. 5-7-7.
Cylinder cover
cylinder cover.
Check the cylinder cover packing. It must be

replaced if worn or deformed.
Packing
Removing the fuel injector assembly ⑧
(1) Remove the fuel injector harness plug: pull out the
Fig. 5-7-7 Removing the cylinder cover fuel injector harness plug.
assembly

255
See Fig. 5-7-8.

mounting hole of fuel injector on the cylinder head.
(5) Remove the bolts of fuel injector ballast bolts.

Fuel injector according to the cylinder sequence numbers 1, 2, 3 and
assembly 4, and make the corresponding marks to these fuel
injectors. Protect them from greasy dirt or being
bumped.
Fig. 5-7-8 Removing the fuel injector
assembly
Removing the camshaft bearing cap ⑨
(1) Remove a hexagon flange face bolt (M6×20)
Camshaft
bearing connecting the vacuum pump to the camshaft bearing
cap cap.
(2) Remove the 22 hexagon flange face bolts (M6×35
and M6×20) fastening the camshaft bearing cap and
cylinder head symmetrically from the both sides of
camshaft bearing cap to the center. See Fig. 5-7-9.
head.
Cylinder head
Removing the intake/exhaust camshaft assembly ⑩

cap (1) Remove the intake/exhaust camshaft assembly from
the cylinder head. See Fig. 5-7-10.
(2) Remove the plug cover and the camshaft front oil
seal from the cylinder head.
Installation
Camshaft
Installing the intake/exhaust camshaft assembly ⑩
(1) Apply a small amount of lubricating oil to the surface
of the camshaft journal and inside the bearing holes of
the intake and exhaust camshafts in the cylinder head.

(2) Install the intake and exhaust camshafts into the
Cylinder head
(3) Align the marks “·∙” on the drive gears of the intake
Fig. 5-7-10 Removing the intake/exhaust and exhaust camshafts, and make these marks flush
camshaft assembly with the upper plane.
(4) Install the camshaft front oil seal and plug cover to
the corresponding position, and make sure the oil seal
and plug cover are properly installed without tilting.

Standard axial clearance of camshaft

Camshaft 0.060~0.115mm
bearing cap
Installing the camshaft bearing cap ⑨

(1) Apply the anaerobic plane sealant to the junction
cylinder head.

Cylinder head
Attention:
——The sealant on the junction surface between
cap
camshaft bearing cap and cylinder head should be
cleared properly if the old cylinder head is to be used.
——The removal and installation of bolts after sale
should not be applied more than two times; replace
them when it exceeds two times.
(2) Tightly screw the 16 hexagon flange face bolts
(M6×35) of the camshaft bearing cap according to
specified torques and sequence, and then screw down
the 6 hexagon flange face bolts (M6×20) around them
Fuel injector
assembly Tightening torque for the fastening bolt of camshaft
bearing cap
Fig. 5-7-12 Installing the fuel injector 9N·m±3N·m
assembly
Attention: Prevent oil seal and plug cover from

tilting when screwing down the fastening bolts of
camshaft bearing cap.
(3) Tighten the hexagon flange face bolt (M6×20)
connecting the vacuum pump and the camshaft bearing
cap according to specified torque.

Sectional view 9N·m±3N·m
of cylinder cover
Fig. 5-7-13 Installing the fuel injector Installing the fuel injector assembly ⑧
assembly (1) Tighten the support bolts of the fuel injector ballast
by the required torques onto the cylinder head.

ballast
23N·m±3N·m

257

Cylinder cover
See Fig. 5-7-12.
injectors, install the fuel injectors to the corresponding
fuel injector mounting holes in the cylinder heads 1, 2, 3
and 4. See Fig. 5-7-13.
Packing
groove.
(5) Install and tighten the fastening bolt components of
Fig. 5-7-14 Installing the cylinder cover fuel injector ballast with the required torques. No air
assembly leakage is allowed at the injector gasket.

25N·m~35N·m
Installing the cylinder cover assembly ⑦

condition, and embed it into the sealing groove of the
cylinder cover. See Fig. 5-7-14.
(2) Install the cylinder cover to the cylinder head; tighten
Fig. 5-7-15 Installing the heater water return 16 hexagon flange face bolts (M6×20) of the fastening
pipe component cylinder cover to the cylinder head as per specified
Water outlet pipe
connecting Tightening torque for fastening bolt of cylinder
component cover
9N·m±3N·m
Installing the heater water return pipe component ⑥

Cylinder cover (1) Install the heater water return pipe component.
Tighten the 2 hexagon flange face bolts (M6×16)
connecting the heater water return pipe to the cylinder
Fig. 5-7-16 Installing the water pipe (2) Tighten the hexagon flange face bolt (M8×16)
connecting component connecting the heater water return pipe and cylinder

M6×16 9N·m±3N·m

M8×16 23N·m±3N·m
Fuel return hose
Fuel inlet pipe component Installing the water outlet pipe connecting pipe
of injector component ⑤
component; tighten the two hexagon flange face bolts
(M8×16) to the cylinder cover as per specified torque.
See Fig. 5-7-16.

outlet pipe connecting pipe
23N·m±3N·m
return hose of fuel injector (2) Connect the vacuum connecting pipe.
Installing the fuel return hose component ④
(1) Use the DELPHI fuel injector. Insert respectively the
fuel return rubber hoses into 4 injector heads and
(2) Use the BOSCH or XINFENG fuel injector. Remove

Install 4 short connectors of the fuel return hose in 4
Timing mark holes at the upper end of the fuel injector, and fix them
tight with the spring clips. Install the other long
pump, and fix it tight with a single-ear stepless clip.
Bone-line
Camshaft
timing pulley After installation, make sure the fuel return hose is
sealed so strictly that no fuel will leak from it.
Fig. 5-7-18 Installing the camshaft timing Installing the fuel inlet pipe of fuel injector ③
pulley
(1) Remove the plug covers at both ends of the fuel
injector.
Timing mark of damping pulley
(2) Install the fuel inlet pipe of fuel injector; tighten
evenly the pipe connectors at both ends of the 4 fuel
injector fuel inlet pipes as shown in Fig. 5-7-17.

fuel injector
32N·m±3N·m
Damping pulley Timing mark of timing
hood component II
Attention: When tightening the fuel inlet pipe of the
fuel injector, tighten the pipe connectors at both ends of
the fuel pipe simultaneously and evenly to prevent the

259
fuel pipe from deforming and being damaged.

Horizontal Timing Fuel pump pulley
mark Installing the timing system ②
bar
deflection.
junction seam (on the exhaust side) which is between
Fig. 5-7-20 Installing the timing system Fig. 5-7-18.

Timing pulley 110N·m±5N·m

Timing
tension (4) Align the timing mark on the fuel pump pulley to the
pulley horizontal bar on the water pump housing. See Fig.
5-7-20.
Fig. 5-7-21 Installing the timing pulley connected with the pulley firmly without any looseness.
See Fig. 5-7-21.
After removing the hexagon socket head spanner, the
mounting dowel pin of camshaft pulley and the
crankshaft locking tooling, turn the camshaft for two
circles clockwise with a spanner to make sure that the
pulley center the corresponding installation timing
marks and the belts mesh perfectly. If there is any pulley
that is not aligned properly, loosen the fasting bolt of
timing pulley and install them again to align the pulley
properly. So that one cylinder is just at the top dead
center of the compression stroke, and the valve timing
is accurate. See Fig. 5-7-22.

Attention: If the pulley mark is not aligned, it is

required to turn the vehicle or not to turn the vehicle
anticlockwise when inspecting. See Fig. 5-7-21.

22N·m~26N·m
Use a hexagon
socket spanner to
adjust the
mounting hole. Arm indicator Notch (7) Install the timing hood and timing hood component I,
screw down 10 hexagon flange face bolts (M6×16,
Fig. 5-7-22 Installing the timing tension pulley and cylinder body as per the specified torque. See Fig.
5-7-23.

45N·m±3N·m

component I
9N·m±3N·m

Fig. 5-7-23 Installing the timing hood (1) Reinstall the wedge idle wheel and tighten it
component according to the required torque.
Visually checked, the pulleys should be on the

same plane.
Rotary
installation Tightening torque for wedge idle wheel
position of
tension pulley
Generator 22N·m~26N·m
belt
After the installation, check the generator belt.

Make sure the belt wedge-shaped teeth perfectly
Fig. 5-7-24 Installing the engine accessories matches the pulley wedge slots.

operations:

261
Fig. 5-7-25.
(4) Start the engine and check the working condition of
the engine. The valve timing mechanism should be in
perfect operation.

storage battery

Section VIII Rocker Arms and Hydraulic Clearance Adjusters
Removal procedure
② Timing system
pipe component
⑥ Heater water return pipe ⑨ Camshaft bearing cap
component ⑩ Intake/exhaust camshaft assembly
⑦ Cylinder cover assembly 11 Rocker arm and hydraulic
○ Installation procedure
⑧ Fuel injector assembly clearance adjuster Install them in the opposite order of removal.
Fig. 5-8-1 Installation and removal procedures of rocker arm and hydraulic clearance adjuster

263
Removal
Preparation
(1) Remove the earthing cable of storage battery.
(2) Drain out the coolant from the engine and the
radiator.

from human.

(1) Remove the generator belt
(2) Removing the wedge idle wheel assembly
5-8-2.

Fig. 5-8-3 Removing the timing system hood. See Fig. 5-8-3.
(2) Remove the timing tension pulley assembly.
Fuel return hose (3) Remove the timing belt.
Fuel inlet pipe component
(4) Remove the camshaft timing pulley. See Fig. 5-8-3.
of injector

(1) Loosen evenly the pipe connectors fastening both
ends of the 4 fuel injectors with spanner.
Fuel inlet pipe of
fuel rail
Fig. 5-8-4 Removing the fuel inlet pipe and Attention:

fuel return hose component of the fuel injector
injector, loosen the pipe connectors at both ends of the
fuel pipe simultaneously and evenly to prevent the fuel
pipe from deforming.
——After removing the fuel inlet pipe of the fuel injector,
use clean 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.

Fig. 5-8-4.
Fig. 5-8-5 Removing the heater water return Removing the water outlet pipe connecting pipe
pipe component component ⑤
the connecting water outlet pipe, and take off the
See Fig. 5-8-6.

Water outlet ⑥
pipe connecting
Cylinder cover pipe (1) Remove the 2 hexagon flange face bolts (M6×16)
component connecting the heater water return pipe component to
the cylinder cover.
Cylinder cover (3) Take off the heater water return pipe component
packing from the cylinder head.
Removing the cylinder cover assembly ⑦
Fig. 5-8-6 Removing the cylinder cover (1) Remove the 16 hexagon flange face bolts (M6×20)
assembly fastening the cylinder cover to the cylinder head, and
cylinder cover.

Fuel injector harness plug self-locking device, and then remove the
assembly fuel injector harness plug.
Fig. 5-8-7 Removing the fuel injector See Fig. 5-8-7.
assembly (3) Remove the fuel injector ballast

265

Camshaft
bearing (5) Remove the bolts of fuel injector ballast bolts.
cap
according to the cylinder sequence numbers 1, 2, 3 and
4, and make the corresponding marks to these fuel
bumped.
Cylinder head (1) Remove a hexagon flange face bolt (M6×20)
connecting the vacuum pump to the camshaft bearing
cap.
Fig. 5-8-8 Removing the camshaft bearing (2) Remove the 22 hexagon flange face bolts (M6×35
cap and the camshaft and M6×20) on the camshaft bearing cap; loosen the
camshaft bearing cap symmetrically from the both sides
of camshaft bearing cap to the center. See Fig. 5-8-8.
head.
(1) Take the intake/exhaust camshaft assembly out of
(2) Remove the blank cover and the camshaft front oil
Removing the rocker arm and hydraulic clearance
Fig. 5-8-9 Removing the hydraulic clearance adjuster ○
11
adjuster and rocker arm Take 16 hydraulic clearance adjusters and 16 rocker
arms respectively out of the corresponding holes on the
Prompt: Mark the removed rocker arms and hydraulic
clearance adjusters and put them in proper order so as
to carry out the installation in original order.
Installation
Lubrication
Installing the rocker arm and hydraulic clearance
adjuster ○11
(1) Lubricate the ball head of the hydraulic clearance

adjuster with lubricating oil of proper amount, and then
embed it into the clip at the rear end of the rocker arm.
See Fig. 5-8-10.
Hydraulic clearance (2) Lubricate the surfaces of the rocker arm and the
adjuster hydraulic clearance adjuster with lubricating oil again,
adjuster and rocker arm


Camshaft (1) Apply a small amount of lubricating oil to the surface

Cylinder head
(3) Align the marks “·” on the drive gears of the intake
and exhaust camshafts, and make these marks flush
with the upper plane.
Fig. 5-8-11 Installing the exhaust/intake Axial clearance of camshaft
camshaft
Camshaft
bearing cap
(1) Apply the anaerobic plane sealant to the junction
Apply the surface between the camshaft bearing cap and the
sealant cylinder head. See Fig. 5-8-12.

Prompt: If the original cylinder head is still used, the
junction surface between the camshaft bearing cap and
Cylinder head the cylinder head should be cleaned before being
spread with sealant.
(2) When installing the camshaft bearing cap, screw
Fig. 5-8-12 Installing the camshaft bearing down 16 hexagon flange face bolts (M6×35) of
cap and applying sealant camshaft bearing cap as per specified torque and order,
then tighten the surrounding 6 hexagon flange face
bolts (M6×20). See Fig. 5-8-13.
Camshaft
bearing
cap Tightening torque for the fastening bolt of camshaft
bearing cap
9N·m±3N·m
to the front oil seal lip and cylindrical surfaces of both
Cylinder head
front oil seal and camshaft plug cover. Use the special
tool to install the front oil seal and plug cover to the
corresponding holes properly without any oil leakage.
Fig. 5-8-13 Installation for camshaft bearing
cap Mobil API CI-4 lubricating oil.
(4) Install the vacuum pump. Tighten the hexagon
flange face bolt (M6×20) connecting the vacuum pump
and the camshaft bearing cap as per specified torque.

9N·m±3N·m

267
Installing the fuel injector assembly ⑧

(1) Tighten the support bolts of the fuel injector ballast
by the required torques onto the cylinder head.

ballast
23N·m±3N·m
Fuel injector injector and make sure there is only one copper washer
assembly
See Fig. 5-8-14.
Fig. 5-8-14 Installing the fuel injector (3) According to the numbers 1, 2, 3 and 4 on the fuel
assembly injectors, install the fuel injectors to the corresponding
and 4. See Fig. 5-8-15.
groove.
fuel injector ballast by the required torques.

Sectional view fuel injector ballast
of cylinder
cover 25N·m~35N·m
Fig. 5-8-15 Installing the fuel injector No air leakage is allowed at the injector gasket after
assembly installation.
Cylinder cover (1) Clean the inside of the sealing groove of the cylinder
cover.
(2) Embed the cylinder cover packing into the sealing
groove of the cylinder cover. See Fig. 5-8-16.
(3) Install the cylinder cover to the cylinder head; tighten
16 hexagon flange face bolts (M6×20) of the fastening
Packing cylinder cover to the cylinder head as per specified

Fig. 5-8-16 Installing the cylinder cover cover
assembly
9N·m±3N·m

(1) Install the heater water return pipe component.


(2) Tighten a hexagon flange face bolt (M8×16)
connecting the heater water pipe as per the specified
torque to the cylinder head. See Fig. 5-8-17.

M6×16 9N·m±3N·m
M8×16 23N·m±3N·m

pipe component
Installing the water outlet pipe connecting pipe

Water outlet pipe component ⑤
connecting pipe
component (1) Install the water outlet pipe connecting pipe
(M8×16) fastening two single ear clips to cylinder cover
as per specified torque. See Fig. 5-8-18.

Cylinder cover outlet pipe connecting pipe
23N·m±3N·m
Fuel return hose fuel return rubber hoses into 4 injector heads and
component position them in place. See Fig. 5-8-19.
holes at the upper end of the fuel injector, and fix them
Fig. 5-8-19 Installing the components of fuel After the installation, make sure the components of
return hose fuel return hose is sealed so strictly that no fuel will leak
from the fuel return hose.

269

(1) Remove the plug covers at both ends of the fuel
injector.
Fuel inlet pipe
of injector
High-pressure
fuel rail
fuel injector
Fig. 5-8-20 Installing the fuel inlet pipe of the
fuel injector 32N·m±3N·m
Attention: Make sure to evenly tighten the two

ends of the fuel injector fuel inlet pipe connectors at the
Timing mark same time in installation so as to avoid the oil pipe
deformation.
Bone-line
Installing the timing system ②
Camshaft
timing pulley install the timing pulley to the exhaust camshaft and
deflection.
pulley

Timing mark of damping pulley
Fig. 5-8-21.

110N·m±5N·m
Damping pulley Timing mark of timing
hood component II

Fig. 5-8-22 Installing the timing system hood II. See Fig. 5-8-22.

(4) Align the timing mark on the fuel pump pulley to the
Timing horizontal bar on the water pump housing. See Fig.
Horizontal Fuel pump pulley
mark 5-8-23.
bar

See Fig. 5-8-24.
Timing pulley
Timing use a hexagon socket head spanner to turn the
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
Fig. 5-8-24 Installing the timing pulley mounting dowel pin of camshaft pulley and the
Use a hexagon is accurate. See Fig. 5-8-25.
socket spanner
to adjust the Arm indicator Notch
mounting hole. Attention: If the pulley mark is not aligned, it is
anticlockwise when inspecting. See Fig. 5-8-25.
22N·m~26N·m

271

and cylinder body upon the required torque. See Fig.
5-8-26.

45N·m±3N·m

component I
9N·m±3N·m
component
Rotary
installation Visually checked, the pulleys should be on the
position of
tension pulley Generator same plane.
belt
Tightening torque for wedge idle wheel
22N·m~26N·m
enough.
Make sure the belt wedge-shaped teeth perfectly match

operations:
Fig. 5-8-28.
Fig. 5-8-28 Installing the earthing cable of
storage battery (4) Start the engine and check the working condition of
the engine. The valve timing mechanism should be in
perfect operation.

Section IX Valve Oil Seal and Valve Spring
Removal procedure
② Timing system
③ Fuel inlet pipes of fuel injector
and fuel rail
12 Cylinder head assembly
○
13 Vacuum pump assembly
○
pipe component
14 Valve spring, valve
○
⑥ Heater water return pipe
15 Valve oil seal
○
component
⑦ Cylinder cover assembly
⑧ Fuel injector assembly
⑨ Camshaft bearing cap
⑩ Intake/exhaust camshaft assembly
removal.
11 Hydraulic clearance adjuster and rocker arm
○
Fig. 5-9-1 Installation and removal procedures of valve oil seal and valve spring

273
Removal
Preparation
Fig. 5-9-2.
(2) Discharge the coolant from engine and radiator.

from human.

storage battery (1) Remove the generator belt
(2) Remove the wedge idle wheel assembly
5-9-3.

(1) Remove the timing hood component 1 and timing
hood: unscrew 10 hexagon flange face bolts (M6 × 16,
M10 × 35 and M10 × 50) fastening the timing hood
Fig. 5-9-3 Removing the engine accessories component 1 and timing hood on the front end of the
engine, and take off the timing hood component 1 and
timing hood. See Fig. 5-9-4.
Removing the fuel inlet pipes of fuel injector and

fuel rail ③
ends of the fuel injector fuel inlet pipes with a spanner,
and take off the fuel inlet pipe of the fuel injector. See
Fig. 5-9-4 Removing the timing system Fig. 5-9-5.
ends of the fuel injector fuel inlet pipes with a spanner,
and take off the fuel inlet pipe of the fuel rail. See Fig.
5-9-5.
Attention:

——When removing the fuel inlet pipes of injector and

Fuel return hose rail, loosen evenly and simultaneously the connectors
Fuel inlet pipe component fastening both ends of the fuel pipe to avoid
of injector deformation of the pipe.
——After removing the fuel inlet pipes of fuel injector
and fuel rail, use clean plug covers to cover the fuel inlet
of fuel injection circuit, the fuel port of high-pressure fuel
rail and both ends of fuel inlet pipe of fuel injector to
prevent impurities from blocking the fuel injector.
Fuel inlet pipe of fuel rail

Fig. 5-9-5 Removing the fuel inlet pipe and (1) Remove the fuel return hose bracket and clamp.
Fig. 5-9-5.

component ⑤
the connecting water outlet pipe, and take off the water
outlet pipe connecting component. See Fig. 5-9-7.

⑥
Fig. 5-9-6 Removing heater water return pipe the cylinder cover.
component
(2) Remove 1 hexagon flange face bolt (M8×16)
Water outlet pipe
connecting pipe (3) Take off the heater water return pipe component
Cylinder cover component from the cylinder head.

Cylinder cover
packing (2) Take out the packing from the sealing groove of
cylinder cover.

275
Fig. 5-9-7 Removing the cylinder cover

assembly Check the cylinder cover packing. It must be
replaced if damaged or deformed.
See Fig. 5-9-8.
Fuel injector (4) Take out the fuel injector assembly from the
assembly
(5) Remove the support bolt for ballast of the fuel
Fig. 5-9-8 Removing the fuel injector injector.
assembly
Camshaft 4, and make the corresponding marks to these fuel
bearing cap injectors. Protect them from greasy dirt or being
bumped.
cylinder head symmetrically from the both sides of
Cylinder head (2) Remove a hexagon flange face bolt (M6×20)
connecting the vacuum pump and camshaft bearing
cap.
cap (3) Remove the camshaft bearing cap from cylinder
head.

Camshaft (1) Take the intake/exhaust camshaft assembly out of
(2) Remove the blank cover and the camshaft front oil
(3) Check the camshaft front oil seal. It must be
replaced if damaged or deformed.
Cylinder head Rocker arm and hydraulic clearance adjuster ○

11
(1) Take 16 hydraulic clearance adjusters and 16 rocker

Fig. 5-9-10 Removing the intake/exhaust arms respectively out of the corresponding holes on the
camshaft
(2) Mark the removed rocker arms and hydraulic

Removing the cylinder head assembly○

12
(1) Remove the clamp at the connecting joint of the

EGR condenser water outlet pipe and the EGR
condenser.
(2) Remove the clamp at the connection of the oil cooler
water inlet pipe and outlet pipe component.
vacuum pump.
Hydraulic clearance adjuster
(4) Remove the cylinder head assembly: loosen orderly
the 10 bolts (M11×1.5×162) for fastening cylinder head
and cylinder body. See Fig. 5-9-12.
Fig. 5-9-11 Removing the hydraulic clearance
(5) Take off the cylinder head and the cylinder head
adjuster and rocker arm
gasket from the cylinder body.
Warning: If the cylinder head bolts are not orderly

Cylinder head
bolt cylinder head might be damaged.
Check the cylinder head gasket. It must be

replaced if burned, deformed or lacking elasticity.
Removing the vacuum pump assembly ○

13
Cylinder head (1) Pull out the vacuum connecting hose from the
vacuum pump.
Fig. 5-9-12 Removing the cylinder head (2) Remove the 2 hexagon flange face bolts (M6×20)
assembly connecting the vacuum pump and cylinder head flange.
See Fig. 5-9-13.
(3) Remove the vacuum pump assembly from the rear
Cylinder head
Removing the valve spring and the valve ○

14
Vacuum pump (1) Compress the valve spring and remove the valve
assembly lock clamp with a special tool.
Valve spring compressor: 9-8523-1423-0.

(2) Take off the valve spring seat, the valve spring and
the valve.
assembly Prompt: Place the removed valves properly according
to the valve number.

277
Removing the valve oil seal ○

15
Valve lock clamp

Remove the valve oil seal with pliers or an oil seal
remover.
Valve spring seat
Caution: A removed oil seal can not be reused

Valve spring
otherwise, it may cause oil leakage.
Installation
Fig. 5-9-14 Removing and installing the valve, Installing the valve oil seal ○
15
spring and lock clamp
valve oil seal sealing surface.

(2) Push the valve oil seal into the valve pipe head with
a special tool.
Valve oil seal
Exhaust Inlet (3) Make pressure leakage test on the valve oil seal.
valve valve The specifications are as follows: under the pressure of
50~70 kPa, the amount of leaking gas should be no
more than 20 mL/min.
Fig. 5-9-15 Removing the valve oil seal Caution: A removed oil seal can not be reused. It
must be replaced with a new valve oil seal.
Removing the valve spring and the valve ○

14
(1) Apply oil on the outer diameter of the valve stem and
inside the valve pipe.

(2) Install the valve.
(3) Install the valve spring on the valve spring gasket.
(4) Instead of stuck on the cylindrical surface, the valve
Fig. 5-9-16 Installing the inlet/exhaust valve spring should be in contact with the bottom plane of the
component valve spring positioning cylinder.
(5) Compress the valve spring with a special tool so as
to push the valve lock clamp into the valve spring seat.
Valve spring compressor: 5-8523-1423-0.
Caution: The valve locking clamp should be firmly

installed.

Cylinder head Installing the vacuum pump assembly ○

13
(1) Install the vacuum pump at the rear end of the

cylinder head exhaust camshaft.
Vacuum pump connecting the vacuum pump and cylinder head flange.
assembly See Fig. 5-9-17.

installation.

assembly 9N·m±3N·m
Installing the cylinder head assembly ○

12
Cylinder head
gasket (1) Check for foreign materials on the joint surface of
the cylinder head and the cylinder body, and clean it
with silk.
(2) Insert the cylinder head dowel pin sleeve into the
assembled; fit the fixing hole sleeve for cylinder head
Cylinder body
gasket to the dowel pin of the cylinder body, and evenly
place the gasket to the cylinder body plane. See Fig.
5-9-18
Fig. 5-9-18 Installing the cylinder head gasket Make sure the cylinder head gasket is in the right
direction after installation.
Cylinder head (3) Fix the cylinder head to the cylinder body, align the
bolt 10 screw holes, and then fit and screw the 10 cylinder
head bolts (M11×1.5×162) according to specified
sequences and torques in three steps. See Fig. 5-9-19.

Cylinder head
50N·m±3N·m Turn it for 90° Turn it for
another 120°
Fig. 5-9-19 Installing the cylinder head and
tightening the bolts in order
Attention: Before the installation, check the
cylinder head bolts for any distortion, extension or
thread slipping. If necessary, replace them.

279
Lubrication

adjuster ○
11

embed it into the clip at the rear end of the rocker arm
and make sure it does not fall off.

adjuster and rocker arm (2) Lubricate the surfaces of the rocker arm and the
Camshaft hole, with the other side of the rocker arm overlapping

Cylinder head
Fig. 5-9-21 Installing the exhaust/intake (2) Install the intake and exhaust camshafts into the
camshaft cylinder head as shown in Fig. 5-9-21.
and exhaust camshafts, and make these marks flush
Camshaft
bearing cap (1) Apply the anaerobic plane sealant to the junction
Apply the cylinder head.
sealant
Attention: If the original cylinder head is used,

clean the joint surface of the camshaft bearing cap and
the cylinder head before applying the sealant.
Cylinder head
(2) When installing the camshaft bearing cap, screw
down 16 hexagon flange face bolts (M6×35) of
Fig. 5-9-22 Installing the camshaft bearing camshaft bearing cap as per specified torque and order,
cap and applying sealant then tighten the surrounding 6 hexagon flange face
bolts (M6×20) from the center to both sides. See Fig.
5-9-22.


Camshaft bearing cap
bearing cap
9N·m±3N·m
Cylinder head tool to install the front oil seal and plug cover to the
Fig. 5-9-23 Installing the camshaft bearing Mobil API CI-4 lubricating oil.
cap
(4) Tighten the hexagon flange face bolt (M6×20)
cap as per specified torque.

9N·m±3N·m

Fuel injector (1) Tighten the support bolts of the fuel injector ballast
assembly by the required torques onto the cylinder head.

Fig. 5-9-24 Installing the fuel injector ballast
assembly
23N·m±3N·m
See Fig. 5-9-24.
injectors, install the fuel injectors to the corresponding
and 4. See Fig. 5-9-25.
Sectional view of
cylinder cover
groove.
assembly (5) Install and tighten the fastening bolt components of
fuel injector ballast with the required torques. No air
leakage is allowed at the injector gasket.

25N·m~35N·m

281

Cylinder cover (1) Clean the inside of the sealing groove of the cylinder
cover.
condition.
(3) Embed the cylinder cover packing into the sealing
groove of the cylinder cover.
Packing (4) Install the cylinder cover to the cylinder head, tighten
6 hexagon flange face bolts (M6×20) fastening the
cylinder cover to the cylinder head as per specified
Fig. 5-9-26 Installing the cylinder cover
assembly Tightening torque for fastening bolt of cylinder
cover
9N·m±3N·m

cover.
pipe component
Water outlet pipe Tightening torque for fastening bolt of heater water
connecting pipe return pipe component
component
M6×16 9N·m±3N·m
M8×16 23N·m±3N·m
Cylinder cover Installing the water outlet pipe connecting pipe

component ⑤
Fig. 5-9-28 Installing the water outlet pipe (M8×16) to cylinder cover as per specified torque. See
connecting pipe component Fig. 5-9-28.

outlet pipe connecting pipe
23N·m±3N·m


Fuel return hose fuel return rubber hoses into 4 injector heads and
component position them in place. See Fig. 5-9-29.
(3) Install the fuel return hose support and clamps.
Fig. 5-9-29 Installing the components of fuel After the installation, make sure the components of
return hose fuel return hose is sealed so strictly that no fuel will leak

Fuel inlet pipe of (1) Install the fuel inlet pipe of injector; tighten evenly
injector
the pipe connectors at both ends of the fuel pipes as
Fuel inlet
pipe of fuel (2) Install the fuel inlet pipe of the fuel rail; tighten
rail evenly the pipe connectors at both ends of the fuel
pipes as shown in Fig. 5-9-30.
Make sure the fuel inlet pipes of fuel injector and

fuel rail are sealed without leakage after installation.

Fig. 5-9-30 Installing the fuel inlet pipes of fuel
fuel injector and fuel rail
injector and fuel rail
32N·m±3N·m

Timing mark ends of the fuel injector fuel inlet pipe connectors during
installation so as to avoid the oil pipe deformation.
Bone-line (1) Install the woodruff key to the exhaust camshaft,
Camshaft tighten the fastening bolt washer component to the
timing pulley required torque. The camshaft timing pulley should be
deflection.
Fig. 5-9-31 Installing the camshaft timing (2) Adjust the mark position of the scribed line on the
pulley camshaft timing pulley till this position aligns with the
Fig. 5-9-31.

283
Timing mark of damping Tightening torque for bolt washer component of

pulley
110N·m±5N·m
Timing mark of timing 5-8-23.
Damping pulley
hood component II
Fig. 5-9-32 Installing the timing system connected with the pulley firmly without any looseness.
See Fig. 5-9-34.
Horizontal Timing Fuel pump pulley (6) Install the timing tension pulley. Fix the limit bracket
bar mark of the timing tension pulley in the place where the bowl

Timing anticlockwise when inspecting. See Fig. 5-9-35.
pulley
22N·m~26N·m
Timing
tension (7) Install the timing hood and timing hood component I,
pulley
and cylinder body upon the required torque. See Fig.
5-9-36.
Fig. 5-9-34 Installing the timing pulley
45N·m±3N·m


component I
9N·m±3N·m
according to the required torque as shown in Fig.
Use a hexagon 5-9-37.
socket spanner
to adjust the Notch
Arm indicator
mounting hole Visually checked, the pulleys should be on the
same plane.
Tightening torque for the wedge idle wheel
22N·m~26N·m



Fig. 5-9-36 Installing the timing hood pulley is not allowed.
component

operations:
Rotary
installation (1) Install the harness connector and make sure it is
position of installed firmly to the right position.
tension pulley
Generator (2) Connect the earthing cable of storage battery.
belt
(4) Start the engine, check its working condition, and
check the cooling system for any leakage and the valve
mechanism for any abnormal operation.

285
Section X Cylinder Head Assembly and Cylinder Head Gasket
Removal procedure
② Timing system
③ Fuel inlet pipes of fuel injector
and fuel rail
⑤ Water outlet pipe connecting ○11 Hydraulic clearance adjuster
pipe component and rocker arm
⑥ Heater water return pipe 13 Cylinder head assembly
○
component 13 Vacuum pump assembly
○
⑦ Cylinder cover assembly 14 Cylinder head gasket
○
⑧ Fuel injector assembly Installation procedure
⑨ Camshaft bearing cap Install them in the opposite order of
⑩ Intake/exhaust camshaft removal.
Fig. 5-10-1 Removal and installation procedures for cylinder head assembly and cylinder head gasket

Removal
Preparation
Fig. 5-10-2.
(2) Discharge the coolant from engine and radiator.

from human.
Fig. 5-10-2 Removing the earthing cable of Removing the engine accessories ①
storage battery (1) Turn the tension pulley with tools until the belt is
loose enough, and then remove the generator belt.
(2) Loosen the fastening bolts of the wedge idle wheel,
and then remove the wedge idle wheel assembly. See
Fig. 5-10-3.

(1) Remove the timing hood component 1 and timing
hood: unscrew 10 hexagon flange face bolts (M6 × 16,
M10 × 35 and M10 × 50) fastening the timing hood
component 1 and timing hood on the front end of the
engine, and take off the timing hood component 1 and
timing hood. See Fig. 5-10-4.
Removing the fuel inlet pipes of fuel injector and

fuel rail ③
ends of the fuel injector fuel inlet pipes, and take off the
fuel inlet pipe of the fuel injector. See Fig. 5-10-5.
(2) Remove the pipe connectors at both ends of the
fastening fuel rail fuel inlet pipe, and take off the fuel
Fig. 5-10-4 Removing the timing system inlet pipe of the fuel rail.
Attention:
——When removing the fuel inlet pipes of injector and
rail, loosen evenly and simultaneously the connectors at
both ends of the fuel pipe to avoid deformation of the
pipe.

287
——After removing the fuel inlet pipes of fuel injector

Fuel return hose and fuel rail, use clean plug covers to cover the fuel inlet
component of fuel injection circuit, the fuel port of high-pressure fuel
Fuel inlet pipe
of injector rail and both ends of fuel inlet pipe of fuel injector to
prevent impurities from blocking the fuel injector.

Fig. 5-10-5 Removing the fuel inlet pipe and Fig. 5-10-5.
fuel return hose component of the fuel injector (3) Use the BOSCH or XINFENG fuel injector. Use a

component ⑤
the connecting water outlet pipe, and take off the water
outlet pipe connecting component. See Fig. 5-10-7.

⑥
Fig. 5-10-6 Removing the heater water return the cylinder cover.
pipe component
Water outlet pipe
connecting pipe
Cylinder cover component
from the cylinder head.

Cylinder cover
packing take off the cylinder cover. See Fig. 5-10-7.
Fig. 5-10-7 Removing the cylinder cover cylinder cover.
assembly


See Fig. 5-10-8.
Fuel injector mounting hole of fuel injector on the cylinder head.
assembly
(5) Remove the support bolt for ballast of the fuel
injector.
Fig. 5-10-8 Removing the fuel injector
assembly
4, and make the corresponding marks to these fuel
Camshaft
bearing cap
bumped.

Cylinder head cylinder head symmetrically from the both sides of
Fig. 5-10-9 Removing the camshaft bearing (2) Remove a hexagon flange face bolt (M6×20)
cap connecting the vacuum pump and camshaft bearing
cap.
Camshaft
head.
Removing the intake/exhaust camshaft assembly

Cylinder head ⑩
(1) Take the intake/exhaust camshaft assembly out of
Fig. 5-10-10 Removing the intake/exhaust the cylinder head. See Fig. 5-10-11.
camshaft (2) Remove the blank cover and the camshaft front oil
Check the front oil seal of camshaft and replace it if

it is damaged.

289

adjuster ○
11
(1) Take 16 hydraulic clearance adjusters and 16 rocker

arms respectively out of the corresponding holes on the
(2) Mark the removed rocker arms and hydraulic
Removing the cylinder head assembly ○

12
(1) Remove the clamp at the connection of the EGR

Fig. 5-10-11 Removing the hydraulic
condenser water outlet pipe and the EGR condenser.
clearance adjuster and rocker arm
(2) Remove the clamp at the connection of the oil cooler
water inlet pipe and outlet pipe component.
Cylinder head (3) Remove the cylinder head assembly: loosen orderly
bolt the 10 bolts (M11×1.5×162) for fastening cylinder head
and cylinder body. See Fig. 5-10-12.
Warning: if the cylinder head bolts are not orderly

Cylinder head
Removing the vacuum pump assembly ○
13

Fig. 5-10-12 Removing the cylinder head vacuum pump.
assembly
See Fig. 5-10-13.
Cylinder head
(3) Remove the vacuum pump assembly from the rear
Vacuum pump Removing the cylinder head gasket ○

14
assembly
(1) Take off the cylinder head gasket from the cylinder
body.
(2) Check the cylinder head gasket. It must be replaced
if burned, deformed or lacking elasticity.

assembly

Cylinder head Installation

gasket
Installing the cylinder head gasket ○
14
(1) Check for foreign materials on the joint surface of

the cylinder head and the cylinder body, and clean it
with silk.
(2) Install the cylinder head positioning pin into the
corresponding pin holes of the cylinder body with
Cylinder body special tool and make sure it is installed firmly to the
right place. See Fig. 5-10-14.
(3) Evenly place the cylinder head gasket on the
cylinder body plane.
gasket Make sure the cylinder head gasket is in the right
Cylinder head
Installing the vacuum pump assembly ○
13
(1) Install the vacuum pump at the rear end of the

cylinder head.
Vacuum pump
assembly
See Fig. 5-10-15.

installation.
assembly Tightening torque of vacuum pump fastening bolt
9N·m±3N·m
(3) Install the vacuum connecting hose.
Cylinder head
bolt
Installing the cylinder head assembly ○
12
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
and torques in three steps. See Fig. 5-10-16.
Cylinder head

tightening the bolts according to sequences
Turn it for
50N·m±3N·m Turn it for 90°
another 120°
Attention: Before the installation, check the


291
Lubrication Rocker arm and hydraulic clearance adjuster ○

11

embed it into the clip at the rear end of the rocker arm.
See Fig. 5-10-17.
(2) Lubricate the surfaces of the rocker arm and the
Hydraulic clearance adjuster and then insert the whole part into the corresponding
hole orderly, with the other side of the rocker arm
overlapping on the valve.
adjuster and rocker arm Mobil API CI-4 lubricating oil.

Camshaft

Cylinder head
and exhaust camshafts.
Fig. 5-10-18 Installing the exhaust/intake
camshaft Standard 0.060~0.115mm
Camshaft
bearing cap
Apply the
sealant (1) Apply the anaerobic plane sealant to the junction

Prompt: If the original cylinder head is still used, the
Cylinder head junction surface between the camshaft bearing cap and
the cylinder head should be cleaned before being
spread with sealant.
Fig. 5-10-19 Installing the camshaft bearing (2) When installing the camshaft bearing cap, screw
cap and applying sealant down 16 hexagon flange face bolts (M6×35) of
camshaft bearing cap as per specified torque and order,
bolts (M6×20) from the center to both sides. See Fig.
5-9-20.

bearing cap

9N·m±3N·m
Camshaft (3) Install the plug cover and the front oil seal of
bearing cap
tool to install the front oil seal and plug cover to the

Cylinder head (4) Tighten the hexagon flange face bolt (M6×20)
cap as per specified torque.
cap Tightening torque for vacuum pump fastening bolt
9N·m±3N·m

(1) Tighten the support bolts of the fuel injector ballast
as per the specified torques onto the cylinder head.

ballast
Fuel injector
assembly

injectors, insert the fuel injectors to the corresponding
Cylinder cover
and 4.
groove. See Fig. 5-10-21.
Packing
fuel injector ballast as per the specified torques.

Fig. 5-10-22 Installing the cylinder cover
assembly 25N·m~35N·m

(1) Clean the inside of the sealing groove of the cylinder
cover.

293
condition, and embed it into the sealing groove of the

cylinder cover.
(3) Install the cylinder cover to the cylinder head, tighten
6 hexagon flange face bolts (M6×20) fastening the
cylinder cover to the cylinder head as per specified

cover
9N·m±3N·m
Fig. 5-10-23 Installing the heater water return Installing the heater water return pipe component ⑥
pipe component
Water outlet pipe
connecting pipe connecting the heater water return pipe to the cylinder
component cover.

Cylinder cover return pipe component
M6×16 9N·m±3N·m
M8×16 23N·m±3N·m
Fuel return hose Installing the water outlet pipe connecting pipe
Fuel inlet pipe component component ⑤
of injector (1) Install the water outlet pipe connecting pipe
(M8×16) to cylinder cover as per specified torque. See
Fig. 5-10-24.

Fuel inlet pipe of fuel rail outlet pipe connecting pipe
23N·m±3N·m
Fig. 5-10-25 Installing the components of fuel (2) Connect the vacuum connecting pipe.
return hose

fuel return rubber hoses into 4 injector heads and


Fuel inlet pipe of the dust cap from the upper end of the fuel injector.
injector Install 4 short connectors of the fuel return hose in 4
Fuel inlet tight with the spring clips. Install the other long
pipe of fuel
rail
(3) Install the fuel return hose support and clamps.
After the installation, make sure the components of

Fuel return hose
component fuel return hose is sealed so strictly that no fuel will leak
Fig. 5-10-26 Installing the fuel inlet pipes of Fuel inlet pipes of fuel injector and fuel rail ③
Timing mark (2) Install the fuel inlet pipe of the fuel rail; tighten evenly
the pipe connectors at both ends of the fuel pipes.
Make sure the fuel inlet pipes of fuel injector and

Bone-line fuel rail are sealed without leakage after installation.
Camshaft Tightening torque for fuel inlet pipe connector of

timing pulley
32N·m±3N·m
pulley Attention: Make sure to evenly tighten the two
ends of the fuel injector and the fuel rail fuel inlet pipe
Timing mark of damping connectors during installation so as to avoid the oil pipe
pulley deformation.

Timing mark of timing pressed and installed to the right position without
Damping pulley
hood component II
deflection.
Fig. 5-10-28 Installing the timing system camshaft timing pulley till this position aligns with the
Fig. 5-10-27.

110N·m±5N·m

295

Horizontal Timing Fuel pump pulley hood II. See Fig. 5-10-28.
bar mark
5-10-29.
See Fig. 5-10-30.
Fig. 5-10-29 Installing the timing system use a hexagon socket head spanner to turn the

Timing anticlockwise when inspecting. See Fig. 5-10-31.
pulley
22N·m~26N·m
Timing
tension (7) Install the timing cover and timing cover component
pulley
I. Fix 10 hexagon flange face bolts (M6×16, M10×35
and M10×50) tight as per the specified torques to the
cylinder head in the front of the cylinder body. See Fig.
5-10-32.
M10 45N·m±3N·m

component I

M6 9N·m±3N·m

according to the required torque as shown in Fig.
5-10-33.
Use a hexagon
socket spanner
to adjust the Notch Visually checked, the pulleys should be on the
Arm indicator
mounting hole same plane.
Fig. 5-10-31 Installing the timing tension Tightening torque for wedge idle wheel
pulley
22N·m~26N·m
(2) Install the generator belt, use a tool to turn the

enough.

Make sure the belt wedge-shaped teeth perfectly
matches the pulley wedge slots.

component After the installation, please carry out the following
operations:
(4) Start the engine, check its working condition, and
check the cooling system for any leakage and the valve
mechanism for any abnormal operation.

297
Section XI Timing Pulley
Removal procedure
③ Timing system
removal.
Fig. 5-11-1 Removal and installation procedures of the timing pulley

Removal
Preparation
Remove the earthing cable of storage battery.
Removing the engine accessories①

(1) Remove the generator belt: rotate the tension pulley
with a tool to disassemble the generator belt after it is
loosened enough.
(2) Remove the tension pulley assembly. See Fig. 4-11-2.
Fig. 5-11-2 Removing the engine (3) Remove the accessory flat idle wheel assembly and
accessories accessory wedge idle wheel assembly.
Removing the damping pulley assembly②

fastening the damping pulley to the front end of the
end of crankshaft.
Removing the timing system③

(1) Remove the timing hood and the timing hood
componentsⅠandⅡfrom the front end of the engine;
Fig. 5-11-3 Removing the damping pulley remove the timing rear hood from the front end of the
assembly cylinder head. See Fig. 5-11-4.
(4) Remove the timing idle wheel assembly.
(6) Remove the timing pulley of crankshaft.
(7) Remove the fuel pump pulley.
Timing pulley of crankshaft Installation

Installing the timing system③
Fig. 5-11-4 Removing the timing system and (1) Install the timing pulley of crankshaft: fit the woodruff
timing hood key and the crankshaft timing pulley to the crankshaft,
and tighten the bolt of crankshaft timing pulley according
to specified torque. The crankshaft timing pulley should
be properly fitted. See Fig. 5-11-5.
Tightening torque of fastening bolt of crankshaft

timing pulley

299
185N·m~195N·m
Camshaft timing pulley
(2) Install the camshaft timing pulley: fit the woodruff key
and the camshaft timing pulley to the exhaust camshaft,
and tighten the bolt and gasket subassembly of the
camshaft timing pulley according to specified torque. The
camshaft timing pulley should be properly fitted without
any inclination. See Fig. 5-11-5.
Tightening torque for fastening bolt subassembly of

Timing belt the camshaft timing pulley
110N·m±5N·m

Attention: Use the cylindrical pin to fix the camshaft
timing pulley when tightening it.
(3) Install and tighten the timing idle wheel assembly with
specified torque.
Timing mark
Tightening torque of fastening bolt of timing idle
wheel
22N·m~26N·m
Bone-line
(4) Adjust the mark position on the camshaft timing belt
pulley so as to align it with the joint (on the exhaust side)
Camshaft
timing pulley
of the cylinder head and the camshaft bearing cap. See
Fig. 5-11-6.
(5) 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.
pulley
sure the belts, except the tension pulley, are connected
with the pulley firmly without any looseness.
(7) Install the timing tension pulley. Embed the limit
support of the timing tension pulley into the position for
adjusted by a socket head spanner so that its analog is
Use a hexagon aligned with the notch position (See Fig. 5-11-7)., screw
socket spanner to the tension pulley bolts with specified torques.
adjust the mounting
hole. Analog Notch
Tightening torque of fastening bolt of timing tension
pulley
pulley 22N·m~26N·m
(8) Install the timing hood components I and II, the timing
hood and the timing rear hood.
——Fit the rear timing hood components to the air intake
side of the cylinder head, and screw the hexagon flange
face bolt (M6×16) with the specified torque.

Tightening torque for fastening bolt of timing rear

hood component
9N·m±3N·m
Sealing strip -Embed the timing hood sealing strips ⅠandⅡ in the
sealing groove of the timing hoods ⅠandⅡ respectively.
See Fig. 5-11-8.
Sealing strip --After aligning the timing hood componentsⅠandⅡand
the timing hood with the mounting hole,screw down the
16 hexagon flange bolts(M6×6,M10×35,M10×50) to the
cylinder head and the front end of the cylinder body with
required torques.
component Tightening torques for fastening bolts of the timing
hood and the timing hoods I and II
Crankshaft
M6 9N·m±3N·m
M10 45N·m±3N·m
Installing the damping pulley assembly ②.
Timing pulley
(1) Install the elastic cylindrical pin into the pin hole of
crankshaft timing belt pulley.
damping pulley to the front end of crankshaft, and screw
Damping pulley
down 4 hexagon flange bolts (M8×20) as per specified
assembly Tightening torque of fastening bolt of damping pulley
23N·m±3N·m
Attention: The timing mark must face forwards after

the installation.

301
Installing the engine accessories①

(1) Install the flat idle wheel and the wedge idle wheel on
the water pump and the timing hood respectively, and
fasten them with bolts. See Fig. 5-11-10.
After the installation, the belt pulleys must be in the

same plane by visual check.
Tightening torques for the flat idle wheel and wedge

idle wheel
22N·m~26N·m
Fig. 5-11-10 Installing the engine

(2) After aligning the bolt hole and the limit boss of the
accessories
tension pulley with the mounting hole of the engine
bracket, tighten the tension pulley with fastening bolts.
Tightening torque for fastening bolt of tension pulley

Rotary
installation
53N·m~57N·m
position of
tension pulley Generator
belt
(3) Install the generator belt. During the installation, make
sure the pulleys, except the flat idle wheel, are exactly
installed. Make sure the belt wedge-shaped teeth
perfectly match the pulley wedge slot.
(4) Use a tool to turn the tension pulley until the generator
belt is loose enough, and insert the flat idle wheel into the
belt. See Fig. 5-11-11.
Fig. 5-11-11 Installing the generator belt
After the installation, check the generator belt for any

operations.
Fig. 5-11-12.
make sure the timing system is in normal operation.

storage battery

Section XII Oil Filter and Oil Cooler
Removal procedure
①Oil filter
② Water inlet pipe and water outlet pipe of cooler.
③ Pipe connector
④ Oil cooler
Fig. 5-12-1 Removal and installation procedures of the oil filter and oil cooler
Removal
Oil filter
Preparation
Oil cooler (2) Drain the cooling system of coolant.
(3)Place a container under the oil filter to connect the
overflowed lubricating oil.
Pipe connector
Warning: Risk of burn from the hot engine
oil.handle the used oil properly and protect the
environment.
Fig. 5-12-2 Removing the oil filter Removing the oil filter①
Take off the oil filter from the pipe connector with the
special tool. See Fig. 5-12-2
Spanner for the engine oil filter: 5-8840-0020-0.

303
Removing the water inlet pipe and water outlet pipe

of cooler②
(1) Loosen the 2 single-ear stepless clamps fastening
the water inlet pipe and water outlet pipe of oil cooler.
(2) Loosen the hexagon flange bolt (M8×12) fastening

the single pipe clamp, and remove the water inlet pipe
and water outlet pipe of oil cooler. See Fig. 5-12-3.
Removing the pipe connector③
Remove the pipe connector from the oil cooler. See Fig.
5-12-2.
Removing the oil cooler④
Remove the oil cooler from the seat of the oil cooler on
the cylinder body. See Fig. 5-12-4.
Installing the oil cooler④
Fig. 5-12-3 Removing the water inlet pipe and Check whether the seal ring of oil cooler is correctly
water outlet pipe of cooler placed. After aligning the positioning notch of the cooler
with the mounting mark on the cylinder body, install the
cooler on the seat of the oil filter on the cylinder body.
Oil cooler See Fig. 5-12-4.
Installing the pipe connector③
(1) Install the oil filter pipe connector into the mounting
hole of the oil cooler, and tighten it into the cylinder
body with specified torque. See Fig. 5-12-4.
Tightening torque for pipe connector of oil cooler.
(2) After the installation, the oil cooler should not loosen
Cylinder body and the sealing ring should not leak.
Installing the water inlet pipe and water outlet pipe
of cooler②
图 5-12-4 Fig. 5-12-4 Removing the oil cooler
(1) Install the water inlet pipe and water outlet pipe of
the cooler, and the 4 single-ear stepless clamps
fastening the water inlet pipe and water outlet pipe of
the oil cooler.
(2) Install the dual pipe clamp and the single pipe clamp
of the cooler water return pipe, and tighten the hexagon
flange bolt(M8×12) fastening the fixing single pipe
clamp .
Installing the oil filter①
(1) Check whether the seal ring of the oil filter is
correctly installed, and apply lubricating oil to the seal
ring.
Fig. 5-12-5 Installing the water inlet pipe and Mobil API CI– 4 lubricating oil.
water outlet pipe of oil cooler
(2) Tighten the filter to the pipe connector and turn 3/4
~1 round after the rubber ring of the oil filter touches the
oil cooler.

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

No oil leakage is allowed at the oil filter.
operations:
Fill coolant into the cooling system.
(3) Fill the lubricating oil in the lubrication system.
make sure the lubrication system is in normal
operation.
Fig. 5-12-6 Installing the oil filter

305
Section XIII Primary shaft front bearing of the flywheel and transmission
Removal procedure
① Transmission assembly
② Clutch assembly
③ Flywheel gear ring assembly
Fig. 5-13-1. Removal and installation procedures of primary shaft front bearing of the flywheel and
transmission
Transmission Removal
Preparation
Clutch assembly
Removing the transmission assembly ①

(1) Lift the vehicle and support it with a proper safety
rack.
(2) Remove the drive shaft at the flange yoke.
(3) Remove the rotation speed sensor connector.
Fig. 5-13-2 Removing the transmission
assembly (4) Remove the transmission assembly.

Attention: The rotation speed sensor installed on

the clutch is a plastic housing and should be protected
carefully.
Removing the clutch assembly ②
Attention: Any fluid should not be allowed to

remain on the surface of the clutch. If there is some
fluid, remove it.
(1) Remove the pressure plate assembly.
-{}-(2) Driven disc assembly.
(3) Use guide centering device to prevent the clutch
(4) Make a mark on the flanges of the flywheel and the
pressure plate to allow alignment during the installation.
Fig. 5-13-3 Removing the clutch assembly (5) Loosen the 9 bolts fastening the pressure plate in
proper order, and remove the clutch assembly. See Fig.
5-13-3.
(6) Remove the primary shaft front bearing of

transmission with the bearing remover and slide
hammer. See Fig. 5-13-4.
Front bearing remover: 5-8840-2000-0.
Slide hammer: 5-8840-0019-0.
Removing the flywheel gear ring assembly ③

Fig. 5-13-4 Removing the primary shaft front
bearing of transmission. (1) Install the flywheel retainer.
(2) Loosen the 8 bolts fastening the flywheel gear ring
assembly in two steps, according to the procedure
rear end of crankshaft.
Installation
Installing the flywheel gear ring assembly ③
(1) Installing the flywheel gear ring assembly to the rear
end of the crankshaft, and align with the mounting
Fig. 5-13-5 Removing the flywheel gear ring holes. See Fig. 5-13-6.
assembly (2) Apply the thread fixative to the flywheel bolt.
LOCTITE243 thread fixative.

(3) Tighten the 8 bolts fastening the flywheel gear ring

307
assembly in the specified order to the specified torque.

See Fig. 5-13-5 and Fig. 5-13-6.
Tightening torque for flywheel bolt

bearing
crankshaft
75N·m±5N·m
flywheel
Fig. 5-13-6 Installing the flywheel gear ring

assembly
(4) Installing the primary shaft front bearing of
transmission. Use the installer to Install the primary
shaft front bearing of transmission. See Fig. 5-13-7.
Installer of front bearing: 5-8522-0024-0.
Fig. 5-13-7 Installing the primary shaft front

bearing of transmission.
Installing the clutch assembly ②
(1) Driven disc assembly.
Grease the spline of the driven disc hub with
Install the clutch driven disc by guide centering device.
Fig. 5-13-8 Installing the clutch assembly

(2) Pressure plate assembly.

Tighten the 9 bolts fastening the clutch pressure plate
assembly to the specified torque, according to the
procedure shown in Fig. 5-13-9
Tightening torque for fastening bolt of clutch

pressure plate assembly.
23N·m±3N·m
Remove the guide centering device.
Attention: if a new pressure plate is installed, after

Fig. 5-13-9 Installing the clutch pressure plate tightening the fixing bolt of pressure plate to specified
assembly torque, make sure to remove the string for protecting
the diaphragm spring.
Transmission Installing the transmission assembly ①
Clutch assembly
(1) Fit the 2 transmission dowel pins into the rear end
face of the cylinder head by a special tool. There should
(2) Install the transmission assembly. Screw down the
fastening bolts connecting the transmission and the
clutch in proper order and as per specified torque.
(3) Install the drive shaft.

Fig. 5-13-10 Installing the transmission operations.
assembly
make sure the clutch and the transmission are in normal
operations.

309
Section XIV Oil pump assembly
Removal procedure
② Damping pulley
assembly
③ Timing system
④ Oil pan lower body
assembly
⑤ Oil pump assembly
Fig. 5-14-1 Removal and installation procedures of the oil pump assembly

Removal
Preparation
See Fig. 5-14-2.
(2) Lift the vehicle.
(3) Drain out the engine oil in the lubrication system of
the engine.

environment.
storage battery Tightening torque of oil drain screw plug
45N·m±5N·m
with a tool to disassemble the generator belt after it is
loosened enough.
wheel assembly.
(4) Remove the power steering pump assembly and the
steering pump bracket: loosen the 3 or 4 hexagon
flange bolts (M8×30) fastening the power steering pump
Fig. 5-14-3 Removing the engine accessories to the steering pump bracket, and take off the power
steering pump; loosen the 3 hexagon flange bolts
(M8×25 and M8×30) fastening the steering pump
bracket to the cylinder body and take off the steering
pump bracket.
(5) Remove the generator and the generator bracket:
loosen the 3 hexagon flange bolts (M8×30,M10×45)
fastening the generator to the generator bracket, and
take off the generator; loosen the 4 hexagon flange
bolts (M8×30,M8×35) fastening the generator bracket to
the cylinder body, and take off the generator bracket.
See Fig. 5-14-3.
Removing the damping pulley assembly ②.
Fig. 5-14-4 Removing the damping pulley
assembly (1) Remove the 4 hexagon flange bolts (M8×20)
fastening the damping pulley to the front end of
end of crankshaft.

311
Removing the timing system ③.

Unscrew the 15 hexagon flange bolts (M6 × 16, M10 ×
35 and M10 × 50) fastening the timing hood
componentsⅠandⅡand the timing hood on the front
end of the engine, and take off the timing hood
componentsⅠandⅡand the timing hood on the cylinder
head and the front end of the cylinder body. See Fig.
5-14-5.
Fig. 5-14-5 Removing the timing system (4) Remove the timing idle wheel assembly: unscrew
the fastening bolts of the timing idle wheel, and remove
the timing idle wheel assembly.
Removing the lower body assembly of oil pan ④

bolts (M6×12) fastening the lower body of oil pan to the
upper body of oil pan in proper order.
Upper body of oil pan (2) Take off the oil pan lower body from the upper body.
See Fig. 5-14-6.
Lower body of Removing the oil pump assembly ⑤
oil pan
subassemblies (M8×40, M8×25 and M8×20) fastening
the engine oil pump assembly to the cylinder body in
proper order, and remove the engine oil pump
Fig. 5-14-6 Removing the lower body
assembly of oil pan (2) Take out the outer rotor of oil pump and rubber seal
oil seal hole of oil pump crankshaft.
Outer rotor Front oil seal stripper: 5-8840-2362-0.

Seal ring

Front oil seal
seal of crankshaft and replace them if there is any
Fig. 5-14-7 Removing and installing the oil Installation

pump assembly Installing the oil pump assembly⑤
(1) Apply a small amount of lubricating oil to the seal
ring of oil pump, and embed the seal ring into the
bottom of the corresponding groove of oil pump
housing. There should not be any scratch, skew or
impropriety.

(2)Coat the surface of the front oil seal of crankshaft

with an appropriate amount of lubricating oil, and then
install the front oil seal of crankshaft to the oil seal hole
of the engine oil pump housing.
Installer of front oil seal: 5-8840-2361-0.

Upper body of oil pan
(3) Apply evenly an appropriate amount of lubricating oil
to the inner surface of engine pump external rotor, and
Lower body of oil pan install the external rotor to the pump chamber of the
upper cylinder body with the marked side facing the
bottom of the oil pump chamber of cylinder body.

(4) Install the oil pump assembly and the cylinder body
together, tighten the 10 hexagon bolt and plain washer
Apply the sealant subassembly bolts (M8×40,M8×20) in proper order and
with specified torques. See Fig. 5-14-7.
Tightening torque for fastening bolt subassembly of

oil pump
23N·m±3N·m
There should be no stagnation when the oil pump

Installing the lower body assembly of oil pan④
Fig. 5-14-9 Installing the lower body of oil pan (1)Check the joint surface between the upper and lower
bodies of oil pan for dirt and scratch. See Fig. 5-14-8.
(2) Apply evenly the silicon rubber flat sealant to the
joint surface between the upper and lower bodies of oil
pan. See Fig. 5-14-9.
LOCTITE587 flat sealant.
(3) Install the lower body of oil pan to the upper body of
oil pan, and tighten the 14 hexagon flange bolts
(M6×12) with the specified torque and in proper order.
Tightening torque of fastening bolt at lower body of

oil pan
Timing idle wheel
9N·m±3N·m
Installing the timing system ③
(1) Install the timing idle wheel, and tighten the
fastening bolt with specified torque. See Fig. 5-14-10.
Fig. 5-14-10 Installing the timing system Tightening torque of fastening bolt of timing idle
wheel
43N·m±4N·m

313
Horizontal Timing Fuel pump pulley horizontal bar on the water pump housing. See Fig.
bar mark 5-14-11.
(4) 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.
(6) 装配正时张紧轮，先把正时张紧轮的限位支架卡入
气缸盖安装碗形塞的位置，然后刚内六角扳于顺时针调
整安装销孔位置使其略超过垂直方向 30°，使张紧轮轮臂
Timing mark
指针超过安装臂缺口下边缘约 1°~2°，拧紧螺栓。Install
the timing tension pulley. Fix the limit bracket of the
timing tension pulley in the place where the bowl
Bone-line use a hexagon socket head spanner to turn the
Camshaft over 30° past the vertical direction and the tension
timing pulley pulley arm indicator is 1°~2° past the lower verge of
the installation arm notch, and tighten the fastening
bolts.
Fig. 5-14-12 Installing the camshaft timing Tightening torque of fastening bolt of timing tension
pulley pulley
23N·m~26N·m

anticlockwise when inspecting.
Use a hexagon
socket spanner
to adjust the Notch
Arm indicator
mounting hole

pulley

(7) Install the timing hood, and tighten the 5 hexagon

flange bolts (M10×35, M10×50) with specified torques
after aligning the mounting holes.
Tightening torque of fastening bolt of timing hood

45N·m±3N·m
——Fit the timing hoodsⅠandⅡ, and screw the 10
hexagon flange bolts (M6×6) with specified torques after
aligning the mounting holes. See Fig. 5-14-14.
Tightening torque of fastening bolt of timing hoods

ⅠandⅡ.
9N·m±3N·m
component
Crankshaft
Installing the damping pulley②.
(1) Install the elastic cylindrical pin into the pin hole of
crankshaft timing belt pulley.
(2) Install the damping pulley to the front end of
crankshaft, and screw the 4 hexagon flange bolts
(M8×20) to the timing pulley of crankshaft with specified
Timing pulley
torques. See Fig. 5-14-15.
Tightening torque of fastening bolt of damping

Damping pulley pulley
23N·m±3N·m
assembly Attention: The timing mark must face forwards
Installing the engine accessories ①.

(1) Install the generator bracket to the front end of the
exhaust side of cylinder body and screw the 3 hexagon
flange bolts (M8×30, M8×25) with specified torques.
Install the generator assembly, and screw the 3
hexagon flange bolts (M10×45, M8×30) with specified
torques. See Fig. 5-14-16.
Tightening torques for fastening bolts of generator

bracket and generator
Fig. 5-14-16 Installing the generator bracket
and the generator
M8 23N·m±3N·m
M10 45N·m±3N·m

315
(2) Install the steering pump bracket on the two sides of

the oil pump housing (See Fig. 5-14-17), and screw the
Steering pump bracket
3 hexagon flange bolts (M8×25, M8×30) with specified
torques.Install the steering oil pump assembly and
Steering pump screw the 2 hexagon flange bolts (M8×30, M8×100) with
specified torques.
Tightening torques for fastening bolts of steering

pump bracket and power steering oil pump.
23N·m±3N·m
Fig. 5-14-17 Installing the power steering

pump assembly
(3) Install the flat idle wheel and wedge idle wheel, and
tighten the bolts with specified torques.
Tightening torques for fastening bolts of flat idle

Generator belt wheel and wedge idle wheel.
22N·m~26N·m
(4) After aligning the limit boss of tension pulley with the
mounting hole of engine bracket, use the bolt to tighten
the tension pulley.
Tightening torque for fastening bolt of tension

Fig. 5-14-18 Installing the generator belt pulley
53N·m~57N·m
Rotary (5) Install the generator belt, and make sure the pulleys
installation
position of are properly installed, except the flat idle wheel. Make
tension pulley sure the belt wedge teeth fit well with the pulley wedge
Generator
slot. <}62{> Turn the tension pulley with tools until the
belt
generator belt is loose enough, and then install the flat
idle wheel into the belt.
(6) After the installation, check the generator belt for any
excessive tension or any insufficient tension. See Fig
5-14-19.


operations.
Fig. 5-14-20.
make sure the lubrication system is in normal operation.

storage battery

317
Section XV Oil pan assembly
Removal procedure
① Generator belt
② Refrigeration compressor assembly
③ Engine oil dipstick guide subassembly and
engine oil dipstick assembly
④ Oil pan lower body assembly
⑤ Oil collector
⑥ Oil pan upper body assembly
Install them in the opposite order
of removal.
Fig. 5-15-1 Installation and removal procedures for the oil pan assembly

Removal
Preparation
the engine.
Warning: The hot oil (lubricating oil) may cause

burn. Handle the used oil properly to protect the
environment.
Fig. 5-15-2 Removing the generator belt
Tightening torque for the oil drain screw plug

Cylinder body
15N·m~20N·m
Removing the generator belt ①

②
Refrigeration compressor
fastening the refrigeration compressor to the cylinder
Fig. 5-15-3 Removing and installing the body and oil pan. See Fig. 5-15-3.
(2) Take off the refrigeration compressor from the
cylinder body.
Engine oil Removing the engine oil dipstick guide

dipstick subassembly and engine oil dipstick assembly ③
(1) Pull out the engine oil dipstick from the engine oil
Engine oil Upper dipstick guide.
dipstick guide scale mark
Lower (2) Remove the 1 hexagon flange face bolts (M8×25)
scale mark fastening the engine oil dipstick guide assembly to the
timing hood.
(3) Pull out the engine oil dipstick guide assembly from
Fig. 5-15-4 Removing the engine oil dipstick the oil pan upper body hole, as shown in Fig. 5-15-4.
and its guide
Removing the lower body assembly of oil pan ④

face bolts (M6×12) connecting the lower body and
upper body of oil pan in order. See Fig. 5-15-5.
(2) Take off the oil pan lower body from the upper body.

319
Removing the oil collector ⑤

Upper body (1) Use a spanner to remove the 2 hexagon flange face
of oil pan
bolts (M6×16) fastening the engine oil pipe and the 2
collector support. See Fig. 5-15-5.
(2) Take off the oil collector and gasket from the oil pan
upper body.
Oil collector
(3) Check the gasket. It must be replaced if damaged or
Lower body of oil pan deformed.
Removing the upper body assembly of oil pan ⑥

Fig. 5-15-5 Removing the oil pan lower body, (1) Use a spanner to remove the 15 hexagon flange
oil collector and oil pan upper body face bolts (M6×20, M6×110, M8×25 and M8×45)
fastening the oil pan upper body to the lower cylinder
body in order. See Fig. 5-15-5.
(2) Take off the oil pan upper body from the lower body.
Cylinder body Installation

Installing the upper body assembly of oil pan ⑥
Check the junction surface between the oil pan

upper body and the cylinder body for dirt and scratches.
Upper body
(1) Apply silastic plane sealant to the junction surface
of oil pan
between the cylinder body and the oil pan upper body
evenly.

(2) Install the oil pan upper body to the cylinder body
assembly and tighten the 15 hexagon flange face bolts
Fig. 5-15-6 Installing the upper body (M8×25, M6×20, M6×110 and M8×45) to the specified
assembly of oil pan torque in order. See Fig. 5-15-6.
Upper body Tightening torque for the fastening bolt of oil pan
of oil pan upper body
M6 9N·m±3N·m
M8 23N·m±3N·m
Oil collector Attention: Clear the residual sealant completely on

assembly
the junction surface between the cylinder body and the
oil pan upper body before applying sealant again.
Fig. 5-15-7 Installing the oil collector
assembly Installing the oil collector ⑤
oil collector seals.

Apply the sealant Mobil API CI-4 lubricating oil

(2) Align the oil collector with the oil suction hole on the
oil pan upper body and install the oil collector gasket.
Later, screw in 2 hexagon flange face bolts (M6x16) and
tighten them to the specified torque.

bolts (M8×12) for fixing the oil collector bracket after
installing the oil pan upper body.
Tightening torque for the fastening bolt of oil

Fig. 5-15-8 Installing the lower body of oil pan collector
and applying sealant M6 9N·m±3N·m
M8 23N·m±3N·m
Installing the lower body assembly of oil pan ④

(1) Check the junction surface between the oil pan
lower body and upper body for dirt and scratches.
Upper body
of oil pan (2) Apply silastic plane sealant to the junction surface
between the oil pan lower body and upper body evenly.
Lower body See Fig. 5-15-8.
of oil pan

(3) Install the oil pan lower body onto the upper body
Fig. 5-15-9 Installing the lower body of oil pan and tighten the 14 hexagon flange face bolts (M6×12) to
the specified torque in order. See Fig. 5-15-9.
Tightening torque for the fastening bolt of oil pan

lower body
9N·m±3N·m
Installing the engine oil dipstick guide subassembly

and engine oil dipstick assembly ③
(1) Check whether the seal ring at the engine oil dipstick
guide connector is in good condition and installed
properly.
(2) Insert the end with seal ring of the engine oil dipstick
guide assembly into the hole on the oil pan upper body
and fix the other end onto the timing hood with 1
hexagon flange face bolt (M10×35) which should be
tightened to the specified torque. See Fig. 5-15-10.
(3) Fit the engine oil dipstick assembly into the engine
oil dipstick guide assembly.
Fig. 5-15-10 Installing the engine oil dipstick
and its guide
After the installation, keep it under good sealing

321
condition to prevent leakage.

Cylinder body
Tightening torque for the fastening bolt of engine
oil dipstick guide
45N·m±3N·m
Installing the refrigeration compressor assembly ②

Install the refrigeration compressor assembly to the
cylinder body and oil pan. Align the mounting holes and
Refrigeration compressor
tighten the 4 hexagon flange face bolts (M8×85) to the
Fig. 5-15-11 Installing the refrigeration
compressor Tightening torque for the fastening bolt of
23N·m±3N·m
Generator belt Installing the generator belt ①

(1) Install the generator belt properly and make sure the
belt wedge-shaped teeth perfectly matches the pulley
wedge slot.
(2) Turn the tension pulley with tools until the belt is
loose enough, and then fit the flat idle wheel into the
generator belt.
Fig. 5-15-12 Installing the generator belt (3) After the installation, check the generator belt for any

operations.
Fig. 5-15-13.
(2) Fill lubricating oil into the lubrication system.
make sure the lubrication system is in normal operation.

storage battery

Section XVI Piston and connecting rod assembly
Removal procedure
① Engine assembly
② Engine accessories
③ Timing system
④Cylinder head assembly
⑤Oil pan upper and
lower body
assemblies and oil
collector assembly
⑥Connecting rod cover
⑦Piston and connecting rod assembly
⑧Piston ring
⑨Clip
⑩Piston pin Installation procedure
11 Piston
○ Install them in the opposite order of removal.
Fig. 5-16-1 Removal and installation procedures for the piston and connecting rod assembly

323
Engine hook
Removal
Removal precautions
The used piston and connecting rod assemblies are not
interchangeable, so check whether there are serial
numbers of cylinders or matching marks on the sides of
the piston top, connecting rod and its cover before
removal.If there is no mark or the marks are illegible,
make up the marks for removal to ensure they can be
reinstalled as they are. After disassembly, the parts for
the same cylinder should be kept at one place to avoid
disorder.
Preparation
Fig. 5-16-2 Removing the engine assembly (1) Disconnect the earthing cable of storage battery.
(2) Drain the cooling system of coolant.
the engine.
Warning: When draining out the engine oil, the hot

oil may cause burn. Handle the used oil properly to
protect environment.
Attention: To install the oil drain screw plug, use a

new copper washer.
Tightening torque for the oil drain screw plug

40N·m±5N·m
Removing the engine assembly ①

(1) Remove the fastening nuts of engine bracket.
(2) Remove the catalytic converter.
(3) Remove the generator belt, the power steering
pump and the refrigeration compressor.
Fig. 5-16-4 Removing the timing system higher than the tail.
(6) Place the engine steadily on the maintenance rack
for repair, removal and reinstallation.
Attention: When taking out the engine, do not

damage the oil pipe, brake pipe, sensors and electric
elements.

Removing the engine accessories ②

Cylinder Remove the wedge idle wheel. See Fig. 5-16-3.
head cover
Removing the timing system ③

Camshaft
bearing cap (2) Remove the timing tension pulley. See Fig. 5-16-4.
Cylinder head (3) Remove the timing belt.
assembly
Removing the cylinder head assembly ④
Fig. 5-16-5.

Upper body
of oil pan (4) Remove 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 head bolts are not orderly

Oil collector unscrewed in several times, the lower surface of the
Lower body
of oil pan
Fig. 5-16-6 Removing the oil pan upper and

assembly
Removing the oil pan upper and lower body
assemblies and oil collector assembly ⑤
Lower face bolts (M6×12) connecting the lower body and
connecting rod
bearing shell upper body of oil pan in order. See Fig. 5-16-6.
Connecting rod cover (2) Use a spanner to remove the 2 hexagon flange face
bolts (M6×16) fastening the oil pipe and the 2 hexagon
Connecting rod bolt
flange face bolts (M8×12) fastening the oil collector
support, and remove the oil collector and gasket.
Fig. 5-16-7 Removing the connecting rod fastening the upper body of oil pan to the lower cylinder
cover body in order, and remove the upper body of oil pan
from the lower cylinder body. See Fig. 5-16-6.

325
Removing the connecting rod cover ⑥

(1) Respectively remove the 8 connecting rod bolts for
tightening the connecting rod cover under the
crankshaft, and take down 4 connecting rod covers and
4 lower connecting rod bearing shells. See Fig. 5-16-7.
(2) If the removed lower connecting rod bearing shells
can be reused, hang a label on each bearing shell (see
Fig. 5-16-7) to indicate the sequential number of each
cylinder and the installation position.
(3) Check the thread of the connecting rod bolts for
damage or stretching, and replace them if damaged.
Fig. 5-16-8 Removing the carbon deposits on
the upper part of cylinder wall
Removing the piston and connecting rod assembly
⑦
(1) Before removing the piston and connecting rod, use
a scraper to clear the carbon deposits on the upper part
of cylinder wall. See Fig. 5-16-8.
(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: Take care during removal. Do not impact

or scratch the connecting rod journal and the internal
Fig. 5-16-9 Marking the connecting rod surface of the cylinder.
bearing shell
(3) If the removed upper connecting rod bearing shells
can be reused, hang a label on each bearing shell. See
Fig. 5-16-9.
Prompt: The removed piston and connecting rod

assemblies should be placed in pair and by group to
ensure correct installation.
Removing the piston ring ⑧

(1) Use a piston ring expander to remove the two
compression rings and one oil ring component
respectively.
See Fig. 5-16-10.
(2) Place the removed piston rings properly according
to the cylinder number.
Caution: Do not try to use other tools to remove

the piston rings. Excessive tension of the piston rings
will impair their elasticity.
Fig. 5-16-10 Removing the piston ring

Removing the clip ⑨

(1) Use a pair of nipper pliers to pull out the piston pin
spring clip from the piston ring groove. See Fig. 5-16-11
and Fig. 5-16-13.
(2) Check the piston pin clip for damage and
deformation, and replace it if necessary.
Removing the piston pin ⑩

(1) Use a wood punch or a copper bar to knock out the
piston pins from the piston pin holes, as shown in Fig.
5-16-12.
Fig. 5-16-11 Removing the piston pin clip
(2) If the pistons and the piston pins can be reused,
hang a label on each piston and piston pin to indicate
the sequential number of each cylinder and the
installation position.
Removing the piston ○

11
(1) Remove the piston copper bushes from both ends of

the piston, as shown in Fig. 5-16-13.
(2) Place the removed pistons by group according to the
cylinder sequential numbers. Protect them from being
bumped.
Fig. 5-16-12 Removing the piston (3) Use a wood scrape or carbon tetrachloride to clear
the carbon deposits on the pistons.
Piston copper
bush
Piston
Installation
Installing the piston ○
11
Install the piston on the connecting rod; the front mark

Piston copper Clip on the piston top should be on the same side with the
bush
connecting rod forward mark. See Fig. 5-16-14.
Piston Piston
pin Attention: Do not change the combination of
Clip
piston and piston pin when the piston and connecting
rod combination is not replaced.
Fig. 5-16-13 Removing the piston
Installing the piston pin ⑩

pistons before installing them into the piston pin hole
and the hole on the connecting rod small end.

327
(2) Install the piston pin into the piston pin hole (see Fig.
5-16-15). The piston should rotate smoothly in the
piston pin hole and without any seizure after installation.
Piston
Installing the clip ⑨
Connecting rod Install the clip (see Fig. 5-16-15) into the piston clip
body groove completely and ensure the clip can perform
circumferential slip. It is not allowed that part of the clip
is outside the ring groove or it is not fall into the groove
Connecting rod
cover
completely.
Caution: the piston pin clip must be firmly fixed.

Fig. 5-16-14 Installing the piston
Installing the piston ring ⑧

(1) Use the piston ring expander to install the oil ring
component, the second compression ring and the first
compression ring into the corresponding piston ring
grooves in order.
(2) 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 upward (see
Fig. 5-16-6 and Fig. 5-16-17).The piston ring should
move smoothly in the ring groove and without any
stagnation, and the clearance meets the requirement
after installation.
Fig. 5-16-15 Installing the piston ring and clip
Attention:
Side marked (TOP)
First compression ring
upwards ——Two compression rings are not interchangeable.
——The piston ring should not tilt.
Second
compression Taper face ——No defect or foreign materials in the piston ring
ring
groove
Clearance of piston ring
Oil ring
Clearance
between the Clearance of
Piston ring piston ring and piston ring
the piston ring open end
groove
Fig. 5-16-16 Installation sequence for piston First
ring compression 0.055~0.100mm 0.20~0.40mm
ring
Second
compression 0.035~0.080mm 0.65~0.85mm
ring
Oil ring
0.030~0.070mm 0.25~0.50mm
component

Installing the piston and connecting rod assembly

⑦
(1) Select the connecting rod bearing shells as
specified. See Table 4-5-2 and Table 4-5-3.
(2) Apply lubricating oil to the cylinder bore, the
connecting rod bearing shell, the crank pin and the
surface of each piston ring and piston.
TOP mark
Compression ring
(3) Stagger the three piston rings at the open end of
piston ring groove for installation. See Fig. 5-16-18.
Fig. 5-16-17 Installing the piston ring
After installation, check whether the position of the
open end of piston ring is correct.
and connecting rod assembly to each cylinder, as
Attention: The front mark on the piston top should

be toward the engine front.
Piston cylinder clearance
0.07~0.09mm
Installing the connecting rod cover ⑥

Open end of first Spiral
compression supporting
ring spring port Attention:
——The connecting rod and the connecting rod cover
should be in pair to ensure they can be reinstalled as
they are.
——Check the connecting rod bolt before installation
and replace it when there is any deformation,
Open end of Second elongation, pulled thread or other faults.
oil ring compression ring
Front end mark
(1) The front end mark of the connecting rod cover
should be toward the front end of the crankcase for
Fig. 5-16-18 Inspection for open end of piston installation.
ring (2) Install the connecting rod bolts to the connecting rod
cover and connecting rod and tighten them to the
specified torque by two steps. See Fig. 5-16-20.
Tightening torque for the connecting rod bolt
Step 1 Step 2
25N·m±3N·m Turn it for 90°±5°

329
Clearance between connecting rod big end and

crankshaft crank
0.22~0.37mm
Front
side
Installing the oil pan upper and lower body
assemblies and oil collector assembly ⑤
(1) Check whether the dowel pin of the oil pan upper
body is installed correctly. Apply silastic plane sealant to
the junction surface between the oil pan and cylinder
body evenly and then install the oil pan upper body onto
Fig. 5-16-19 Installing the piston connecting the cylinder body.
rod assembly
LOCTITE587 plane sealant
Attention: Make sure the junction surface between

the upper body of oil pan and the cylinder body is clean
before reapplying sealant.
(2) Tighten the 15 hexagon flange face bolts (M8×25,
Connecting M6×20, M6×110 and M8×45) connecting the oil pan
rod cover upper body and the lower cylinder body to the specified
Connecting torque in order. See Fig. 5-16-21. The junction surfaces
rod bolt should cling to each other tightly after installation.

Fig. 5-16-20 Installing the connecting rod upper body
cover
M6 9N·m±3N·m
Cylinder body
M8 23N·m±3N·m
(3) After applying an appropriate amount of lubricating

oil to the seals of the oil collector, align the oil suction
holes of the oil pan and fit the oil collector gasket. Later,
Upper body of screw in the 2 hexagon flange face bolts (M8×16) and
oil pan tighten them to the specified torque. See Fig. 5-16-22.

bolts (M6×12) for fixing the oil collector bracket after
Fig. 5-16-21 Installing the upper body installing the oil pan upper body. See Fig. 5-16-22.
assembly of oil pan
Tightening torque for the fastening bolt of oil
collector
M6 9N·m±3N·m
M8 23N·m±3N·m

(4) Check the junction surface between the oil pan

Upper body of lower body and upper body for dirt and scratches. Apply
oil pan
silastic plane sealant to the junction surface evenly, and
then install the lower body to the upper body by tighten
the 14 hexagon flange face bolts (M6×12) to the
specified torque in order. See Fig. 5-16-23.
LOCTITE587 plane sealant
Lower
body of oil lower body
pan
9N·m±3N·m
Fig. 5-16-22 Installing the oil pan lower body
and the oil collector
Attention:
leakage may occur.
——Before applying sealant again, make sure the
junction surface between the upper and lower bodies of
oil pan is clean.
Installing the cylinder head assembly ④

(1) Install the cylinder head.
Fig. 5-16-23 Installing the lower body of oil ——Check the junction surface between the cylinder
pan and tightening the bolts in order head and the cylinder body for foreign matters, and
wipe it by silk cloth.
——Insert the cylinder head dowel pin sleeve into the
Cylinder corresponding pin hole on the cylinder body properly
head bolt with a special tool; fit the cylinder head gasket to the
dowel pin of the cylinder body, and evenly place the
gasket on the cylinder body plane.

——Fix the cylinder head to the cylinder body, and align
Cylinder head the 10 screw holes, then fit and screw the 10 fastening
bolts (M11×1.5×162) by three steps according to the
specified sequence. See Fig. 5-16-24.
tightening the bolts in order
Tightening torque for the fastening bolt of cylinder
head
50N·m±3N·m Turn it for 90° Turn it for 120°

331
Attention: Check the cylinder head bolts before

Apply lubricating oil installation and conduct replacement when there is any
deformation, elongation, pulled thread or other faults.
(2) Install the hydraulic clearance adjuster and rocker
arm.
——Before installation, apply an appropriate amount of
lubricating oil to the ball head of the hydraulic clearance
Hydraulic clearance adjuster adjuster. See Fig. 5-16-25.

Fig. 5-16-25 Installing the hydraulic clearance ——Fit the ball head of the hydraulic clearance adjuster
adjuster and rocker arm into the clip at the rear of the rocker arm and ensure the
tappet will not fall off after installation.
——Lubricate the surfaces of the rocker arm and the
on the valve, as shown in Fig. 5-16-25.
(3) Install the intake and exhaust camshafts.
——Apply an appropriate amount of lubricating oil in the
bearing holes of intake and exhaust camshafts of
cylinder head and on the surface of the camshaft
journal.

Camshaft
bearing cap ——Install the intake and exhaust camshafts into the
——Align the marks “·∙” on the driving gears of exhaust
and intake camshafts and get it in line with the upper
surface.
(4) Install the camshaft bearing cap.
——Apply anaerobic plane sealant to the junction
Cylinder head surface between the camshaft bearing cap and the
cylinder head.
Fig. 5-16-26 Installing the intake and exhaust LOCTITE510 anaerobic plane sealant
camshafts and the camshaft bearing cap
——When installing the camshaft bearing cap, screw
down the 16 hexagon flange face bolts (M6×35) of
camshaft bearing cap as per specified torque and order,
bolts (M6×20) from the center to both sides.

bearing cap
9N·m±3N·m

(5) Install the vacuum pump assembly.

——Install the vacuum pump at the rear of the exhaust
Cylinder head camshaft, with the flat bump on the shaft inserted into
the groove on the shaft end at the rear end of the
exhaust camshaft and with the rabbet and the rabbet
round hole fitting well.
Vacuum pump
assembly ——Tighten the 2 hexagon flange face bolts (M6×20)
fastening the vacuum pump and the cylinder head to
——Install the vacuum connecting hose.
Fig. 5-16-27 Installing the vacuum pump There should be no deflection or misplacement
assembly after installation.
Tightening torque for the fastening bolt of vacuum

pump
9N·m±3N·m
(6) Install the fuel injector.
ballast to the cylinder head as specified.
Sectional view Tightening torque for the supporting bolt of fuel

of cylinder head injector ballast
23N·m±3N·m
Fig. 5-16-28 Installing the fuel injector ——Install the copper washer and O-ring of fuel injector
to the fuel injector, and make sure that only one copper
washer is installed to each fuel injector and placed
horizontally.
——According to the numbers 1, 2, 3 and 4 on the fuel
injectors, install the fuel injectors to the fuel injector
mounting holes on the cylinder head corresponding to
cylinders 1, 2, 3 and 4. See Fig. 5-16-28.
——Place one end of the fuel injector ballast on the
ballast supporting bolt and the other end in the fuel
Fuel injector assembly injector ballast groove. See Fig. 5-16-29.
——Install and tighten the fastening bolt assemblies of
fuel injector ballast to the specified torque.
assembly Tightening torque for the fastening bolt component
of fuel injector ballast
25N·m~35N·m
After installation, gas leakage at the fuel injector

gasket is forbidden.

333
(7) Install the fuel return hose.

Fuel return hose ——Use the DELPHI fuel injector. Insert respectively
Fuel inlet pipe component the fuel return hoses into 4 injector heads and position
of injector them in place. See Fig. 5-16-30.
——Use the BOSCH or XINFENG fuel injector. Remove
Install 4 short connectors of the fuel return hose in the
holes at the upper ends of the 4 fuel injectors, and fix
them tightly with spring clips. Install the other long
connector to the fuel return tee on the high-pressure
pump, and fix it tightly with a clamp.
——Install the fuel return hose bracket and hose
clamps.
After the installation, make sure the fuel return
hose component is sealed so strictly that no fuel will
leak from the fuel return hose.
Timing mark
(8) Install the fuel inlet pipe of the fuel injector.
——Take off the dust covers at both ends of the fuel
inlet pipe of the fuel injector.
Junction seam
——Install the fuel inlet pipe of the fuel injector as
shown in Fig. 4-5-30 and tighten the pipe connectors to
Camshaft
timing pulley the specified torque.
Tightening torque for the fuel inlet pipe connector of

fuel injector
pulley 32N·m±3N·m
Timing mark on damping pulley Make sure the fuel pipe is sealed and there is no
fuel leakage after installation.

connectors at both ends of the fuel injector fuel inlet
pipe at the same time in installation so as to avoid the
fuel pipe deformation and damage.
Damping pulley Timing mark on timing
hood component II (1) Install the woodruff key to the exhaust camshaft,
install the timing pulley to the exhaust camshaft (see
Fig. 5-16-31) and tighten the fastening bolt and washer
Fig. 5-16-32 Installing the timing system component to the specified torque. The camshaft timing
pulley should be installed to the right position and
without deflection.
(2) Adjust the position of the scribed line on the
junction seam (on the exhaust side) between the
cylinder head and the camshaft bearing cap. See Fig.
5-16-31.

Tightening torque for the bolt and washer assembly

Horizontal bar
Timing mark Fuel pump pulley of camshaft timing pulley
110N·m±5N·m
(4) Align the timing mark on the fuel pump pulley with
the horizontal bar on the water pump housing. See Fig.
5-16-33.
Fig. 5-16-33 Installing the timing system connected with the pulley firmly and without any
looseness.
shaped plug is to be installed on the cylinder head, and
then use a hexagon socket head spanner to turn the
mounting pin hole clockwise until it deflects from the
vertical direction by 30° and the tension pulley arm
indicator deflects from the lower verge of the installation
arm notch by 1°~2°, and tighten the fastening bolts.
After taking off the hexagon socket spanner, camshaft
pulley dowel pin and crankshaft locking tooling, turn the
crankshaft by 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 there is any
pulley that is not aligned properly, loosen the fastening
bolts of timing pulley and install them again to align the
pulley properly. This is to make one cylinder just at the
top dead center of the compression stroke, and the
valve timing is accurate. See Fig. 5-16-35.
Attention: When the pulley mark is not aligned, if it

is required to turn the vehicle or carry out inspection, do
not turn the vehicle anticlockwise. See Fig. 5-16-35.
Timing pulley
Tightening torque for the fastening bolt of timing
tension pulley
Timing tension
pulley 22N·m~26N·m
(7) Install the timing cover and timing cover component
I. Fix 10 hexagon flange face bolts (M6×16, M10×35
and M10×50) tightly to the cylinder head and the front of
the cylinder body. See Fig. 5-16-36.
hood

335
45N·m±3N·m

hood component I
9N·m±3N·m
Installing the engine accessories ②
Use a hexagon Install the wedge idle wheel assembly and tighten it as
socket spanner to
per the specified torque.
adjust the
Arm indicator Notch
mounting hole.
Tightening torque for the wedge idle wheel
Fig. 5-16-35 Installing the timing tension 22N·m~26N·m
pulley
Installing the engine assembly ①
carefully, and then place the engine steadily at the
mounting position of the frame.
(2) Tighten the fastening nuts connecting the brackets
on both sides of the engine to the frame stud.
Tightening torque for the fastening nuts of engine

bracket
95N·m±10N·m
(3) Install the power steering pump, the refrigeration
compressor and the generator belt.
component After the installation, check the generator belt.
the pulley wedge slot.
Rotary
installation Caution: Excessive or insufficient tension of the
position of pulley is not allowed.
tension
pulley Generator (4) Install the catalytic converter.
belt
Attention: During the installation of engine, do not

damage the oil pipe, electric elements and sensors.
operations.
Fig. 5-16-37 Installing the engine accessories (1) Install the harness connectors and make sure they
are installed firmly to the right positions.
(3) Fill coolant into the cooling system
(4) Fill lubricating oil into the lubrication system.
(5) Start the engine and check it for normal working, and
check the cooling system and the lubrication system for
leakage.

Section XVII Front oil seal of crankshaft
Removal procedure
②Damping pulley assembly
③Timing hood
④Timing belt
⑤Timing pulley of crankshaft Installation procedure
⑥Front oil seal of crankshaft Install them in the opposite order of removal.
Fig. 5-17-1 Removal and installation procedures for the front oil seal of crankshaft

337
Removal
Preparation

with a tool to remove the generator belt after it is loosened
enough.
Fig. 5-17-2 Removing the engine accessories (3) Remove the flat idle wheel assembly and wedge idle
wheel assembly, as shown in Fig. 5-17-2.
Damping pulley Removing the damping pulley assembly ②

(1) Remove the 4 hexagon flange face bolts (M8×20) for
Timing pulley of
fastening the damping pulley at the front end of crankshaft.
crankshaft See Fig. 5-17-3.
end of crankshaft.
Removing the timing hood ③

Fig. 5-17-3 Removing the damping pulley and (1) Remove the 6 hexagon flange face bolts (M6×16)
the timing pulley of crankshaft fastening the timing hood I, the 6 hexagon flange face bolts
(M6×16 and M10×50) fastening the timing hood II, and the
5 hexagon flange face bolts (M10×35) fastening the timing
(2) Take off the timing hood components I and II and the
timing hood from the front end of the engine, as shown in
Fig. 5-17-4.
Removing the timing belt ④

Release the timing tension pulley and then remove the
timing belt after it is loosened enough, as shown in Fig.
5-17-4.
Fig. 5-17-4 Removing the timing hood and Removing the timing pulley of crankshaft⑤
belt
(1) Remove the bolts tightening the timing pulley of
crankshaft.
(2) Remove the timing pulley of crankshaft and the
woodruff key from the front end of the crankshaft.

Removing the front oil seal of crankshaft ⑥

(1) Use an oil seal remover or a plastic hammer and a
screwdriver to knock around the front oil seal of crankshaft
and then remove it from the hole on the engine oil pump, as
Engine oil shown in Fig. 5-17-5.
pump
Front oil seal Crankshaft Front oil seal remover: 5-8840-2362-0.

of crankshaft
Attention: Do not damage the mating surface of the
(2) Check the front oil seal of crankshaft. Replace it in case
Fig. 5-17-5 Removing the front oil seal of of any deformation or damage.
crankshaft
Installation
Installing the front oil seal of crankshaft ⑥
Engine oil pump front oil seal of crankshaft.

Front oil seal of
crankshaft (2) Press the front oil seal of crankshaft into the
corresponding hole on the engine oil pump with special
tools. See Fig. 5-17-6.
Fig. 5-17-6 Installing the front oil seal of Installer of front oil seal: 5-8840-2361-0.
crankshaft (3) After installation, check the oil seal. Any scratch,
deflection or poor installation is forbidden.
Installing the timing pulley of crankshaft ⑤

(1) Install the woodruff key onto the crankshaft, install the
timing pulley of crankshaft to the crankshaft, and then
tighten the fastening bolts to the specified torque. See Fig.
5-17-7.
(2) After installation, check whether the timing pulley of
Timing belt crankshaft is installed properly and without deflection.
Tightening torque for the fastening bolt of crankshaft

Fig. 5-17-7 Installing the timing pulley of timing pulley
crankshaft
185N·m~195N·m
Installing the timing belt ④

(1) Install the timing belt. During the installation, make sure
the belts, except the tension pulley, are connected with the
pulley firmly and without any looseness. See Fig. 5-17-8.
(2) Install the timing tension pulley: Fix the limit bracket of

339
the timing tension pulley in the place where the bowl

shaped plug is to be installed on the cylinder head. After
that, use a hexagon socket head spanner to adjust the
mounting pin of the timing tension pulley to be aligned with
Timing pulley
the notch, and tighten the timing tension pulley bolts to the
specified torque.

Timing tension
pulley tension pulley
22N·m~26N·m
Fig. 5-17-8 Installing the timing belt Installing the timing hood ③
——Align the mounting holes to install the timing hood and
tighten the 5 hexagon flange face bolts (M8×35 and
M8×50) to the specified torque. See Fig. 5-17-9.
Tightening torque for the fastening bolt of timing hood

45N·m±3N·m
——Fit the seal strips I and II of the timing hood into the
sealing grooves I and II of the timing hood respectively.
——Align the mounting holes to install the timing hood
components I and II, and tighten the 10 hexagon flange
face bolts (M6×16) to the specified torque.
Fig. 5-17-9 Installing the timing hood Tightening torque for the fastening bolt of timing hood
component components I and II
9N·m±3N·m
Installing the damping pulley assembly ②

Crankshaft (1) Install the spring pin into the pin hole on the crankshaft
timing belt pulley.
(2) Align the damping pulley pin holes, install the damping
pulley to the front end of crankshaft, and screw down 4
hexagon flange face blots (M8×20) to the specified torque.
See Fig. 5-17-10.
Timing
pulley Tightening torque for the fastening bolt of damping
pulley
Damping pulley 23N·m±3N·m
Attention: The timing mark of the damping pulley

should be set forward.
assembly

Installing the engine accessories ①

(1) Install the tension pulley to the cylinder body and then
tighten the bolts to the specified torque.
Tightening torque for the fastening bolt of tension

pulley
53N·m~57N·m
(2) Install the flat idle wheel assembly and wedge idle
wheel assembly, and then tighten the bolts to the specified
torque, as shown in Fig. 5-17-11.
Fig. 5-17-11 Installing the engine accessories Tightening toque for the flat idle wheel and wedge idle
wheel
22N·m~26N·m
Rotary (3) Install the generator belt properly and make sure the
installation
position of
belt wedge-shaped teeth perfectly match the pulley wedge
tension pulley Generator slot. Rotate the tension pulley by tools to make the belt
belt loose enough, and then fit the flat idle wheel into the belt,

operations.
Fig. 5-17-12 Installing the generator belt (2) Start the engine and check whether it works normally.

341
Section XVIII Rear Oil Seal of Crankshaft
Removal procedure
② Clutch assembly
③ Flywheel gear ring
assembly
④ Rear oil seal of crankshaft
Fig.5-18-1 Removal procedure of the rear oil seal of crankshaft
Removal
Preparation
See Fig. 5-18-2.
(2) Lift the vehicle to an appropriate height and support
it with a safety rack.

storage battery


Transmission
Clutch assembly (2) Remove the transmission assembly.
——Remove the bolts connecting the transmission and
clutch in proper order, and remove the transmission
assembly. See Fig.5-18-3.
Removing the clutch assembly ②
Fig. 5-18-3 Removing the transmission and Attention: Any fluid should not be allowed to
the clutch assembly remain on the surface of the clutch. If there is some
fluid, remove it.
from falling off the driven disc assembly freely, as

(2) Make a mark on the flanges of flywheel and
installation.
(3) Loosen 9 bolts that fasten the clutch pressure plate
assembly in proper order, and remove the clutch
assembly.
Removing the flywheel gear ring assembly ③

Flywheel and (2) Loosen 8 flywheel fixing bolts that fasten the
gear ring flywheel gear ring to the rear end of the crankshaft in
proper order, and remove the flywheel gear ring
Removing the rear oil seal of crankshaft ④

Crankshaft (1) While pushing the rear oil seal of crankshaft inside,
use a special tool to carry out the installation as shown
in Fig. 5-18-6 to facilitate the removal of the oil seal.
assembly Detacher for the rear oil seal: 5-8840-2360-0.
(2) Remove the rear oil seal of crankshaft from the rear
end of cylinder body.
Attention: When removing the rear oil seal of

crankshaft, do not damage the crankshaft and the
cylinder body.

343
Installation
Installing the rear oil seal of crankshaft ④
(1) Use oil seal installer to install the rear oil seal of
crankshaft to the cylinder body. See Fig. 5-18-7.
Rear oil seal installer: 5-8840-2539-0.

crankshaft
(2) Clean the iron rust and oddments on the pushed-in

part of the crankshaft rear oil seal.
Attention: The pushed-in direction of the oil seal

(3) Install the connector of the special tool to the rear
end of the crankshaft with 2 bolts.
(4) Install the oil seal to the cylindrical surface of the
connector.
(5) Insert the socket into the connector, and tighten the
bolt (M12×1.75 ， L=70) until the end face of the
connector supports the socket.
Fig. 5-18-7 Installing the rear oil seal of (6) Remove the connector and the socket.
crankshaft
After installing the oil seal, check whether it is
installed properly.
Installing the flywheel gear ring assembly ③

Align the pin holes to install the flywheel gear ring
assembly to the rear end of crankshaft, and tighten 8
flywheel bolts according to the specified torque and
order. See Fig. 5-18-8.
Tightening torques for fastening bolts of flywheel

gear ring assembly
Fig. 5-18-8 Tightening order of fastening bolts 75N·m±5N·m

of flywheel
Installing the clutch assembly ②

——Grease the spline of the driven disc hub with

Install the driven disc assembly by guide centering

device.

——Tighten the 9 bolts that fix the clutch pressure plate
in Fig. 5-18-9.

Fig. 5-18-9 Installing the clutch pressure plate 23N·m±3N·m
assembly
Transmission wire for protecting the diaphragm spring must be
removed after the fixing bolts of the pressure plate are
Clutch assembly tightened to specified torques.
Installing the transmission assembly ①

——Fit 2 transmission dowel pins into the back end
face of the cylinder head by a special tool; there should
Fig. 5-18-10 Installing the transmission in proper order and as per specified torque.
assembly (3) Install the drive shaft.
operations.
(2) Start the engine, and check it for abnormal working.

345
Section XIX Crankshaft
Removal procedure
② Engine assembly
③ Engine accessory ○
11 Piston and connecting rod
④ Damping pulley assembly assembly

⑤ Timing system ○
⑥ Cylinder head assembly ○

⑦ Clutch assembly ○
14 Crankshaft and crankshaft
⑧ Flywheel gear ring assembly position signal panel Installation procedure
⑨ Oil pan upper and lower body Install them in the opposite
assemblies and oil collector order of removal.
assembly
⑩ Oil pump assembly
Fig. 5-19-1 Removal procedure of crankshaft

Removal
Preparation
(1) Disconnect the grounding cable of storage battery.
See Fig. 5-19-2.
(3) Drain out the engine oil (lubricating oil) in the
lubrication system.

storage battery
Transmission
environment.
Clutch assembly
(2) Remove the transmission assembly.
——Remove the bolts connecting the transmission and
clutch in proper order, and remove the transmission
assembly
Removing the engine assembly ②.
Engine hook (1) Remove the nuts fastening the engine bracket:
loosen the 2 fixing nuts that connect the engine left /
right bracket and the frame studs so as to separate the
engine from the frame.
(2) Remove the generator belt, the refrigerating
compressor and the power steering pump.
(3) Remove the catalyst pipe.
Fig. 5-19-4 Removing the engine assembly repair, removal and reinstallation.
Attention: When removing the engine assembly,

do not damage the oil pipe, the brake pipe, the sensor
or electric elements, etc.

347
Removing the engine accessories ③.

wheel assembly.
(3) Remove the steering pump support component. See
Fig. 5-19-5.
(4) Remove the generator and the generator bracket.
Removing the damping pulley assemblies ④.

(1) Remove 4 hexagon flange bolts (M8×20) for
fastening damping pulley at the front end of crankshaft.
See Fig. 5-19-6.
end of crankshaft.
Fig. 5-19-6 Removing the damping pulley

assembly
Removing the timing system ⑤.
(1) Remove the timing hood components I and II and
the timing hood from the front end of the engine, and
the timing rear hood from the front end of the cylinder
head.
(3) Remove the timing belt. See Fig. 5-19-7.
(4) Remove the timing idle wheel assembly: unscrew
the fastening bolts of timing idle wheel, and remove the
Fig. 5-19-7 Removing the timing system (5) Remove the camshaft timing pulley: loosen the bolt
gasket component of camshaft timing pulley and

Removing the cylinder head assembly ⑥.

(1) Remove the cylinder head cover component.
Cylinder head
bolt
(4) Remove the cylinder head assembly: loosen 10
bolts (M11×1.5×162) fastening the cylinder head to the
cylinder body in separated times, and remove the
cylinder head assembly. See Fig. 5-19-8.
Cylinder head
Caution: if the cylinder cap bolts are not orderly
Fig. 5-19-8 Removing the cylinder head cylinder cap might be damaged.
assembly
Removing the clutch assembly ⑦.

Fig. 5-19-9 Removing the clutch assembly (4) Make a mark on the flanges of flywheel and
installation.
(5) 按顺序分两次松开固定压盘总成的 9 个螺栓，拆下离
合器总成，如图 5-19-9 所示。 Loosen orderly in two
times the 9 bolts fastening the pressure plate assembly,
and remove the clutch assembly as shown in Fig.
5-19-9.
Removing the flywheel gear ring assembly ⑧

(2) Loosen 8 bolts that fasten the flywheel gear ring
Crankshaft position assembly in order by two steps. See Fig. 5-19-10.
signal panel
Flywheel gear ring
rear end of the crankshaft. See Fig. 5-19-10.
assembly
Crankshaft

assembly

349
Upper body of
oil pan
Removing oil pan upper and lower body assemblies

and oil collector assembly ⑨
(1) Use a spanner to remove 14 hexagon flange bolts
(M6×12) fastening the oil pan lower body to upper body
Oil collector in proper order, and remove the oil pan lower body. See
Lower body of Fig. 5-19-11.
oil pan (2) Use a spanner to remove 2 hexagon flange bolts
(M6×16) fastening the engine oil pipe and 2 hexagon
flange bolts (M8×12) fastening the engine oil collector
Fig. 5-19-11 Removing the oil pan upper and support, and remove the engine oil collector.
assembly 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 pan from
the lower cylinder body.
Outer rotor
Removing engine oil pump assembly ⑩
Seal ring
(1) Remove 10 hexagon bolts and flat ring components
(M8×40, M8×25 and M8×20) fastening the engine oil
Front oil seal pump and cylinder body in proper order, and remove
the engine oil pump assembly. See Fig. 5-19-12.
(2) Take out the outer rotor of oil pump and rubber seal
See Fig 5-19-12.
Fig. 5-19-12 Removing the oil pump assembly
Front oil seal stripper: 5-8840-2362-0.

Piston
Removing the piston connecting rod assembly ○

11
Connecting
rod (1) Unscrew and remove 8 connecting rod bolts in two
separated times following the order of cylinders 1st, 4th,
Crankshaft 2nd and 3rd, and take down 4 connecting rod covers and
the lower connecting rod bearing shell. See Fig.
4-19-13.
Connecting rod (2) Take out the 4 piston components, connecting rod
cover bodies and upper connecting rod bearing shells from
the upper part of the cylinder body respectively. Make a
Fig. 5-19-13 Removing the connecting rod mark according to the cylinder sequence.
assembly and piston

Caution: Carry out removal with care, do not

collide or scratch the connecting rod bearing journal
and inner surface.
Removing the rear oil seal of crankshaft ○

12
(1) Use a rear oil seal remover to take out the rear oil
seal of crankshaft from the oil seal groove of the
cylinder body as shown in Fig. 5-19-14.

(2) Check the rear oil seal of crankshaft and replace it if
there is any damage or deformation.
Cylinder body
Removing the lower cylinder body ○
13
Rear oil seal
(1) Remove 10 main bearing cap bolts orderly.
Fig. 5-19-14 Removing the rear oil seal of (2) Remove 11 hexagon flange bolts (M8×80)
crankshaft connecting the lower cylinder body and the upper
cylinder body. See Fig. 5-19-15.
Lower cylinder (3) Remove the lower cylinder body from the upper
body cylinder body.
Attention: Remove the fastening bolts of the lower

cylinder body from both sides of the cylinder body to the
middle in proper order.
Upper cylinder
body Removing the crankshaft and the crankshaft
14
(1) Remove 3 hexagon lobular socket countersunk

head screws (M6×12) that fix the signal panel, as
Fig. 5-19-15 Removing the lower cylinder shown in Fig. 5-19-16.
body
(2) Take down the signal panel from the rear end of the
crankshaft.
(3) Remove the crankshaft from the inner side of the
cylinder body, and check the wear conditions of the
Crankshaft surfaces of the crankshaft main bearing journal and the
position signal crank pin and the matching surface of the crankshaft oil
panel seal, and the blockage conditions of the crankshaft oil
Flywheel gear ring hole.
assembly
Installation
Installing the crankshaft and the crankshaft position
Crankshaft signal panel ○ 14
(1) Optionally install the main shaft bearing shell

according to table 4-4-1 and 4-4-2.Install the upper
Fig. 5-19-16 Removing and installing the main shaft bearing shell with oil groove and oil hole to
crankshaft and the position signal panel the upper cylinder body; and install the lower main shaft
bearing shell without oil groove and oil hole to the lower
cylinder body. A wrong installation is not allowed. See
Fig. 5-19-17. After installing the upper and lower main

351
shaft bearing shells, apply an appropriate amount of

Upper main shaft
bearing shell
lubricating oil.
Upper thrust plate

(2) Install the crankshaft position sensor signal panel to
Crankshaft the 8th crank arm of crankshaft. Tighten 3 hexagon
lobular socket countersunk head screws (M16×12) as
per specified torque.There should be no deflection or
Lower main shaft improper mounting after installation, as shown in Fig.
bearing shel 5-19-18.
Lower thrust plate
Tightening torque of hexagon lobular socket

countersunk head screw
Fig. 5-19-17 Installing the thrust plate
9N·m±3N·m
Apply an appropriate amount of lubricating oil to the
upper bearing journal and the oil hole of crankshaft, and
install the crankshaft to the upper cylinder body:

Axial clearance of the crankshaft
0.10~0.28mm

13
Crankshaft (1) Apply an appropriate amount of lubricating oil

Crankshaft thrust surface.
position signal
panel
(2) Install the upper thrust plate in the rabbet of the
upper cylinder body, with the side with the oil groove
facing the crank arm. Install the lower thrust plate in the
rabbet of the lower cylinder body, with the side with the
oil groove facing the crank arm.
Fig. 5-19-18 Installing the crankshaft position
sensor signal panel Attention: the lower thrust plate rather then the
upper thrust plate has a positioning lip. See Fig.
5-19-17.
Lower cylinder
(3) Apply the sealant to the top surface of the lower
body
cylinder body evenly, align the dowel pins of the upper
cylinder body to install the lower cylinder body, install 10
main bearing cap bolts (M11×1, 5×X87), and tighten
them by three steps and as per specified torque. See
Crankshaft Fig. 5-19-20.Install the 11 hexagon flange bolts (M8×80)
that fix and connect the upper and lower cylinder bodies
(M8×80), and tighten them as per specified torque. See
Fig. 5-19-19 and Fig. 5-19—20.

Fig. 5-19-19 Installing the lower cylinder body

Attention: Before applying the sealant to the top
surface of lower cylinder body, make sure the joint of
the upper and lower cylinder bodies are clean.
Tightening torques of fastening bolts of the main

bearing cap and the lower cylinder body
Front
end
Main bearing cap bolt 40N·m±3N·m
(screw it down tightly by Turn for 90°: then turn for
three steps) another 90°
Lubricate it with oil
Hexagon flange face bolt
23N·m±3N·m
(M8×80)
Fig. 5-19-20 Installing main bearing cap bolt
After the installation, rotate the crankshaft
manually, and the crankshaft should rotate freely
Installing the rear oil seal of crankshaft ○

12
(1) Check the crankshaft rear oil seal to be installed and

make sure it is clean without impurity.
Cylinder body (2) Apply an appropriate amount of lubricating oil to the
Rear oil seal lip oil groove and the cylindrical surface of the oil seal
assembly.
Fig. 5-19-21 Installing the rear oil seal of Mobil API CI-4 lubricating oil
crankshaft
(3) Use a special tool to install the rear oil seal of the
crankshaft to the oil seal groove of the cylinder body.
See Fig. 5-19-21.
Caution: make sure the oil seal end face does not
tilt and it is properly installed.
Installing the piston connecting rod assembly ○

11
(1) Carefully remove dirt on the back of connecting rod

bearing shell and matching surface of connecting rod
bearing seat.
(2) Install the connecting rod bearing shell in the same
group to the connecting rod as per the numbers marked
crank pin.
Fig. 5-19-22 Installing the connecting rod Mobil API CI-4 lubricating oil

353
bearing shell (4) Apply an appropriate amount of lubricating oil to the

piston ring before the installation: 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. 5-19-23. 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 upward. See Fig. 5-19-24.
The piston ring moves smoothly in ring slot without any
after installation.
Fig. 5-19-23 Installing the connecting rod Attention:

assembly and piston
——Two compression rings are not interchangeable.
——Piston ring should not tilt.
——There should not be any defect or impurity in the
piston ring groove.
The three piston rings should be installed into their

grooves with their open ends staggered as shown in
Fig. 5-19-25.
TOP mark (5) Use the piston ring compressor to install the piston
(compression connecting rod to the cylinder, as shown in Fig. 5-19-26.
ring)
Fig. 5-19-24 Installing the piston ring Piston cylinder clearance
0.07~0.09mm
ring
Attention: The front marks on the piston and the
connecting rod should face the front end of the diesel
engine.
(6) Reinstall the connecting rod cover to its originally
matched connecting rod. Install the connecting rod bolt
and tighten it as per specified torque by two steps.
Open end of Open end of
oil ring second
Front end mark Tightening torque for the connecting rod bolt
compression
ring
Step 1 Step 2
Fig. 5-19-25 Inspection for open end of piston
ring 25N·m±3N·m Turn for 90°±5
Clearance between connecting rod big end and

crankshaft crank
0.22~0.37mm
Attention: The front end mark on the connecting

rod cover should face the front end of the crankcase

during the installation.
Installing the engine oil pump assembly ⑩

(1) Apply a small amount of lubricating oil to the seal
ring and insert the seal ring to the bottom of the
corresponding groove on the engine oil pump housing
Front without any scratch, skew or impropriety.
side
(2) Coat the front oil seal of crankshaft with an
appropriate amount of lubricating oil, and install it to the
oil seal hole of the engine oil pump housing. After the
installation, there should not be any scratch, skew or
impropriety.
Fig. 5-19-26 Installing the piston connecting Installer of front oil seal: 5-8840-2361-0.
rod group (3) Apply an appropriate amount of lubricating oil to the
the external rotor to the engine pump cavity of the upper
Outer rotor
Seal ring
(4) Install the engine oil pump assembly and the
Front oil seal cylinder body together. Tighten the 10 hexagon bolts
and the plain washer subassembly (M8×40, M8×25,
M8×20) according to specified torque and order.

Fig. 5-19-27 Installing the engine oil pump pulley is rotating after installation.
Installing oil pan upper and lower body assemblies

Cylinder body and oil collector assembly ⑨
(1) Check whether the dowel pin of the oil pan upper
body is installed correctly. Evenly apply silicon rubber
plane sealant to the junction surfaces of the oil pan and
the cylinder body. And then install the oil pan upper
body to the cylinder body. See Fig. 5-19-28.
Upper body of
oil pan LOCTITE587 plane sealant.
Attention: make sure the joint surface between the

(2) Tighten the 15 hexagon flange bolts (M6×20,
Fig. 5-19-28 Installing the upper body of oil M6×110, M8×25, M8×45) of the oil pan upper body
pan according to specified torque and order. See Fig.
5-19-29. The junction surfaces should be connected
tightly

355
Tightening torque of fastening bolt of oil pan upper

body
M6 9N·m±3N·m
M8 23N·m±3N·m

seal surface of the oil collector. Align the oil suction
holes on the oil pan, place the oil collector gasket at the
same time, and tighten it with 2 hexagon flange bolts
(M6×16). See Fig. 5-19-30.
Fig. 5-19-29 Installing the upper body of oil
pan Mobil API CI-4 lubricating oil
Tightening torque of fastening bolt of oil collector
M6 9N·m±3N·m
M8 23N·m±3N·m
Upper body Attention: install and fix 2 hexagon flange face

of oil pan bolts (M8×12) on the fixing oil collector bracket after
installing oil pan.
(4) Check the junction surfaces of the upper and lower
bodies of the oil pan and make sure there is no dirt or
scratch. Apply silicon rubber plane sealant to the
junction surfaces. And then install the oil pan lower body
Oil collector to the oil pan upper body. Tighten the 14 hexagon
assembly flange bolts (M6×12) according to the specified torque
and order. See Fig. 5-19-31.

Fig. 5-19-30 installing the oil collector
assembly
Tightening torques for fastening bolts of the oil pan
9N·m±3N·m
Attention:
leakage may occur.
junction surface of upper and lower bodies of the oil pan
is clean.
Installing the flywheel gear ring assembly ⑧
Fig. 5-19-31 Installing the lower body of oil (1) Insert the cylindrical pin into the pin hole at the
pan flange face of the crankshaft output end.
Align the pin holes to install the flywheel gear ring

assembly to the crankshaft, and tighten the 8 flywheel

bolts according to the specified torque and order. See
Fig. 5-19-32.
Tightening torques for fastening bolts of the

flywheel gear ring assembly
75N·m±5N·m
Attention: Thread fixing agent should be applied to

the thread of the flywheel bolt before fitting it.

Fig. 5-19-32 Tightening order of fastening
bolts of flywheel Check whether the end face runout is within the
range of specified values. This value should be or less
than 0.12.
(3) Install pressure plate dowel pin into flywheel gear
ring assembly.
Installing the clutch assembly ⑦
——Install the driven disc by guide centering device.

Fig. 5-19-33 Installing the clutch pressure
plate assembly
in Fig. 5-19-33.

23N·m±3N·m
装配气缸盖总成⑥ Installing cylinder head assembly

⑥
Cylinder
head bolt (1) Install the gasket of the cylinder head.
Check the junction surface of the cylinder head and the
cylinder body for foreign matters, and wipe it by silk
cloth. Insert the cylinder head dowel pin sleeve into the
assembled; while fixing the cylinder head gasket, fit the
Cylinder head
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.

357
Fig. 5-19-34 Installing the cylinder cap

assembly Make sure that the cylinder head gasket is placed
correctly at all directions after the assembly.
Lubrication Fix the cylinder head to the cylinder body, and align the
bolts (M11×1.5×162) according to specified sequences.
See Fig. 5-19-34.
Tightening torque of cylinder head fastening bolt
Hydraulic clearance Step 1 Step 2 Step 3

adjuster
50N·m±3N·m Turn it for 90° Turn it for 120°
adjuster Attention: Before the installation, check the
Camshaft
(3) Install the hydraulic clearance adjuster and the
rocker arm
——Lubricate the ball head of the hydraulic clearance
adjuster with lubricating oil of proper amount.
——Fit the hydraulic clearance adjuster to the clip at the
rear end of the rocker arm, as shown in Fig. 5-19-35.
And make sure the tappet don’t fall off after installation.
Cylinder head ——Lubricate the surfaces of the rocker arm and the
Fig. 5-19-36 Installing the exhaust/intake and then insert the whole part into the corresponding
camshaft hole, with the other side of the rocker arm overlapping
on the valve.
Camshaft
bearing
cap (4) Install the intake and exhaust camshafts
——Apply an appropriate amount of lubricating oil in the
bearing holes of intake and exhaust camshafts of
cylinder head and on the surface of the camshaft
bearing neck.

Cylinder
head ——Install the intake and exhaust camshafts to the
——Align the marks “．” on the drive gears of the
cap
intake/exhaust camshafts to make these marks flush
——Coat the junction surface of the camshaft bearing
cap and the cylinder head with plane sealant.


——Tightly screw 6 hexagon flange bolts (M6×35) of
the camshaft bearing cap according to specified torques
and sequence, and then screw down the 6 hexagon
flange bolts (M6×20) around them according to the
requirements. See Fig. 5-19-37.
Tightening torque of fastening bolt of overhead

9N·m±3N·m
Attention: if the original cylinder cap is used, clean

the joint surface of the camshaft bearing cap and the
cylinder cap before applying the sealant.
(6) Install the vacuum pump assembly. See Fig.

5-19-38.
Cylinder head (7) Install the fuel injector assembly.
Screw down the supporting bolt of fuel injector ballast to
the cylinder cap as specified.
Vacuum pump Tightening torque of supporting bolt of fuel injector

assembly
ballast
23N·m±3N·m
Fig. 5-19-38 Installing the vacuum pump washer is installed to each fuel injector and placed
assembly horizontally.
Place one end of the fuel injector ballast on ballast
groove.
(3) Plug the fuel injectors into the mounting holes on the
cylinder head corresponding to cylinders 1st, 2nd, 3rd and
4th respectively according to the number 1, 2, 3 and 4
on fuel injector.
Install the tightening bolt assembly of fuel injector
Fuel injector
ballast, and screw it down according to the specified
assembly torque, without gas leakage on the injector gasket.
Tightening torque of fastening bolt component of

Fig. 5-19-39 Installing the fuel injector fuel injector ballast
assembly
25N·m~35N·m
(8) Install the fuel return hose. See Fig. 5-19-40.

359
Install the fuel inlet pipe of the fuel injector, and evenly
Fuel return hose tighten the pipe connectors on the two ends of the fuel
component inlet pipe of the fuel injector as per specified torque as
Fuel feeder of
the fuel shown in Fig. 5-19-40.
injector
Make sure the oil pipe is sealed without oil leakage
after installation.
Tightening torque of fuel inlet pipe connector of fuel

injector
Fuel inlet pipe
of fuel rail 32N·m±3N·m
Fig. 5-19-21 Installing the fuel inlet pipe and Attention: Make sure to evenly tighten the two
the fuel return hose for the fuel injector ends of the fuel injector fuel inlet pipe at the same time
in installation so as to avoid the oil pipe deformation.
Installing the timing system⑤
(1) Install the camshaft timing pulleys and the
crankshaft timing pulleys.
——Fit the woodruff key and the camshaft timing pulley
to the exhaust camshaft, and tightly tighten the
fastening bolt and gasket subassembly according to
specified torques. The camshaft timing pulley should be
Timing rear hood properly fitted without any inclination.
Tightening torques for the fastening bolt and gasket

subassembly of the camshaft timing pulley
110N·m±5N·m
– Fit the woodruff key and the crankshaft timing pulley
to the crankshaft, and tightly tighten the fastening bolt
according to specified torques; the crankshaft timing
pulley should be properly fitted without any inclination.
Tightening torque of fastening bolt of crankshaft

timing pulley
185N·m~195N·m
Attention: use the cylindrical pin to fix the

overhead camshaft timing pulley and the flywheel gear
ring assembly when tightening the timing pulleys of
overhead camshaft and crankshaft.

Install the idle wheel assembly and tighten the fastening

bolts as per specified torque.
Timing mark Tightening torques of fastening bolt of the timing

idle wheel
22N·m~26N·m
Bone-line
(3) Adjust the mark position on the camshaft timing belt
Camshaft pulley so as to align it with the joint (on the exhaust
timing pulley side) of the cylinder head and the camshaft bearing
cap. See Fig. 5-19-42.
(4) Adjust the crankshaft timing pulley until the scale
mark on the belt pulley is aligned with the arrow on the
pulley
oil pump housing.
(6) Install the timing tension pulley: Embed the limit
Use a hexagon adjusted by a socket head spanner so that it is aligned
socket head
spanner to adjust with the notch position, screw the tension pulley bolts
the mounting hole. Analog Notch with specified torques. See Fig. 5-19-43.
Tightening torque of fastening bolt of timing tension

pulley
22N·m~26N·m
(7) Install the timing hood components I and II, the
timing hood and the timing rear hood. See Fig. 5-19-44.
——Fit the rear timing hood components to the cylinder
head, and screw the hexagon flange bolt (M6×6) with
Tightening torque of fastening bolt of timing rear

hood
9N·m±3N·m
——Insert the sealing strips I and II to the sealing
Fig. 5-19-44.Installing the timing hood grooves of timing hoods I and II respectively.
components, the timing hood and the timing ——After aligning the mounting holes of the timing hood
rear hood and timing hood components I and II, screw the 15
hexagon flange bolts (M6×16, M10×35 and M10×50) to
the cylinder head and the front cylinder body according
to specified torques.
Tightening torques for fastening bolts of the timing

hood and the timing hood components I and II

361
Crankshaft
M6 9N·m±3N·m
M10 45N·m±3N·m
Installing the damping pulley assembly④
(1) Fit the elastic cylindrical pin into the pin hole of the
crankshaft timing pulley.
Timing
pulley (2) Align the damping pulley pin holes, install the
damping pulley to the front end of crankshaft, and screw
down 4 hexagon flange blots (M8×20) as per specified
Damping pulley torque. See Fig. 5-19-45.
Tightening torque of fastening bolt of damping

Fig. 5-19-45 Installing the damping pulley pulley
assembly
23N·m±3N·m
After assembly, the timing mark of the damping

pulley should be set forward.
Installing the engine accessories ③

(1) Install the steering pump support.
(2) Install the engine bracket and the engine assembly.
See Fig. 5-19-46.
(3) Install the accessories such as the flat idle wheel
assembly and the wedge idle wheel.
(4) Install the tension pulley.
Installing the engine assembly ②

(1) Use a crane to evenly place the engine to the frame
Fig. 5-19-46 Installing the engine accessories mounting position with the engine hook attached to the
crane. See Fig. 5-19-47.
Engine hook (2) Tighten the 2 fastening nuts that connect the engine
left / right bracket and the frame studs.
Tightening torques for fastening nuts of the engine

bracket
95N·m±10N·m
(3) Install the power steering pump, the refrigerating
(4) Install the front exhaust pipe.

damage the oil pipe, electric elements and sensor etc.
Fig. 5-19-47 Installing the engine assembly


Transmission (1) Install the transmission dowel pins: Fit the 2
transmission dowel pins into the back end face of the
Clutch assembly cylinder head by a special tool; there should be no
in proper order and as per specified torque.
(3) Install the drive shaft.

Fig. 5-19-48 Installing the transmission operations.
assembly (1) Install the harness connector and make sure it is
leakage.

363
Section XX Cylinder Body Assembly
Removal procedure
② Engine assembly
③ Engine accessory
④ Damping pulley
assembly
⑤ Timing system
⑥ Cylinder head assembly
⑦ Water pump assembly
⑧ Clutch assembly
⑨ Flywheel gear ring
assembly
⑩ Oil pan lower part
assembly, oil collector
assembly and
11 Oil pump assembly
○
12 Piston and connecting
○
rod assembly
○
○
15 Crankshaft and
○
crankshaft position signal
Installation procedure panel
16 cooling nozzle assembly
○
17 upper cylinder body
○
Fig. 5-20-1 Cylinder Body Assembly Removal Procedure

Removal
Preparation
(1) Disconnect the grounding cable of storage battery.
See Fig. 5-20-2.
(3) Drain out the engine oil (lubricating oil) in the
lubrication system.

storage battery
environment.
Transmission
Clutch assembly
(2) Remove the transmission assembly.
(3) Remove the bolts connecting the transmission and
the clutch in proper order, and remove the transmission

assembly
Removing the engine assembly ②.
Engine hook
(1) Remove the catalyst pipe.
(2) Remove the generator belt, the power steering oil
pump and the refrigeration compressor.
(3) Remove the engine bracket fastening nuts: remove
the 2 fastening nuts connecting the engine left and right
brackets with the frame studs to separate the engine
from the frame.
Fig. 5-20-4 Removing the engine assembly repair, removal and reinstallation.
Attention: when removing the engine assembly,

take care not to damage the sensor, oil pipe, brake pipe,
electric elements, etc.

365
Removing the engine accessories ③.

wheel assembly.
(3) Remove the steering pump bracket component.
(4) Remove the engine and the engine bracket. See Fig.
5-20-5.
Removing the damping pulley assembly ④.
Damping pulley (1) Remove the 4 hexagon flange bolts (M8×20)

fastening the damping pulley at the front end of
Timing pulley of (2) Remove the damping pulley assembly from the front
crankshaft end of crankshaft.
Removing the timing system ⑤.

(1) Remove the timing hood components Ⅰand II, the
timing hood and the timing rear hood: loosen
respectively the 15 hexagon flange bolts (M6×16,
Fig. 5-19-6 Removing the damping pulley M10×35, M10×50) fastening the timing hood
assembly components Ⅰ and II, and the timing hood, and remove
them from the cylinder head and the front end of
cylinder body. Loosen the hexagon flange bolt (M6×16)
fastening the timing rear hood and remove it from the
(4) Remove the timing idle wheel assembly: unscrew
the fastening bolts of timing idle wheel, and remove the
(5) Remove the camshaft timing pulley: loosen the bolt
Fig. 5-20-7 Removing the timing system gasket component of camshaft timing pulley and

拆卸气缸盖总成⑥ Removing cylinder head assembly

Cylinder cover ⑥
(1) Remove the cylinder cover component. See Fig.
5-20-8.
Camshaft bearing (4) Remove the cylinder head assembly: loosen in
cap
several times the 10 cylinder head bolts fastening the
Cylinder head cylinder head to the cylinder body and remove the
cylinder head from the cylinder body.

Caution: if the cylinder cap bolts are not orderly
assembly
cylinder cap might be damaged.
Removing the clutch assembly ⑦.

(1) Remove the 6 hexagon flange bolts (M8×25, M8×30,
M10×25) connecting the water pump assembly and the
cylinder body, and remove the water pump assembly as
Water pump gasket shown in Fig. 5-20-9.
(2) Remove the water pump gasket.
Water pump assembly (3) Use guide centering device to prevent the clutch
Fig. 5-20-9 Removing the cylinder head Check the water pump gasket and replace it if any
assembly damage or deformation exists.
Removing the clutch assembly ⑧
Attention: Any fluid should not be allowed to

remain on the surface of the clutch. If there is some
fluid, remove it.
(2) Remove the driven disc assembly.

367


(4) Make a mark on the flanges of the flywheel and the
pressure plate to allow alignment during the installation.
(5) Loosen in order by two steps the 9 bolts fastening
the clutch pressure plate and remove the clutch
assembly as shown in Fig. 5-20-10.
Removing the flywheel gear ring assembly ⑨
(2) Loosen in order by two steps the 8 bolts fastening
the flywheel gear ring to the rear end of crankshaft.
rear end of crankshaft. See Fig. 5-20-11.
Crankshaft position Removing the oil pan lower body assembly, oil
signal panel collector assembly and oil pan upper body
assembly ⑩.
Flywheel gear
ring assembly
(1) Use a spanner to remove in order the 14 hexagon
flange bolts (M6×12) fastening the oil pan lower body
and remove the oil pan lower body. See Fig. 5-20-12.
Crankshaft (2) Use a spanner to remove 2 hexagon flange bolts
(M6×16) fastening the engine oil pipe and 2 hexagon
flange bolts (M8×12) fastening the engine oil collector
Fig. 5-20-11 Removing the flywheel gear ring support, and remove the engine oil collector.
assembly (3) Use a spanner to remove the 15 hexagon flange
bolts (M6×20, M6×110, M8×25 and M8×45) fastening
Upper body of
oil pan
the upper body of the oil pan to the lower cylinder body
in proper order, and remove the upper body of the oil
pan from the lower cylinder body.
Removing the engine oil pump assembly ○
11

subassemblies (M8×40, M8×25 and M8×20) fastening
Oil collector
the engine oil pump assembly to the cylinder body in
Lower body of oil proper order, and remove the engine oil pump
pan assembly. See Fig. 5-20-13.
Fig. 5-20-12 Removing the oil pan upper and See Fig 5-20-13.
assembly (3) Take out the front oil seal of crankshaft through the


Outer rotor
Removing the piston connecting rod assembly ○
12
Seal ring
(1) Unscrew and remove the 8 connecting rod bolts in
two separated times following the order of cylinders 1st,
Front oil seal 4th, 2nd and 3rd, and take down the 4 connecting rod
covers and the lower connecting rod bearing shell. See
Fig. 5-20-14.
(2) Remove the 4 piston components, the connecting
Fig. 5-20-13 Removing the oil pump assembly rod body and the upper connecting rod bearing shell,
and mark them in groups according to the cylinder
order.
Caution: Special care shall be taken not to hit or

scratch the connecting rod journal or the inner surface
of the connecting rod.
Removing the crankshaft rear oil seal ○

13
Piston
(1) Remove the crankshaft rear oil seal from the rear oil
sealing groove behind the cylinder body with special
tools. See Fig. 5-20-15.
Connecting
rod
Crankshaft (2) Remove the rear oil seal of crankshaft from the rear
end of cylinder body.
Connecting rod Attention: when removing the crankshaft rear oil

cover seal, do not damage the crankshaft and the rear oil seal
seat.
Fig. 5-20-14 Removing the connecting rod
14
assembly and piston
(1) Remove the 10 main bearing cap bolts
(M11×1.5×87) in order from the lower cylinder body.
See Fig. 5-20-16.
connecting the lower and upper cylinder bodies. See
Fig. 5-20-16.
cylinder body.
Cylinder body
Rear oil seal

Attention: the removing of the lower cylinder body
fastening bolts shall be performed in the order from the
two sides of the cylinder body to the middle.
crankshaft Removing the crankshaft and the crankshaft
15
(1) Remove the crankshaft from the lower cylinder body.


369
head screws (M6×12) fastening the signal panel and

remove the panel from the rear end of the crankshaft.
Lower cylinder
body See Fig. 5-20-17.
Removing the cooling nozzle assembly ○
16
(1) Remove the 4 hexagon socket mushroom head

screws (M6×12) fastening the cooling nozzle and
Upper cylinder
remove the 4 cooling nozzles from the upper cylinder
body body.
Attention: When removing it, do not bump the head

of the cooling nozzle.
Fig. 5-20-16 Removing the lower cylinder (2) Keep the cooling nozzle properly after removing it to
body avoid pollution and bumping.
Removing the upper cylinder body ○
17
(1) Remove the thermostat cover, the thermostat and

the thermostat shield from the upper cylinder body.
Crankshaft
position signal (2) Remove the water drain bolt, the crankshaft position
panel sensor and the oil pressure alarm from the right side of
Flywheel gear
the upper cylinder body.
ring assembly
(3) Check the wearing condition of the wall of the
cylinder bore and replace the upper and lower cylinder
bodies if the condition is worse than that required.
Crankshaft
Installation
Installing the upper cylinder body ○
17
Fig. 5-20-17 Removing the crankshaft and the
crankshaft position signal panel (1) Install the oil return pipe assembly. After applying a
small amount of sealant to the oil return pipe installing
position, beat it into the corresponding hole on the
upper cylinder body with a hand hammer.
Lower cylinder
body (2) Install the positioning sleeve to the corresponding
position on the cylinder body.
(3) Install the turbocharger oil return pipe connector to
the upper cylinder body after applying a small amount of
sealant to the connector.
Upper cylinder
body (4) Install the 2 Ø18mm bowl-shaped plugs to the main
oil duct of the cylinder body after applying a small
amount of sealant to them.
The new 1608 bowl-shaped plug sealant can be

Fig. 5-20-18 装配上缸体 Fig. 5-20-18
used.
Installing upper cylinder body
(5) Install the crankshaft position sensor and the engine
oil pressure alarm to the right side of cylinder body.
(6) Installing the water drain bolt
Apply anaerobic thread lock sealant to the thread of the
water drain bolt.Install the water drain bolt into the
mounting screw hole on the cylinder body and tighten it

with required torque. Ensure that it is sealed without

leakage of water after installation. See Fig. 5-20-19.
Water Drain bolt tightening torque

50N·m±3N·m
LOCTITE 243 thread fixative.

(7) Install the thermostat shield, the thermostat and the
thermostat cover to the intake side of the cylinder body.
Installing the cooling nozzle assembly ○
16
Water drain bolt Install the cooling nozzle and fasten the hexagon socket
mushroom head screw (M6×12) to the upper cylinder
body. See Fig. 5-20-20.
Fig. 5-20-19 Installing the water drain bolt
Tightening torque for fastening screw of the cooling
nozzle
Cylinder body
9N·m±3N·m
Installing the crankshaft and the crankshaft position
signal panel ○ 15
Choose the main shaft bearing shell as shown in Fig.

4-4-1, 4-4-2.Install the upper main shaft bearing shell
with oil groove and oil hole to the upper cylinder body
and the lower main shaft bearing shell without oil groove
and oil hole to the lower cylinder body.A wrong
Cooling nozzle
installation is not allowed. And apply a proper amount of
lubricating oil after the completion of the upper and the
lower main shaft bearing shell installation.
Fig. 5-20-20 Installing the cooling nozzle
Install the crankshaft position sensor signal panel to the
Crankshaft
eighth crank arm of the crankshaft and tighten 3
hexagon lobular socket countersunk head screws
Crankshaft (M6×12) with required torque.Any deviation or
position signal displacement is not allowed. See Fig. 5-20-21.
panel
Tightening torque for hexagon lobular socket
countersunk head screw
9N·m±3N·m
crankshaft main bearing journal and the oil holes, and
Fig. 5-20-21 Installing the crankshaft position then install the crankshaft to the upper cylinder body.
sensor signal panel
Crankshaft axial clearance
0.10~0.28mm

371
Installing the lower cylinder body ○

14
(1) Apply an appropriate amount of lubricating oil

thrust surface.

(2) Install the upper thrust plate to the rabbet of the
upper cylinder body, with its oil groove side facing the
crank arm, and the lower thrust plate to the rabbet of the
lower cylinder body, with its oil groove side facing the
crank arm.
Fig. 5-20-22 Installing the thrust washer
Attention: The lower thrust plate rather than the
upper thrust plate has a positioning lip.
(3) Evenly apply the sealant to the top surface of the
lower cylinder body, install the lower cylinder body and
align it to the upper cylinder body dowel pin; install the
Front 10 main bearing cap bolts (M11×1.5×X87) and tighten
end them with required torque in order by three steps. See
Fig. 5-19-20.Install the 11 hexagon flange bolts (M8×80)
connecting and fastening the upper and the lower
cylinder body, and tighten them with required torque.
See Fig. 5-20-23.
Lubricate it with oil
LOCTITE510 anaerobic flat sealant.
Fig. 5-20-23 Tightening the main bearing cap
bolts Attention: Before applying the sealant to the top
surface of lower cylinder body, make sure the joint of the
upper and lower cylinder bodies are clean.
Tightening torques for fastening bolts of the main

bearing cap and the lower cylinder body
Main bearing cap bolt 40N·m±3N·m
(screw it down tightly by Turn for 90°: then turn for
three steps) another 90°
Hexagon flange face bolt 23N·m±3N·m
Cylinder body
Rear oil seal After the installation, rotate the crankshaft

manually, and the crankshaft should rotate freely
Fig. 5-20-24 Installing the rear oil seal of
Installing the crankshaft rear oil seal ○
13
crankshaft
(1) Check the crankshaft rear oil seal to be installed for
cleanness and impurities.
lip oil groove and the cylindrical surface of the oil seal
assembly.

Install the crankshaft rear oil seal to the cylinder body oil
sealing groove with special tools. See Fig. 5-20-24.
Caution: make sure the oil seal end face does not
tilt and it is properly installed.
Installing the piston connecting rod assembly ○
12
(1) Carefully remove dirt on the back of connecting rod

bearing shell and matching surface of connecting rod
bearing seat.
Fig. 5-20-25 Installing the connecting rod (2) Install the connecting rod bearing shell in the same
bearing shell group to the connecting rod as per the numbers marked
crank pin.

piston ring before the installation: use the piston ring
Piston expander to install the oil ring component, the second
compression ring and the first compression ring in
proper order. See Fig. 5-20-26. The piston ring should
Connecting be installed to the piston ring groove in a correct
rod direction with the top marks (TOP) of the first and
second compression rings upward. See Fig. 5-20-27.
Crankshaft
The piston ring moves smoothly in ring slot without any
after installation.
Connecting rod
cover
Fig. 5-20-26 Installing the connecting rod Attention:

assembly and piston
——Two compression rings are not interchangeable.
——Piston ring should not tilt.
——There should not be any defect or impurity in the
piston ring groove.
The open ends of the three piston rings installed in

their grooves shall be staggered as shown in Fig.
5-20-28.
TOP mark (5) Use the piston ring compressor to install the piston
(compression connecting rod to the cylinder, as shown in Fig. 5-19-26.
ring)

Fig. 5-20-27 Installing the piston ring Piston cylinder clearance

373
0.07~0.09mm
ring
Attention: the front marks of the piston and the
connecting rod must face the front of the diesel engine.
See Fig. 5-20-29.
(6) Reinstall the connecting rod cover to its originally
matched connecting rod and install the connecting rod
bolts, and screw them by two steps down with required
Open end of Open end of torque.
oil ring second
Front end mark
compression Clearance between connecting rod big end and
ring crankshaft crank
Fig. 5-20-28 Inspection for open end of piston 0.22~0.37mm

ring
Connecting rod bolts tightening torque
Step 1 Step 2
Front 25N·m±3N·m Angle 90°±5

side
Attention: During the installation, the front mark of

the connecting rod cover shall face the front of
crankcase.
Installing the engine oil pump assembly ○
11
Fig. 5-20-30 Installing the piston connecting (1) Apply a small amount of lubricating oil to the engine
rod group oil pump seal ring and insert the seal ring into the
bottom of the corresponding groove on the oil pump
housing without scratch, skew or impropriety.
(2) Coat the front oil seal of crankshaft with an
installation, there should not be any scratch, skew or
impropriety.
Installer of front oil seal: 5-8840-2361-0.


(4) Install the oil pump assembly and the cylinder body
together and tighten in order the 10 hexagon bolts and
the plain washer components (M8×40, M8×25, M8×20)
with the required torque. See Fig. 5-20-30.
Outer rotor
Seal ring
Tightening torque for fastening bolt of oil pump
23N·m±3N·m
Front oil seal

Installing the oil pan lower body assembly, oil
Fig. 5-20-30 Installing the oil pump assembly collector assembly and oil pan upper body
assembly ⑩
(1) Check the installation of the dowel pin on the oil pan
upper body for correctness, apply the silicon rubber flat
sealant evenly to the junction surfaces of the oil pan and
the cylinder body and install the oil pan upper body to
the cylinder body.
Attention: make sure the joint surface between the

(2) Screw down the 15 hexagon flange bolts (M8×25,
Fig. 5-20-31 Installing the upper body of oil M8×45, M6×20, M6×110) on the oil pan upper body and
pan the lower cylinder body in order with required torque.
See Fig. 5-20-31. The junction surfaces shall connect
tightly.
oil pan upper
body
Tightening torque for fastening bolt of the oil pan
upper body
M6 9N·m±3N·m
M8 23N·m±3N·m
(3) After applying an appropriate amount of lubricating
Oil collector oil to the sealing position of the oil collector, align the oil
assembly suction holes of the oil pan and meanwhile put in an oil
collector gasket and tighten it with 2 hexagon flange
bolts (M6×16). See Fig. 5-19-32.
Fig. 5-20-32 Installing the upper body of oil Tightening torque for fastening bolt of oil collector
pan
M6 9N·m±3N·m
M8 23N·m±3N·m
Attention: install and fix 2 hexagon flange face

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

375
(4) Check the joint faces of the oil pan upper and the
lower body for spoils and scratches; apply silicon rubber
plain sealant evenly to the joint faces and then install
the lower body to the upper body and tighten the 14
hexagon flange bolts (M6×12) with required torque and
in required order as shown in Fig. 5-20-33.
Tightening torque for fastening bolt at lower body of

oil pan
9N·m±3N·m
Fig. 5-20-33 Installing the lower body of oil

pan
Attention:
leakage may occur.
——Before applying sealant again, make sure the joint
faces of the upper and lower bodies of the oil pan are
clean.
Installing the electric wheel gear ring assembly ⑨
(1) Insert the cylindrical pin into the pin hole at the
flange face of the crankshaft output end.
Fig. 5-20-34 Tightening order of fastening (2) Align the pin holes, install the flywheel gear ring
bolts of flywheel assembly to the crankshaft and tighten the 8 flywheel
bolts with required torque and in required order as
Tightening torque for fastening bolt of flywheel gear

ring assembly.
75N·m±5N·m
Attention: Apply thread fixing agent to the thread

of the flywheel bolt before fitting it.
Fig. 5-20-35 Installing the clutch assembly Check whether the end face runout is within the
range of specified values. This value should be or less
than 0.12.
(3) Install pressure plate dowel pin into flywheel gear
ring assembly.
Installing the clutch assembly ⑧


——Install the driven disc assembly by the guide
centering device.

Water pump Tighten the 9 bolts fastening the clutch pressure plate
gasket assembly in the order as shown in Fig. 5-20-35 to the
required torque.
Water pump
assembly
Tightening torque for fixing bolt of the clutch
Fig. 5-20-36 Installing the water pump
Installing the water pump assembly ⑦
Cylinder (1) Install the water pump packing.
head bolt
(2) Install the water pump assembly to the cylinder body
and tighten the 6 hexagon flange face bolts (M8×25,
M8×30, M10×25) with required torque. See Fig.
5-20-36.
Tightening torques for fastening bolt of the water

pump
Cylinder head
M8 23N·m±3N·m
Fig. 5-20-37 Installing the cylinder head M10 45N·m±3N·m

assembly
The stagnation when the water pump pulley

rotating shall not occur after installation.
Installing the cylinder head assembly ⑥
(1) Install the gasket of the cylinder head.
Check the junction surface of the cylinder head and the
cylinder body for foreign matters, and wipe it by silk
cloth. Insert the cylinder head dowel pin sleeve into the
assembled; while fixing the cylinder head gasket, 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.

377
Make sure that the cylinder head gasket is placed

Lubrication correctly at all directions after the assembly.
Fix the cylinder head to the cylinder body, and align the
bolts (M11×1.5×162) by three steps according to the
specified sequence. See Fig. 5-20-37.
Hydraulic clearance
adjuster

adjuster 50N·m±3N·m Turn it for 90° Turn it for 120°
Camshaft Attention: Check the cylinder head bolt before

deformation, elongation, pulled thread or other faults.
(3) Install the hydraulic clearance adjuster and rocker
arm
——Lubricate the ball head of the hydraulic clearance
adjuster with lubricating oil of proper amount.
——Insert the hydraulic clearance adjuster to the clip at
Cylinder head the rear end of the rocker arm as shown in Fig. 5-20-38
and ensure that the tappet will not drop after installation.
Fig. 5-20-39 Installing the exhaust/intake ——Lubricate the surfaces of the rocker arm and the
camshaft hydraulic clearance adjuster with lubricating oil again,
Camshaft on the valve.
bearing
cap
(4) Install the intake and exhaust camshafts
——Apply an appropriate amount of lubricating oil to the
bearing holes of the intake and exhaust camshafts of
cylinder head and the surface of the camshaft journal.
Cylinder
head Mobil API CI-4 lubricating oil
——Install the intake and the exhaust camshaft into the
cap
——Align the marks “．” on the driving gears of the
intake/exhaust camshaft to make these marks flush with
the upper plane.
0.060~0.115mm

——Coat the junction surfaces of the camshaft bearing

cap and the cylinder head with plane sealant.
Cylinder head
LOCTITE510 anaerobic flat sealant.
——Tightly screw the 6 hexagon flange bolts (M6×35)
for fastening the camshaft bearing cap according to
Vacuum pump specified torques and sequence, and then screw down
assembly the 6 hexagon flange bolts (M6×20) around them
Tightening torque for fastening bolt of overhead

Fig. 5-20-41 Installing the vacuum pump 9N·m±3N·m
assembly
Attention: if the original cylinder cap is used, clean

the joint surface of the camshaft bearing cap and the
cylinder cap before applying the sealant.
(6) Install the vacuum pump assembly. See Fig.
5-20-40.
(7) Install the fuel injector assembly.

——Screw down the fuel injector ballast supporting bolt
to the cylinder head as specified.

ballast
23N·m±3N·m
Fuel injector to the fuel injector, and make sure only one copper
assembly washer is installed to each fuel injector and the copper
washer is placed horizontally.
Fig. 5-20-42 Installing the fuel injector ——Place one end of the fuel injector ballast on the
assembly ballast supporting bolt and the other end in the fuel
Fuel return hose ——According to the oil injector number 1, 2, 3 and 4,
component respectively insert them to the fuel injector mounting
Fuel feeder of
the fuel holes of cylinder head 1, 2, 3 and 4.
injector
——Install the fastening bolt component of the fuel
injector ballast, and screw it down according to the
specified torque. No gas leakage is allowed at the
injector gasket.
Fuel inlet pipe Tightening torque for fastening bolt component of

of fuel rail fuel injector ballast
25N·m~35N·m
Fig. 5-20-43 Installing the fuel inlet and return
pipes of fuel injector ——Install the fuel injector harness plug.
(8) Install the fuel return hose. See Fig. 5-20-43.

379

Remove the shields on the two ends of the fuel injector
fuel intake pipe as shown in Fig. 5-20-43, install the fuel
intake pipe and evenly tighten the pipe connectors at
the two ends with the required torque.
Make sure the oil pipe is sealed without oil leakage

after installation.
Timing rear hood

fuel injector
32N·m±3N·m
ends of the fuel injector fuel inlet pipe at the same time
in installation so as to avoid the oil pipe deformation.
Timing mark
Installing the timing system⑤
(1) Install the camshaft timing pulleys and the
Bone-line crankshaft timing pulleys.
——Fit the woodruff key and the camshaft timing pulley
Camshaft to the exhaust camshaft, and tighten the fastening bolt
timing pulley and gasket subassembly according to specified
torques.See Fig. 5-20-45.
Fig. 5-20-45 Installing the camshaft timing The camshaft timing pulley should be properly fitted
pulley without any inclination.
Tightening torques for the fastening bolt and gasket

subassembly of the camshaft timing pulley
110N·m±5N·m
– Fit the woodruff key and the crankshaft timing pulley
to the crankshaft, and tighten the fastening bolts
pulley should be properly fitted without any inclination.
Tightening torque for fastening bolt of crankshaft

timing pulley
185N·m~195N·m

Attention: use the cylindrical pin to fix the

overhead camshaft timing pulley and the flywheel gear
ring assembly when tightening the timing pulleys of
Timing pulley overhead camshaft and crankshaft.
(2) Install the idle wheel assembly and tighten the
fastening bolts with required torque.
Timing
tension
pulley Tightening torque for fastening bolt of timing idle
wheel
22N·m~26N·m
Fig. 5-20-46 Installing the timing pulley (3) Adjust the mark position on the camshaft timing belt
pulley so as to align it with the joint (on the exhaust
side) of the cylinder head and the camshaft bearing cap.
See Fig. 5-20-45.
mark on the belt pulley is aligned with the arrow on the
oil pump housing.
(5) Install the timing belt: during the installation, make
Use a hexagon sure that the belts, except the tension pulley, are
socket head
spanner to adjust
connected with the pulley without any looseness as
the mounting hole. Analog Notch shown in Fig. 5-20-46.
(6) Install the timing tension pulley: Embed the limit
Fig. 5-20-47 Installing the timing tension mounting the bowl-shaped plug onto the cylinder head.
pulley After the mounting pin of the timing tension pulley is
adjusted by a socket head spanner so that it is aligned
with the notch position, screw the tension pulley bolts
with specified torques. See Fig. 5-20-47.
Tightening torque for fastening bolt of timing

tension pulley
22N·m~26N·m
(7) Install the timing hood components I and II, the
timing hood and the rear timing hood. See Fig. 5-20-48.
——Fit the rear timing hood component to the cylinder
head, and screw the hexagon flange bolt (M6×6) with
component and the timing hood Tightening torque for fastening bolt of timing rear
hood
9N·m±3N·m
——Insert the timing hood sealing strips Ⅰand II
separately into their sealing grooves. See Fig. 5-20-48.
——After aligning the mounting holes of the timing hood
and the timing hood components I and II, screw the 15
hexagon flange bolts (M6×16, M10×35 and M10×50) to

381
the cylinder head and the front end of the cylinder body
Crankshaft according to specified torques.
Tightening torques for fastening bolts of the timing

hood and the timing hood components I and II
M6 9N·m±3N·m
Timing
pulley M10 45N·m±3N·m
Installing the damping pulley assembly④

Damping pulley (1) Install the elastic cylindrical spring pin into the pin
hole of the crankshaft timing belt pulley.
Fig. 5-20-49 Installing the damping pulley (2) Align the damping pulley pin holes, install the
assembly damping pulley to the front end of crankshaft, and screw

pulley
23N·m±3N·m
Attention: After the assembly, the timing mark of

the damping pulley should be set forward.
Installing the engine accessories ③
(1) Install the steering pump support.
(2) Install the engine bracket and the engine assembly.
See Fig. 5-20-60.
Fig. 5-20-50 Installing the engine accessories (3) Install the accessories such as the flat idle wheel
assembly and the wedge idle wheel.
Engine hook
(4) Install the tension pulley.
Installing the engine assembly ②
(1) Use a crane to evenly place the engine to the frame
mounting position with the engine hook attached to the
crane. See Fig. 5-20-51.
(2) Tighten the 2 fixing nuts connecting the left and right
brackets of the engine with the frame studs. See Fig.
5-20-52.
Tightening torques for fastening nuts of the engine

bracket
95N·m±10N·m
Fig. 5-20-51 Installing the engine assembly (3) Install the power steering pump, the refrigerating
(4) Install the front exhaust pipe.


damage the oil pipe, electric elements and sensor etc.

(1) Install the transmission dowel pins: Fit the 2
transmission dowel pins into the back end face of the
cylinder head by a special tool; there should be no
Fig. 5-20-52 Installing the engine bracket fastening bolts connecting the transmission and the
fastening nuts clutch in proper order and as per specified torque in
several times. See Fig. 5-20-53.
Transmission (3) Install the drive shaft.
Clutch assembly
After the installation, carry out the following operations:
leakage.
Fig. 5-20-53 Installing the transmission

assembly

383
Chapter VI Fuel System

Section I General
Attention: When performing the maintenance work of fuel supply system, bear the following items
in mind:
(1) When the fuel supply system is working, you should disconnect the earthing wire of storage batteries
unless the test needs the storage batteries for power supply.
(2) A (Grade B) dry chemical fire extinguisher shall always be prepared near the work site.
(3) Replace all the removed fuel pipes and fittings with the same new ones.
(4) Before repairing any parts of the fuel supply system, firstly release the pressure in the pipeline.
(5) Do not repair the fuel supply system, if you have not read this User’s Guide and checked the
drawings and technical materials related with repair.
GW4D20/GW4D20B turbocharged diesel engine can be equipped with a DELPHI, BOSCH, or
XINFENG electronic fuel injection system.
1. Components of Fuel Supply System
A GW4D20/GWD20B turbocharged diesel engine employs high-pressure common-rail fuel supply
system.It primarily consists of sensor group, ECU, actuator group and the harnesses connecting with
these parts.There are different sensors, such as camshaft position sensor, crankshaft position sensor,
knock sensor, coolant temperature sensor, turbocharger pressure sensor, high-pressure fuel rail
pressure sensor and air flow sensor.
The actuator part is composed of low-pressure fuel circuit and high-pressure fuel circuit.The
low-pressure fuel circuit contains fuel tank, fuel delivery pipe, fuel filter, fuel delivery pump and the
low-pressure area of high-pressure fuel pump.The high-pressure fuel circuit contains high-pressure fuel
rail, high-pressure fuel pipe, fuel injector, and the part of high pressure area in high-pressure fuel
pump.The electronic control unit (ECU) automatically controls the fuel supply process of
GW4D20/GW4D20B turbocharged diesel engine.For the arrangements of the fuel supply pipelines of
DELPHI, BOSCH and XINFENG common-rail systems, see Fig. 6-1-1, Fig. 6-1-2 and Fig. 6-1-3
respectively.
Fuel tank
High-pressure fuel
rail assembly
Manual fuel
pump
Fuel
return
Fuel filter tee
Fuel injector assembly
High-pressure fuel
pump assembly
Electronic control unit
Fig. 6-1-1 Arrangement for fuel supply pipeline of DELPHI common-rail system

High-pressure fuel rail assembly
Fuel tank
Fuel return tee Fuel injector

assembly
Fuel filter
Electronic
High-pressu
re fuel pump control unit
assembly
Fig. 6-1-2 Arrangement for fuel supply pipeline of BOSCH common-rail system
High-pressure fuel rail assembly
Fuel tank Fuel return tee
Fuel
return tee
Fuel filter Fuel injector
assembly
High-pressure fuel pump assembly

Electronic
control unit
Fig. 6-1-3 Arrangement for fuel supply pipeline of XINFENG common-rail system

385
Fuel delivery Transported to high-pressure fuel 2. Components of High Pressure Common

pressure pump via IMV
control valve
Rail System
Rotor
Fuel inlet Vane 2.1 Fuel Delivery Pump
The fuel delivery pump functions to provide enough fuel
for the high-pressure fuel pump.This requirement
should be satisfiled during the whole service life of fuel
delivery pump despite various working conditions and
different necessary pressures of engine.
(1) Vane Type Fuel Delivery Pump
Fuel inlet Stator
pressure The GW4D20/GW4D20B turbocharged diesel engine
Fuel delivery pressure
equipped with a DELPHI common rail system employs
the vane type fuel delivery pump, which has a shifty
Fig. 6-1-4 Vane type fuel delivery pump volume. The high-pressure fuel pump is integrated with
the fuel delivery pump.The GW4D20B turbocharged
diesel engine equipped with a XINFENG common rail
system also employs the vane type fuel delivery pump.
The vane type fuel delivery pump is used to provide fuel
for the high-pressure fuel pump.
The main parts are a rotor, a stator, 4 vanes equally
divided by 90°(each vane is tightly pressed on the stator
by the helical spring) and 2 sealing discs, as is shown in
Fig. 6-1-4.
The vane type fuel delivery pump delivers fuel to the
high-pressure fuel pump through the low-pressure
actuator (MV).The fuel delivery volume is in direct
Fig. 6-1-5 Low-pressure actuator (IMV) proportion to diesel engine speed.
The low-pressure actuator (i.e. IMV, see Fig. 6-1-5)
sends a certain volume of fuel into the high-pressure
Driving
gear fuel pump so as to make the common-rail pressure
Fuel meet the ECU requirements.
suction
end
The low pressure actuator (IMV) is installed on the
pump head.The fuel delivery pump offers fuel to the
low-pressure actuator (IMV) through two semicircular
Pressure
end holes.
A cylindrical filter is attached at the fuel inlet of the
low-pressure actuator (IMV) to protect the actuator
(IMV) and also all the parts behind it (IMV).
Fig. 6-1-6 Gear type fuel delivery pump (2) Gear Type Fuel Delivery Pump
The GW4D20B turbocharged diesel engine equipped
with a BOSCH common-rail system employs a gear fuel
delivery pump (see Fig. 6-1-6).The fuel delivery pump
and high-pressure fuel pump are integrated.
The gear type fuel delivery pump is used to provide fuel
for the high-pressure fuel pump as shown in Fig. 6-1-6.
Fuel is sucked into the cavity between the fuel delivery
pump and the gear, and delivered to the fuel outlet on
pressure side. Turning the contacting line between the
gears can ensure a good sealing effect and avoid the
fuel backflow.
The fuel supply volume of gear fuel delivery pump is in

direct proportion to the speed of diesel engine.The fuel

Filter cover Fuel outlet
supply volume is limited by the throttle valve on fuel inlet
Filter cover end or the overflow valve on fuel outlet end.
2.2 Fuel Filter
The fuel containing impurities will cause damage to the
Paper filter high-pressure fuel pump parts, fuel outlet valve and fuel
core
injector.Therefore the diesel engine must be installed
with a fuel filter to filter the fuel.
Housing The fuel filter must meet the specific requirements for
the injection system, or else a normal working of the fuel
Moisture supply system and the designed service lives of
collector relevant elements will not be obtained.
Diesel oil contains soluble emulsion or free water (such
Drain plug as the cooling water used for shifting the temperature).
If such water enters the injection system, it will cause
Fig. 6-1-7 Structure of fuel filter cavitations to the fuel system elements.
The GW4D20/GW4D20B turbocharged diesel engine is
equipped with a fuel filter, which has an oil-water
separator used for draining (see Fig. 6-1-7).With the
engine application time increasing and the water level in
the fuel filter reaching a certain height, the water level
alarm lamp of automatic alarm device will light and
remind the driver of draining.
2.3 High-pressure Fuel Pump
The high-pressure fuel pump functions to provide the
sufficient high-pressure fuel for the diesel engine and
meanwhile ensure the extra fuel supply volume and
required pressure for the quick start of diesel engine.
2.3.1 DELPHI DFP3.4 High-pressure Fuel Pump
The GW4D20/GW4D20B turbocharged diesel engine
having a DELPHI common-rail system is equipped with
Fig. 6-1-8 DELPHI DFP3.4 high-pressure fuel a DELPHI DFP3.4 high-pressure fuel pump as shown in
pump assembly Fig. 6-1-8.
The DELPHI DFP3.4 high-pressure fuel pump produces
high pressure through two stages: ① sucking the fuel
from the fuel tank through the filter; ② enhancing the
pressure.
Technical parameters of DELPHI DFP3.4 high-pressure
fuel pump:
Plunger: two, with a diameter of 6.5mm.
Capacity: 0. 5cc/rev~0. 7cc/rev.
Pressure: 1600-1800 bar.
The low pressure actuator is used to control the fuel
volume.
Drive method: by belt.
Fig. 6-1-9 BOSCH CP1H high-pressure fuel Maximum speed: 4000 r/min.
pump assembly 2.3.2 BOSCH CP1H High-pressure Fuel Pump

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The GW4D20B turbocharged diesel engine having a

BOSCH common-rail system is equipped with a
BOSCH CP1H high-pressure fuel pump as shown in
Fig. 6-1-9.
The BOSCH CP1H high-pressure fuel pump is an
in-line three-plunger pump, with a maximum injection
pressure of 1600 bar.
2.3.3 XINFENG M680 High-pressure Fuel Pump
XINFENG common-rail system is equipped with a
XINFENG M680 high-pressure fuel pump. See Fig.
6-1-10.
Technical parameters of XINFENG M680 high-pressure
Fig. 6-1-10 XINFENG M680 high-pressure
fuel pump:
fuel pump assembly
Rated rail pressure: 1500 bar.
Rated speed: 4000 r/min.
Theoretical output: 380 mm3/r/min.
Cylinder body
The XINFENG M680 high-pressure fuel pump is
equipped with a proportional solenoid valve, which
controls the internal pressure of rail.The high-pressure
fuel pump has a sliding sheet type fuel delivery pump,
which provides a fuel delivery pressure of 0~8 bar.
XINFENG M680 high-pressure fuel pump is a in-line
two-cylinder plunger pump and can withstand a certain
axial force.
When replacing or removing the XINFENG M680
high-pressure fuel pump, fill 15mL of diesel oil to the
fuel delivery pump before the reinstallation, or use the
Fig. 6-1-11 Installing the DELPHI DEP3.4 manual fuel pump on fuel-water separator to expel the
High-pressure Fuel Pump air and add the fuel before the start of engine.Before
you perform this work, the start of diesel engine is
forbidden to avoid the damage to high-pressure fuel
pump.
Cylinder body The XINFENG M680 high-pressure fuel pump is
attached to the diesel engine by 3 M8 bolts, and its front
leans against taper-face driving gear, which is tightly
pressed by M14×1.5 nuts.
Tightening torque for compression nuts of driving

gear:
90 N•m ~ 95 N•m
2.3.4 Precautions for Using High-pressure Fuel Pump
(1) The air in the low-pressure circuit of high-pressure
fuel pump shall be exhausted before you start the
Fig. 6-1-12 Installing the BOSCH CP1H engine.When using the manual fuel pump, carefully
high-pressure fuel pump check and ensure that there are no leakage points
(2) The inlet pressure (absolute pressure) of vane type
fuel delivery pump shall range between 0.35 bar and
1.00 bar (the fuel tank shall be ventilated).

(3) It is strictly forbidden to add an automatic fuel

Cylinder body delivery device before the high-pressure fuel pump.Or
else, the proportional solenoid valve will be damaged.
(4) A high precise couple is installed in the
high-pressure fuel pump. If a failure occurs, send the
pump to a professional maintenance department for
check and repair instead of removing it randomly.
2.3.5 Installing the High-pressure Fuel Pump
(1) Plug the fuel return pipe subassembly in the fuel
return pipe connector of high-pressure oil pump.
(2) Install the high-pressure oil pump, and tighten 2
hexagon flange bolts (M8×30) and a hexagon flange
nut with required torques. See Fig. 6-1-11, Fig. 6-1-12
Fig. 6-1-13 Installing the XINFENG M680 and Fig. 6-1-13.
high-pressure fuel pump
Tightening torques for the fastening bolts and nuts
of high-pressure fuel pump:
23 N•m ± 3 N•m
High-pressure
fuel rail 2.4 High-pressure fuel rail
The high-pressure fuel is included in the high-pressure
fuel rail.The fuel supply in high-pressure fuel pump and
the high-pressure oscillation generated by fuel injection
attenuate in the high-pressure fuel rail volume, so as to
ensures that the injection pressure maintains a fixed
Inlet hole of fuel Outlet hole of Rail pressure
value when fuel injector is opened.The high-pressure
rail fuel rail sensor fuel rail meanwhile serves as a fuel distributor. One of
the fuel pipe connectors is used as a fuel inlet hole on
the high-pressure fuel rail. The high-pressure fuel pump
is connected with the high-pressure fuel pipe and other
Fig. 6-1-14 DELPHI High-pressure fuel rail
4 fuel pipe connectors are connected with the fuel
assembly
injectors. See Fig. 6-1-14.The rail pipe shall be
attached to diesel engine and shall not run by
suspending in the air, or else the common-rail system
will be damaged.It is not allowed to disassemble the
High-pressure Rail pressure
fuel rail safety valve for regulation without permission.The rail
sensor
pressure sensor is a electronic component which shall
not be knocked or disassembled without
permission.During the its application, the inside of the
fuel rail must be kept clean without the entry of water,
so as to avoid getting rusty.
2.4.1 High-pressure Fuel Rail of DELPHI System
Fuel from High-pressure
high-pressure fuel pipe to
For the high-pressure fuel rail of DELPHI system, see
fuel pump fuel injector Fig. 6-1-14.
Technical parameters of DELPHI high-pressure
common rail:
Fig. 6-1-15 BOSCH High-pressure fuel rail High pressure range: 1600-1800-2000 bars
assembly Fuel distribution from fuel pump to fuel injector:
repeated fuel injections are assisted by means of flow
calibration together with damp optimization.

389
Rail pressure sensor: it provides the pressure

Rail pressure parameters of common rail system (rail pressure
sensor control part).
Fuel inlet
Rail pressure range: 1800-2200 bars
2.4.2 BOSCH High-pressure Fuel Rail
Safety valve
For the high-pressure fuel rail of BOSCH system, see
Fig. 6-1-15.
2.4.3 XINFENG System High-pressure Fuel Rail
High-pressure For the high-pressure fuel rail of XINFENG system, see
fuel rail Fuel return Fig. 6-1-16.
connector
Precautions for Using High-pressure Fuel Rail of
XINFENG System:
Fig. 6-1-16 XINFENG High-pressure Fuel Rail (1) When you are running the system, the
Assembly high-pressure fuel pipe connector at each part shall not
be loosened to avoid damage, since the fuel pressure
Fuel injector in the rail pipe may reach 1500 bar.
Fuel inlet pipe feeder
of high-pressure (2) The rail pipe must not be welded.
fuel rail (3) Make sure that the connector rubber ring of rail
pressure sensor is complete, and avoid the water
shock.
(4) Pressure release will be started to ensure the
system safety, when the pressure of common-rail pipe
High-pressure is higher than the safe pressure (1800 bar ± 50 bar) of
fuel rail
system..It is a normal phenomenon that a part of the
hot fuel at this time flows out of the fuel return
connector of safety valve.The safety valve closes after
the pressure is released and the system restore to the
Fig. 6-1-17 Installing the High-pressure fuel
normal working status.If the safety valve is under the
rail assembly
“opened” state for a long time, it shall be stopped and
Nozzle spring Coil Outer the system shall be checked and repaired.
Control edge filter 2.4.4 Installing the High-pressure Fuel Rail
valve C2I code
spring (1) To ensure the cleanness of high-pressure fuel rail,
its protective cover shall not be detached before the
installation.
(2) Fit a high-pressure fuel rail and 2 hexagon flange
Nozzle and Casing bolts (M8×30) to the cylinder cover and tighten them
needle valve Fuel return with required torques. See Fig. 6-1-17.
Valve body connector
Tightening torque for the fastening bolts of
Transition plate Adjusting Connector high-pressure fuel rail:
gasket
23 N•m ± 3 N•m
Fig. 6-1-18 DFI1.5 Fuel Injector Assembly
2.5 Fuel Injector
(DELPHI Common Rail System) The fuel injector functions to start at the scheduled time
according to the ECU control and inject fuel into the
cylinder for combustion.
2.5.1 DFI1.5 Fuel Injector
The GW4D20/GW4D20B turbocharged diesel engine
having a DELPHI common-rail system is provided with
a DFI1.5 fuel injector. See Fig. 6-1-18.The fuel injector
can realize multiple injections within quite a short
time.Under the electronic control, the heat produced in

Return spring
the course of injection may be minimized.
Needle valve Pivot disc Structure of DFI1.5 Fuel Injector:
control chamber Fuel return The inner part of fuel injector casing contains a fuel inlet
Drain hole Coil pipe hole and a fuel return hole.
Fuel nozzle
The nozzle part contains a needle valve and a fuel
injection hole.
Fuel nozzle A complete set of coil components are contained in the
Fuel return
bearing pin pipe fuel injector.
Ball
Control piston valve Control valve components
Transition plate (the apertures for needle valve control
High pressure are available in the control chamber)
connection Lock nuts
2.5.2 CRI2.0 Fuel Injector
Fig. 6-1-19 CRI2.0 fuel injector assembly (of
BOSCH common rail system) The GW4D20B turbocharged diesel engine having a
BOSCH common-rail system is equipped with a CRI2.0
fuel injector. See Fig. 6-1-19.
Fuel pipe 2.5.3 JCRT3 Fuel Injector
connector
Copper pad of XINFENG common-rail system is equipped with a
Fuel return bolt JCRT3 fuel injector. See Fig. 6-1-20.
Fuelballast injector
2.5.4 Precautions for Using Fuel Injector
(1) The fuel nozzle gasket and O-ring are easy to wear
and shall not be reused.
(2) The fuel injector is a precise device and shall not be
O-ring installation knocked. Magnetic and antimagnetic devices shall be
position kept away from the fuel injector when it is working.
(3) The fuel injector is electrically driven and can not be
Fig. 6-1-20 JCRT3 fuel injector assembly (of shocked by water.
XINFENG common-rail system) (4) Do not dismantle the faulty fuel injector without
permission. Instead, you should and get in contact with
the maintenance department promptly.
(5) Take dust prevention measures to avoid the
possible blockage in the fuel injector when installing or
removing it.
(6) The I3C code of the fuel injector must be written into
ECU after the fuel injector has been replaced.
2.5.5 Installing the Fuel Injector Assembly
(1) Tighten the support bolts of fuel injector ballast to
cylinder cover by the required torques.
Section view of
cylinder cover Tightening torques for the support bolts of fuel
injector ballast:
Fig. 6-1-21 Installing the fuel injector 23 N•m ± 3 N•m
assembly (2) Fit a copper pad and a O-ring to the fuel injector.
Make sure that there is only one copper pad on each
single fuel injector and the pad is levelly placed.
(3) Insert the fuel injectors 1, 2, 3 and 4 respectively
into the corresponding holes (on the cylinder cover)
marked with 1, 2, 3 and 4. See Fig. 6-1-21.

391
(4) Put one end of fuel injector ballast on the ballast

support bolt and then put the other end in the ballast
groove.
(5) Install the fastening bolt components of fuel injector
ballast, and tighten them with required torques. Any
leakage on the fuel injector gasket is not allowed.
Tightening torques for fastening bolt components

of fuel injector ballast:
25 N•m~35 N•m
Attention: during the fuel injector installation,

Fig. 6-1-22 DELPHI common-rail system ECU keep the fuel injector clean. Do not bump or drop the
fuel injector.After the installation, the fuel inlet pipe
opening of the fuel injector assembly shall face the rear
end of the engine.
(6) Install the harness plugs of fuel injector.
2.6 ECU (Electronic Control Unit)
ECU is the abbreviation for the electronic control unit of
common-rail system. Its built-in processor chip is
responsible for collecting the signals from all sensors,
calculating the parameters, controlling the rail pressure,
fuel injection volume and injection timing and achieving
other functions like diagnosis and communication.
2.6.1 DELPHI ECU
For the ECU configured for DELPHI common-rail
system, see Fig. 6-1-22.
Fig. 6-1-23 BOSCH common-rail system ECU 2.6.2 BOSCH ECU
For the ECU configured for BOSCH common-rail
2.6.3 XINFENG ECU
For the ECU configured for XINFENG common-rail
2.6.4 Usage Precautions:
(1) Users shall not open the ECU without permission,
since it is a precise electrical component.
(2) The temperature of ECU installation place shall be
-40℃~80℃.ECU shall be kept dry at any time. In order
to ensure its heat dissipation, no cover or dust shall be
kept at the ECU installation position.
(3) ECU and connectors shall not be directly shocked
by water.

2.6.5 Installing the ECU

Fix the ECU to the relative installation position of the
complete vehicle with bolts. It is unallowable to install
the ECU on the engine.
2.7 Sensors
2.7.1 Coolant Temperature Sensor
For the coolant temperature sensor, see Fig. 6-1-25.
The temperature resistance of coolant temperature
sensor is a part of the 5V voltage division circuit.Both
ends of coolant temperature sensor are connected with
energized circuit.When the temperature resistance of
coolant temperature sensor changes with the
temperature, the voltage of energized circuit varies and
Fig. 6-1-24 XINFENG common-rail system is input into the analog-to-digital interface conversion
ECU circuit of ECU.
Installating the coolant temperature sensor: install the
sensor to the screw hole by the required torque after
coating the sealant on the sensor thread.
Coolant
LOCTITE 243 thread fixing agent
Tightening torque for the fastening bolt

components of fuel injector ballast:
18 N•m ~ 22 N•m
NTC
Electronic Housing resistance After the installation, make sure that the sensor is
connector
sealed so strictly that no water leakage will occur.
2.7.2 Camshaft Position Sensor
Fig. 6-1-25Coolant temperature sensor Camshaft position sensor works on the principle of Hall
effect. The trigger wheel of a ferromagnet rotates
Camshaft
position together with the camshaft.The integrated Hall-effect
sensor circuit is installed between trigger wheel and permanent
magnet which produces a magnetic field perpendicular
to the Hall-effct elements. See Fig. 6-1-28.
If one of the trigger wheel teeth travel through the
intercepting linear sensor elements (semiconductor
chips), the intensity of the magnetic field normal to
Hall-effect elements will be changed. Consequently, the
electrons in the direction of long shaft, driven by the
voltage, will deviate towards the direction perpendicular
to the current and then produce the Grade-mV voltage
signals in the latter direction. The amplitude of such a
voltage signal is involved with the sensor speed relative
Fig. 6-1-26 Camshaft position sensor to the trigger wheel.The calculation circuit incorporated
with the sensor’s Hall-effect integrated circuit
processes these signals and output them as
square-wave signals.
Installing the camshaft position sensor: check whether
the O-ring has been properly mounted on the camshaft
position sensor, install the sensor into the hole of

393
cylinder head cover, and use the specified torque to

tighten 2 hexagon flange bolts (M6×12). See Fig.
Sensor coil
Sensor coil 6-1-26.
Attention: A close fit between sensor plane and
cylinder head cover installation plane shall be
maintained after the installation.
Alternating current sine wave Tightening torque for the fastening bolts of
Positive
voltage camshaft position sensor:
9 N•m±3 N•m
Negative
voltage
2.7.3 Crankshaft Position Sensor
The installed crankshaft position sensor is opposite to
Fig. 6-1-27 Working principles of crankshaft the ferromagnetic trigger wheel, and they are separated
position sensor by a small air gap.There is a soft iron core in the
sensor. This core is surrounded by the coils and
connected with a permanent magnet.
Two circuit
Controlled voltage designs are
Magnetic field
optional
Direction of
turning Computer
Constant current Impeller Voltage
Ignition switch sensing circuit
Permanent
Vane
magnet
Window Computer
Voltage
sensing circuit
When the transistor comes

Gallium arsenide crystal into the “On” status from the
“Off” status, the voltage of
Amplified Transistor collector circuit will increase
Weak phase switch to approximately 12V.
Turned off Turned on
analog inversion
Digital
signal signal signal
Schmidt Collector
Amplifier trigger
Emitter
Switch
transistor
Fig. 6-1-28 Working principle of Hall-Effect phase sensor (camshaft position sensor)

The magnetic field sent by the permanent magnet is

transferred to the trigger wheel through the soft iron
Crankshaft Cylinder body core, and the strength of magnetic field is affected by
position sensor the magnetic clearance between the trigger wheel and
the sensor. When the trigger wheel gear gets close to
the sensor, the magnetic field gets stronger; when the
trigger wheel gear gets away from the sensor, the
magnetic field gets weaker. When the trigger wheel
rotates, an alternating magnetic field will be created so
that the electromagnetic coil produces a sinusoidal
sensing voltage; the amplitude of alternating voltage
increases as the rotating speed of trigger wheel
increases (i.e. mV…＞100V). It is required to generate
a proper signal voltage at 30 r/min. See Fig. 6-1-27.
Fig. 6-1-29 Installing crankshaft position
sensor The installation of the crankshaft position sensor: check
whether the O-ring is installed properly, and then install
the sensor to the sensor hole on the rear end of the
exhaust manifold of the cylinder body. The mounting
plane should be well fitted with the cylinder body
mounting plane without any air leakage. Tighten 1
hexagon flange face bolt (M8×30) as per specified

position sensor
9 N•m±3 N•m

395
2.7.4 Knock Sensor

A knock sensor is an essential part of the electronic
Cylinder body control system in the diesel engine. It is used to check
Knock sensor the diesel engine for any knock and to send the signal
to ECU.
GW4D20/GW4D20B turbocharged diesel engine adopt

piezoelectric knock sensor. See Fig. 6-1-30.
This kind of sensor takes advantage of piezoelectricity

of crystal or ceramic polycrystalline crystal to work, but
some use the piezoresistance with silicon to work. The
sensor is equipped with piezoelectric component,
Fig. 6-1-30 Installing knock sensor clump weight and wire, etc. Its working principle is as
follows: when the shock of the cylinder body of the
diesel engine occurs and it is transferred to the sensor
housing, relative movement happens between the
housing and the clump weight. The pressure on the
piezoelectric component between the housing and the
clump weight changes, thus resulting in voltage.

ECU detects this voltage and judges the knock intensity

according to the voltage.
ECU
(electronic control
unit) The installation of the knock sensor: install the knock
on sensor and 1 hexagon flange face bolt (M6×12) to the
sensor hole on the exhaust manifold end of the cylinder
electric
sensor body and tighten them as per specified torque. The
signal
brush mounting planes of the knock sensor and the cylinder
body should be well fitted without any clearance. See
Voltage
Fig 6-1-30.
sensing
ground circuit Tightening torque for fastening bolt of knock
off sensor
23 N•m±3 N•m
Fig. 6-1-31 Working principle of accelerator 2.7.5 Accelerator pedal position sensor
pedal position sensor The working principle of potentiometer type pedal
position sensor is voltage divider circuit. ECU supplies
5V voltage for the sensor circuit. The accelerator pedal
is connected to the electric brush of the sliding rheostat
inside the sensor through the rotating shaft. The
voltages of the electric brush and the earthing end vary
as the position of the accelerator pedal position sensor.
The voltage sensing circuit inside the ECU will change
the voltage into the position signal of the accelerator
pedal. See Fig. 6-1-31.

397
2.7.6 Air flow sensor

The hot-film air flow sensor is an air flow sensor with
Wire connecting logic output. In order to obtain air flow, the sensor film
terminal for the Integrated
measuring circuit on the sensor element is heated by the heating
component resistance mounted in the center, then the temperature
Sensor seat
distribution is measured by the temperature resistance
Casing
Integrated
circuit
mounted parallel to the heating resistance. The
Sensor temperature distribution is changed by the air flow
Mounting through the sensor, so the values of the two
plate temperature resistances are different. The difference of
the resistance values depends on the direction and flow
O-ring
of air; therefore, the air flow sensor has high
requirements for the air flow and direction. If necessary,
Sensor casing Temperature sensor an air intake temperature sensor can be mounted
inside the sensor to measure the air intake
Fig. 6-1-32 Air flow sensor temperature. See Fig. 6-1-32.
Installation of the air flow sensor: Mount the air flow
sensor between the air intake guide pipe and the
exhaust pipe of air flow meter, and then tighten the clip.
See Fig. 6-1-33.
Air flow sensor
Attention: The arrow on the air flow sensor
should be in the direction of air intake.
2.7.7 Turbocharger pressure sensor
The function of the turbocharger pressure sensor is to
detect the pressure and temperature of the air intake
compressed by the turbocharger.
Installation of the turbocharger pressure sensor: Check
Fig. 6-1-33 Installing the air flow sensor whether the O-ring on the turbocharger pressure
sensor is properly installed, then mount the sensor in
the sensor hole of air intake manifold pipe’s pressure
maintaining chamber; screw up the 2 hexagon flange
Turbocharger face bolts (M6×10) to the specified torque. Air leakage
pressure is not allowed. See Fig. 6-1-34.
sensor
Tightening torque for the fastening bolts of the
turbocharger pressure sensor
9 N•m±3 N•m
2.8 Diesel engine harshness
Intake manifold See Fig. 6-1-35 for the schematic diagram of the
GW4D20 turbocharged diesel engine harshness.
Fig. 6-1-34 Installing the turbocharger Attention: The harshness connector is equipped
pressure sensor with a self-lock device; when remove or mount the
harshness, hold the harshness connector tightly. It is
strictly prohibited to violently remove or mount the
harness by directly holding the harshness.

Crankshaft
Coolant Position
Vacuum temperature Knock sensor Air conditioning
control valve Sensor
sensor clutch
Fuel
temperature
sensor
Turbocharger pressure sensor
Phase
sensor
Benchmark A
1: Power supply from main relay

2: “Earthing” signal of fuel-water separator
Glow 3: Signal of fuel-water separator Flow valve
4: Glow plug 4
plug 4 5: Glow plug 3
6: Glow plug 2
8: Glow plug 1
9: Compressor power supply
Glow 12: Control line for coil end of glow relay
plug 3 Rail pressure 14: “Earthing” signal of air flow sensor
15: Temperature signal of air flow sensor
sensor 16: Flow signal of air flow sensor
Nozzle 1 Nozzle 3 Nozzle 2 Nozzle 4 Glow
plug 2
Glow
plug 1
Outgoing direction
of harnesses Connected to engine

compartment harness

Fig. 6-1-35 Schematic diagram for harnesses of GW4D20 turbocharged diesel engine
399
Section II On-Board Maintenance

1. Fuel Filter Assembly
Removal order
① Fuel hose
② Fuel filter
③ Drain plug of fuel-water separator Installation order
Fig. 6-2-1 Removal order for fuel filter assembly
Removal
Preparation
Removing the fuel hose ①
(1) Loosen the fuel hose clip on fuel filter and pull out
fuel inlet and outlet hoses. See Fig. 6-2-2.
(2) Block off fuel hose ends to avoid the fuel overflow.
Removing fuel filter ②
(1) Loosen the filter counterclockwise with a fuel filter
spanner.
Fuel filter spanner: 5-8840-0253-0
Fig. 6-2-2 Removing the fuel hose (2) Remove the fixing bolt of fuel filter support and then
remove the fuel filter.
Removing the drain plug of fuel-water separator ③.

Manual fuel pump

Installation
Installing the drain plug of fuel-water separator ③

Installing the fuel filter ②
(1) Clean the installation face of fuel filter core to make
the core fit well.
(2) Fit a drain plug on the new filter core. See Fig.
6-2-3.
(3) Coat a thin layer of engine oil on the new filter core
Drain plug O-ring.
Fig. 6-2-3 Installing the fuel filter The API Grade C1-4 lubricating oil produced by
Exxon Mobil Oil Corporation shall be used.
(4) For easily expelling the air, pour the fuel into the
new filter core.
(5) Tighten the new filter core until the fuel filter O-ring
stick to the sealing face. Pay close attention to avoid
the fuel spillage.
(6) Turn the core for another 1/3~2/3 circle with a fuel
filter spanner.
Fuel filter spanner: 5-8840-0253-0
(7) Operate the manual fuel delivery pump (manual fuel

pump) for several times to check it for the fuel leakage.
Fig. 6-2-4 Installing the fuel hose (8) Install the fuel filter support and tighten its fixing
bolts.
Fuel inlet pipe Fuel return hose
connector
Prompt: It is recommended to employ an original fuel
Clip filter manufactured by Great Wall Internal Combustion
Engine Manufacturing Company Limited.
Installing the fuel hose ①
(1) Connect fuel inlet and outlet hoses separately to the
Fuel return Fuel fuel filter inlet and out pipe connectors, and then clamp
pipe return
connector tee them with clips. Any leakage shall not be allowed. See
High-pressure
Fig. 6-2-4.
fuel pump (2) Deliver the fuel into the high-pressure fuel pump by
the manual fuel delivery pump and expel the air from
the fuel supply system.
Fig. 6-2-5 High-pressure fuel pump
Air Release
(1) Operate the manual fuel delivery pump (see Fig.
6-2-3) and expel the air from the fuel supply system to
the high-pressure fuel pump.
(2) Remove the return pipe of high -pressure fuel pump
(see Fig. 6-2-5) and operate the manual fuel delivery
pump for fuel filter until air bubbles are all eliminated.

401
(3) Install the fuel return pipe of high-pressure fuel

pump.
(4) Start the engine. If the engine fails to start within 10
seconds, repeat the air release steps mentioned above.
(5) Ensure that no leakage of fuel exists, and tighten
the cover of manual fuel delivery pump.
Draining
When water in the fuel-water separator reaches the
required amount, the alarm lamp in cab instrument
board will go on (see Fig. 6-2-6).At this time, the
following steps for draining shall be obeyed:
Fig. 6-2-6 Alarm indicator lamp of fuel-water
separator (1) Stop the vehicle at a safe and flat place.
Manual fuel pump

(2) Open the engine hood and put the container
(capacity: 0.2 L) at the drain pipe end below the
fuel-water separator drain plug.
Fuel return (3) Loosen the drain plug. The tightening and loosening
pipe connector directions for drain plug are the same with those for
Fuel intake pipe Electric socket
common bolts. See Fig. 6-2-7.
connector port (4) Operate the manual fuel delivery pump to drain
Filter pot core
repeatedly until the fuel-water separator is full of fuel.
Unscrew (5) Tighten the drain plug after draining.
Tighten
(6) Operate the manual fuel delivery pump repeatedly
Drain plug and check whether any fuel leakage is present.
(7) Start the engine, ensure that no fuel leaks out from
Fig. 6-2-7 Draining by using the fuel filter the drain plug, and meanwhile check whether the alarm
indicator lamp goes out.
Attention: The fuel used does not accord with the

requirements, if the operation of draining are frequently
needed. If the accumulated water exists in the fuel tank,
the fuel tank shall be sent to the service station for the
purpose of draining.
After installation, perform the following steps:
(1) Connect the earthing cables of storage battery. See
Fig. 6-2-8.
(2) Start the engine and check the fuel system for
normal working.
Fig. 6-2-8 Connecting the earthing cables of

storage battery

2. Fuel Injector Assembly
Removal order
① Fuel injector harness connector
② Fuel return pipe components
③ Fuel inlet pipe of fule injector
④ Fuel injector assembly
Installation order
Fig. 6-2-9 Fuel Injector Assembly Removal order (DELPHI Fuel Supply System)

403
Removal
Removing the fuel injector harness plug ①

Loosen the plug of diesel engine harness plug-in
connected with fuel injector electromagnetic valve. See
Fig. 6-2-10.
Removing the fuel return pipe assembly ②
(1) Remove the support and pipe clamp of fuel return
pipe.
(2) For the DELPHI fuel injector, pull out 4 fuel return
pipes connected with the fuel injectors, and then take
Fig. 6-2-10 Removing the fuel injector down the fuel return pipe components. See Fig. 6-2-11.
harness plug (3) If a BOSCH or XINFENG fuel injector is chosen,
push the clamp spring out with a tool, then pull the fuel
return pipe connector out from the injector, and finally
Fuel return pipe
components
take down the fuel return pipe assembly.
(1) Use a spanner to uniformly loosen the pipe
connectors used to fasten both ends of 4 fuel inlet pipes
of fuel injector. See Fig. 6-2-12.
(2) Take down 4 fuel inlet pipes of fuel injector
separately.
Warning:
Fig. 6-2-11 Removing the fuel return pipe (1) When removing them, ensure that the pipe
components connectors on both ends of fuel inlet pipes shall be
simultaneously and uniformly loosened to avoid any
Fuel injector deformation of these pipes.
intake pipe (2) After removing the fuel inlet pipes, cover the fuel
injector inlet, the high-pressure fuel rail inlet and both
ends of fuel inlet pipes by the clean plug covers to
prevent the fuel injector from being blocked by foreign
matters.
Removing the fuel injector ④
See Fig. 6-2-13.
(2) Take down the fuel injector ballast.
(3) Gently take out the 4 fuel injectors inserted in their
holes.
Fig. 6-2-12 Removing the fuel inlet pipe of fuel
injector
Attention: properly protect the fuel injectors after
removing them. Carefully place and mark them in
accordance with cylinder numbers 1, 2, 3 and 4 to avoid
any bumping or pollution.
Attentions:

(1) When removing the fuel injector, do not pollute or

bump the pinhole at its end. If severe wear or damage
to it is found during the check, a repair or parts
replacement shall be performed.
(2) Each fuel injector is marked with an I3C code which
has already been entered into ECU. Therefore, each
fuel injector keeps a one-to-one correspondence with
ECU (computer). The installation position of each fuel
injector shall be neither replaced nor changed.
Otherwise, the engine can not work in a normal
Fuel injector condition.
assembly (3) A repaired fuel injector shall be marked with a new
I3C code. If a fuel injector whose code differs from that
Fig. 6-2-13 Removing the fuel injector of the original high-pressure fuel pump is used, the new
code shall be reentered into ECU.
Likewise, if the original ECU is replaced, the I3C code
of existing fuel injector shall be entered into the new
ECU.
Installation
Installing the fuel injector ④

(1) Fit the O-ring of fuel injector in its groove.
(2) Make sure that each fuel injector has only one
Sectional view
of the cylinder copper gasket that shall be placed horizontally and
head installed into the nozzle of the fuel injector.
Fig. 6-2-14 Installing the fuel injector (3) (3) According to the designations 1, 2, 3 and 4 on
the fuel injectors, install the fuel injectors to the
Fuel inlet pipe of injector corresponding fuel injector mounting holes in the
cylinder heads 1, 2, 3 and 4. See Fig. 6-2-14.
(4) Rest one end of the fuel injector ballast on the
ballast supporting bolt, and the other end in the fuel
(5) Install the fastening bolt components of fuel injector
ballast, and screw them down according to the
specified torque, without any gas leakage on the
injector gasket.
Tightening torque for the fastening bolt

components of fuel injector ballasts:
Fig. 6-2-15 Installing the fuel inlet pipe of fuel 23 N•m ± 3 N•m
injector
(1) Install the fuel inlet pipe of injector as shown in Fig.
6-2-15 and uniformly tighten the pipe connectors on
both ends of 4 fuel inlet pipes of injector with specified
torque.
(2) After the installation, check them and ensure that

405
the fuel inlet pipes of injectors are sealed so strictly that

no oil leakage will occur.
Fuel return hose
component Tightening torque of fuel inlet pipe connector of fuel
injector:
32 N•m±3 N•m
Attention: make sure to simultaneously and

uniformly tighten the pipe connectors on both ends of
fuel inlet pipes when tightening these fuel inlet pipes of
injectors, so as to avoid any deformation or damage to
them.
Fig. 6-2-16 Installing the fuel return pipe
Installing the fuel return pipe assembly ②
components
(1) (1) For the DELPHI fuel injector, insert respectively
the fuel return rubber hoses into 4 injector heads and
(2) (2) For the BOSCH or XINFENG fuel injector,
remove the dust cap from the upper end of the fuel
injector. Install 4 short connectors of the fuel return
pipes in 4 holes at the upper ends of the fuel injectors,
and fix them tight with spring clips. Install the other long
connector to the fuel return tee connector on the high
pressure pump, and fix it tight with a clip.
(3) Install the support and pipe clamp of fuel return pipe.
After the installation, make sure the fuel return

Fig. 6-2-17 Installing the fuel injector harness
pipe is sealed so strictly that no fuel will leak from it.
plug
Installing the fuel injector harness plug ①
Insert the fuel injector harness plugs on diesel engine
harnesses separately into 4 fuel injectors. See Fig.
6-2-17.
Attention: Do not insert them in wrong positions.

3. High-Pressure Fuel Pump Assembly
Removal procedure
① Engine accessory
② Timing belt
③ Fuel pump pulley
④ Fuel inlet and outlet pipes of high-pressure fuel pump
⑤ Fuel rail inlet pipe components
⑥ High-pressure fuel pump assembly
Installation order
Fig. 6-2-18 Removal and installation orders for High-pressure fuel pump assembly

407
Removal
Removing the engine accessory ①

by a tool to make the generator belt loose enough, and
then remove the generator belt.
(2) Remove the accessory tension pulley.
(3) Remove the flat and wedge idle wheel assemblies of
accessory as shown in Fig. 6-2-19.
Removing the timing belt ②

Fig. 6-2-19 Removing the engine accessory
(1) Remove timing hood, timing hood Ⅰ and Ⅱ.
(2) Loosen the timing tension pulley to slack the belt and
then remove it as shown in Fig. 6-2-20.
Remove the fuel pump pulley ③

(1) Remove the all-metal hexagon flange locknuts
(M14×1.5), which is used to fasten the fuel pump pulley
to the fuel pump.
(2) Take off the fuel pump pulley from the fuel pump.
Removing the fuel inlet and outlet hoses of

high-pressure fuel pump ④
Fig. 6-2-20 Removing the timing belt Pull the fuel inlet and outlet hoses of high-pressure fuel
pump out from their connectors.
Removing the fuel inlet pipe component of fuel rail

Fuel return hose
Fuel inlet pipe of component
⑤
fuel injector
(1) Loosen the pipe connectors on the fuel rail and furl
pump ends of fuel inlet pipe of fuel rail as shown in Fig.
6-2-21.
(2) Remove the hexagon flange bolt (M6×12), which is
used to fasten the pipe clamp components for fuel inlet
pipe of fuel rail to the air intake manifold pipe.
(3) Remove the fuel inlet pipe components of fuel rail.
Fig. 6-2-21 Removing the fuel inlet pipe of

fuel rail

Removing the high-pressure fuel pump assembly ⑥

(1) Remove a hexagon flange nut and 2 hexagon flange
bolts (M8×30) used to fasten the high-pressure fuel
pump to the cylinder block as shown in Fig. 6-2-22.
(2) Remove the high-pressure fuel pump assembly from
the left side of the cylinder block.
Attention:
(1) While removing the fuel inlet pipe of the fuel rail, be
sure to evenly and simultaneously loose the connectors
at the two ends of the fuel pipes, so as to avoid any fuel
pipe deformation.
Fig. 6-2-22 Removing the High-Pressure fuel (2) Keep the high-pressure fuel pump, fuel inlet pipe
pump (for DELPHI fuel supply system) component of the fuel rail and the high-pressure fuel rail
clean, and avoid bumping.
(3) Wrap each fuel hole on the high-pressure fuel pump
by the rubber covers (or equivalent articles) to avoid the
Cylinder body introduction of foreign matters.
Installation
Installing the high-pressure fuel pump assembly ⑥

(1) Install the high-pressure fuel pump to the left of the
cylinder block, and tighten a hexagon flange nut and 2
hexagon flange bolts (M8×30) used to fasten the
high-pressure fuel pump by specified torque as shown
in Fig. 6-2-23.
(2) After the installation, check the high-pressure fuel
Fig. 6-2-23 Installing the high-pressure fuel pump assembly for deviation.
pump
Tightening torques for the fastening bolts and nuts of
high-pressure fuel pump:
23 N•m ± 7 N•m
Fuel return hose
Fuel inlet pipe of component Installing the fuel inlet pipe component of fuel rail ⑤
fuel injector
(1) Remove the dust shield for fuel inlet pipe of fuel rail,
install the fuel rail fuel inlet pipe, and tighten the pipe
connectors on the fuel rail and high-pressure fuel pump
ends.
(2) Install the fuel inlet pipe clamp components of fuel
rail to the air inlet manifold and tighten them with a
hexagon flange bolt (M6×12). See Fig. 6-2-24.
Tightening torques for the pipe connectors of fuel inlet
pipe components of fuel rail:
Fig. 6-2-24 Installing the fuel inlet pipe
component fuel rail
32 N•m±3 N•m
Caution: Make sure to tighten the pipe connectors

409
at both ends of the fuel pipe simultaneously and

uniformly.
Installing the fuel inlet and outlet hoses of
high-pressure fuel pump ④
Insert the fuel inlet and return hoses of high-pressure
fuel pump separately to their connectors.
Installing the fuel pump pulley ③
Install the fuel pump pulley to the fuel pump, and tighten
the pulley by a all-metal hexagon flange locknut
Timing belt
(M14×1.5). See Fig. 6-2-25.
Tightening torque for the locknuts of the fuel pump
pulley:
Fig. 6-2-25 Installing the fuel pump pulley and
timing belt 65 N•m ± 3 N•m
Installing the timing belt ②

(1) Install the timing belt. See Fig. 6-2-25.
(2) Install the timing tension pulley.
Installing the engine accessory ①.
(1) Install the flat and wedge idle wheels assemblies of
accessory.
(2) Install the accessory tension pulley. See Fig. 6-2-26.
(3) Install the generator belt: turn the tension pulley by a
tool to make the belt loose enough and then perform the
installation. After the installation, make sure that the belt
Fig. 6-2-26 Installing the engine accessory wedge teeth and the pulley wedge tooth grooves match
well.

Chapter VII Cooling System

Section I General
The cooling system of GW4D20/GW4D20B turbocharged diesel engine works by means of pressurized
controlled circulation. For its schematic diagram, see Fig. 7-1-1.It consists of water pump, thermostat,
fan, radiator, water supply tank and other parts. Circulating coolant meanwhile cools the oil in the engine
oil filter.
Cylinder head
Water supply tank
of radiator
Thermostat
Water pump
Radiator Fan
Oil
cooler
Automobile heater
Fig. 7-1-1 Schematic diagram for engine cooling system
1. Water pump
The water pump is a centrifugal vane type (see Fig.
7-1-2) one, installed to the front of the cylinder block
and driven by a timing belt.
The delivery lift of this water pump is 16m, in the case of
a water temperature at 80℃±2℃, a pump speed at
4500r/min and a flow at 240 L/min.
Water pump
gasket
Water pump
assembly
Fig. 7-1-2 Water pump assembly

411
2. Thermostat
(1) The thermostat is wax pill type one and a small
swing valve (rock valve) is on the valve. See Fig. 7-1-3.
(2) Its initial and full opening temperatures are
respectively 76 ℃ ± 2 ℃ and 88 ℃. Its full opening
stroke is not less than 8.5 mm.
(3) The thermostat is installed inside its cap. See Fig.
7-1-3.
Fig. 7-1-3 Installing the thermostat
3. Radiator
(1) The radiator is ribbon-tubular type one. See Fig.
Water outlet 7-1-4.To elevate coolant boiling point, a valve with cover
rubber pipe is mounted on the radiator. This valve opens at a
pressure of 88~118 kPa.
Overflow tank (2) The overflow rubber pipe of radiator is connected
with overflow tank as shown in Fig. 7-1-4.
Radiator
(3) A drain plug (water drain switch) is attached at the
bottom of radiator water chamber.
Water inlet (4) A fan assembly is installed in front of the radiator as
rubber pipe shown in Fig. 7-1-5.
Fig. 7-1-4 Radiator of cooling system
4. Antifreeze fluid
(1) Relation between mixing ratio and freezing point
The freezing point of engine coolant changes with the
proportion of antifreeze fluid in water. To determine a
correct mixing ratio, you may refer to the curve shown in
Fig. 7-1-6.
(2) Calculation of mixing ratio
Antifreeze fluid (L)
Mixing ratio=
Antifreeze fluid (L) ﹢ water (L)
Fan assembly Attention: The volume of antifreeze plus water is

10L (i.e. the total capacity of cooling system).
Fig. 7-1-5 Radiator fan assembly of cooling If total capacity of cooling system is 10L, the mixing
system ratios listed in the following table are available.

Mixing ratio (%) Mixing ratio Antifreeze fluid (L) Water (L)
(%)
0 0 10
Freezing point (℃)
5 0.5 9.5
10 1.0 9.0
15 1.5 8.5
20 2.0 8.0
25 2.5 7.5
30 3.0 7.0
35 3.5 6.5
40 4.0 6.0
45 4.5 5.5
50 5.0 5.0
Fig. 7-1-6 Mixing ratio of antifreeze fluid
(3) Mixing ratio

Mixing ratio
Measure the specific gravities of coolant between 0℃
and 50℃ in the engine cooling system, and then refer to
the curves as shown in Fig. 7-1-7 to determine the
coolant mixing ratios.
The coolant used shall be the high-quality
Specific gravity
ethylene-glycol base (-35℃) antifreeze fluid.
Coolant temperature (℃)
Fig. 7-1-7 Mixing ratio of coolant

413
Section II On-Board Maintenance

1. Water Pump Assembly
Removal order
① Engine accessory
③ Timing system
④ High-pressure fuel pump
assembly
⑤ Water pump assembly
Installation order
Fig. 7-2-1 Removal and installation orders of water pump assembly

Removal
Preparation
(1) Disconnect the earthing cables of storage battery.
(2) Let out the coolant from the engine cooling system.
Warning: The coolant is poisonous and must be

stored in the original container to avoid its contact with
personnel.
Removing the engine accessory ①
(1) Removing the generator belt: turn the enclosed
Fig. 7-2-2 Removing the engine accessory tension pulley by a tool to make the generator belt loose
enough, and then remove the belt.
(2) Remove the accessory tension pulley. See Fig.
7-2-2.
(3) Removing the flat idle wheel assembly of accessory.
Crank timing (4) Removing the wedge idle wheel assembly of
pulley accessory.
(1) Remove the 4 hexagon flange bolts (M8×20), which
are used to fasten damping pulley at the front end of
Fig. 7-2-3 Removing the damping pulley end of crankshaft.
assembly
Removing timing system ③
(1) Remove timing hoodⅠ, timing hoodⅡ, timing hood
(2) Remove the timing belt: loosen the timing tension
pulley to make the timing belt slack, and then remove
the timing belt. See Fig. 7-2-4.
(3) Remove the timing idle wheel: loosen the bolts which
fix the timing idle wheel, and then remove timing idle
wheel assembly.
Removing the high-pressure fuel pump assembly ④
(1) Remove the fuel inlet pipe of fuel rail.
Fig. 7-2-4 Removing the timing system (2) Remove the fuel return pipe components and the
fuel inlet pipe of fuel pump.
(3) Remove the fuel pump pulley.
(4) Remove 1 hexagon flange nut and 2 hexagon flange
bolts (M8×30) used to fasten the high-pressure fuel
pump, and then remove the high-pressure fuel pump
assembly as shown in Fig. 7-2-5.
Attention:

415
(1) When removing the fuel inlet pipe of fuel rail,

simultaneously and uniformly loosen the pipe
connectors at both ends of the fuel pipe to avoid any
deformation of this pipe.
(2) Maintain the high-pressure fuel pump, fuel inlet pipe
components and high-pressure fuel rail clean, and avoid
any bumping.
Removing the water pump assembly ⑤
fastening the water pump and connecting with the
cylinder block, and then remove the water pump. See
Fig. 7-2-6.
Fig. 7-2-5 Removing the high-pressure fuel (2) Remove the sealing gasket of water pump.
pump assembly
Inspection
If any severe wear is found during the check, the

necessary repair and parts replacement shall be
performed. The whole water pump assembly shall be
replaced if any of the following symptoms occurs.
(1) The water pump block has any crack.
Water pump (2) The coolant leaks out from the water seal.
gasket
(3) A play or abnormal noise take places on the bearing.
Water pump (4) The water pump vane has been cracked or
assembly corroded.
Fig. 7-2-6 Removing the water pump Installation

assembly
Install the water pump assembly ⑤
Impeller (1) Install the sealing gasket of water pump.
Water seal
assembly (2) Install the water pump assembly to the front end of
cylinder block, and then use the specified torques to
mount 6 hexagon flange bolts (M8×25、M8×30 and
M10×25) which fasten the water pump assembly. See
Water pump
Shaft and bearing pulley
Fig. 7-2-8.
assembly
After installation, turn pulley water pump. At this
Water pump time, the water pump shall not be sluggish.
housing
Tightening torques for the fastening bolts of water
Fig. 7-2-7 Removing and checking the water pump:
pump assembly
M8 23 N•m ± 3 N•m
M10 45 N•m ± 3 N•m
Install high-pressure fuel pump assembly ④

(1) Install high-pressure fuel pump and use the specified

torque to tighten 1 hexagon flange nut and 2 hexagon

Cylinder body flange bolts (M8×30), which fasten used to fasten the
Water pump pump. See Fig. 7-2-9.
assembly
high-pressure fuel pump:
23 N•m±3 N•m
Sealing
After the installation, the high-pressure fuel pump
gasket assembly shall not be skew.
(2) Install the fuel pump pulley and tighten it by the
Fig. 7-2-8 Installing the water pump assembly specified torque to make its timing mark directed at the
horizontal bar of water pump.
Cylinder body Tightening torque for the fuel pump pulley:
65 N•m ± 3 N•m
(3) Install the components for fuel inlet pipe and fuel
return pipe of high-pressure fuel pump.
(4) Install the fuel inlet pipe components of fuel rail, and
use the specified torque to uniformly tighten the pipe
connectors at both ends of this pipe.
Tightening torque for the pipe connectors of fuel

inlet pipe components of fuel rail:
Fig. 7-2-9 Installing the high-pressure fuel
pump assembly
32 N•m ± 3 N•m
Attention: During the installation of pipe

connectors, simultaneously and uniformly tighten the
pipe connectors at both ends of the fuel pipe, so as to
avoid any pipe deformation or damage.
(1) Install the timing idle wheel, and tighten the
fastening bolts by the specified torque as shown in Fig.
7-2-10.
Tightening torque for the fastening bolts of timing

idle wheel:
43 N•m ± 4 N•m
(2) Align the timing mark of camshaft timing pulley with

that of and crankshaft timing pulley.

417
(3) Install the timing belt and tighten timing tension

pulley assembling bolts by the specified torque. During
the installation, ensure that all pulleys (except the
tension pulley) shall closely fit the belt pulley and shall
not be slack.
Sealing strip
Tightening torque for the fastening bolts of timing

tension pulley:
Sealing strip
22 N·m ~ 26 N·m
(4) Install the timing hoodsⅠ, Ⅱ, and the timing hood:

insert the timing hood sealing stripsⅠand Ⅱ separately
Fig. 7-2-11 Installing the timing hood into the corresponding sealing grooves of timing hoods
assembly I and II. Align the timing hood and the timing hoods I
and II respectively with their corresponding installation
Crankshaft holes. Mount 15 hexagon flange bolts (M6×16, M10×35
and M10×50) to the front end of cylinder head and the
cylinder body, and then tighten these bolts by the
required torques. See Fig. 7-2-11.
Tightening torques for the fastening bolts of

timing hood and timing hoodsⅠandⅡ:
Timing pulley
M6 9 N•m ± 3 N•m
M10 45 N•m ± 3 N•m

Damping pulley
Fig. 7-2-12 Installing Damping pulley (1) Fit an elastic cylindrical pin into the pin hole of
Assembly crankshaft timing pulley.
(2) Align the pin hole of damping pulley, install the
damping pulley to the front end of crankshaft, and
mount and tighten 4 hexagon flange bolts (M8×20) by

damping pulley:
23 N•m ± 3 N•m
Attention: after installation, the timing mark must

face the front end.
Fig. 7-2-13 Installing the engine accessory
Installing the engine accessory ①
(1) Fit the flat and wedge idle wheels of accessory
separately to the water pump and timing hood, and
tighten them with bolts. See Fig. 7-2-13. See Fig.
7-2-13.
After the installation, any pulley non-coplanarity

visible by eye inspection shall not be allowed.
Tightening torque for the flat and wedge idle

wheels of accessory:
Rotary
installation
position of 22 N•m ~ 26 N•m
belt (2) Align the bolt hole of accessory tension pulley with
the installation hole of generator support, and then align
the limit boss of tension pulley with the installation hole
of generator. Tighten the tension pulley by the fastening
bolts.

Fig. 7-2-14 Installing the generator belt accessory tension pulley:
53 N•m ~ 57 N•m
(3) Install the generator belt to make the belt of all

pulleys (except flat idle wheel) in place, and ensure that
the belt wedge teeth and the pulley wedge tooth
sockets match well.
(4) Turn tension pulley by a tool till the generator belt
become loose enough, and then fix the flat idle wheel of
accessory in the belt. See Fig. 7-2-14.

Over-tension or under-tension of generator belt is not
allowed.
Fig. 7-2-15 Installing the earthing cables of After the installation, perform the following steps:
storage battery
(1) Connect the earthing cables of storage battery. See
Fig. 7-2-15.
(2) Fill the cooling system with sufficient coolant.
(3) Start the engine, and check its working state. Ensure
that there is no leakage in the cooling system.

419
2. Thermostat
Removal order
① Water inlet pipe
② Thermostat cap
Installation order ③ Thermostat assembly
Install them in the opposite order of removal. ④ Thermostat shield
Fig. 7-2-16 Removal and Installation orders of thermostat
Removal
Preparation
(1) Disconnect the earthing cabled of storage battery.
See Fig. 7-2-17.
(2) Prepare a standby container for collecting the
discarded coolant, since the coolant is poisonous.
Properly dispose of the discarded coolant so as to
protect the environment.
(3) Remove the drain plug on cylinder body and drain
the coolant from the cooling system.
Warning: when removing the drain plug to drain

Fig. 7-2-17 Removing the earthing cables of
storage battery away the coolant, take special care to avoid being
burnt by the machine body or coolant.

Removing the water inlet pipe ①

Loosen the clip used to fasten water inlet pipe, and
Water inlet remove the water inlet pipe from water inlet of
pipe thermostat cap. See Fig. 7-2-18.
Cylinder body
Fig. 7-2-18 Removing the water inlet pipe
Removing the thermostat cap ②

(1) Remove 2 hexagon flange bolts (M6×20) (used
Cylinder body
for fastening the thermostat cap) to the thermostat
chamber in cylinder body.
(2) Remove the thermostat cap from the cylinder
Thermostat cap
Fig. 7-2-19 Removing the thermostat and its cap
Removing the thermostat assembly ③

Take thermostat and rubber seal ring from the
Thermostat Thermostat shield thermostat cap on the left side of cylinder body as
Thermostat cap
Removing the thermostat shield ④
Take the thermostat shield from the thermostat
chamber on the left side of cylinder body as shown in
Fig. 7-2-20.
Fig. 7-2-20 Removing the thermostat cap and

thermostat shield

421
Check and Repair

Thermometer
(1) Immerse the thermostat assembly in the
noncorrosive neutral clear water as shown in Fig.
7-2-21.
(2) Put the wooden block at the bottom of the water
container. Do not heat the thermostat directly. See
Heated water Fig. 7-2-21.
Wooden block (3) Elevate water temperature progressively and
Thermostat
constantly mix it to make the water temperatures in
the container uniform.
——Ensure that thermostat main valve opens at
specified temperature.
Temperature for thermostat valve to open:
Fig. 7-2-21 Checking the thermostat
76℃
——Confirm that the second valve of thermostat fully

opens at specified temperature.
Temperature for thermostat valve to fully open:
Size of 88℃
fully-open
valve
If any severe wear or damage is found on the
thermostat during the check, then the necessary
repair and parts replacement shall be performed.
(4) Check the thermostat valve lift as shown in Fig.
The valve lift shall be at least 8.5 mm in the
case of a water temperature at 88℃. 7-2-22.
Fig. 7-2-22 Checking the thermostat valve lift The valve lift shall be at least 8.5 mm in the case of a
water temperature at 88℃.
If the valve lift does not accord with the requirements,
the thermostat assembly shall be replaced.
Cylinder
body
Installation
Thermostat Installing the thermostat shield ④
shield
(1) Clean the thermostat chamber on the left side of
cylinder body.
(2) Install the thermostat cap into the thermostat
chamber on the left side of cylinder body, and ensure
its installation is in place as shown in Fig. 7-2-23.
Thermostat Installing the thermostat ③
(1) Check whether the rubber seal ring on thermostat
assembly correctness is correctly installed.
Fig. 7-2-23 ①Installing the thermostat and Its
shield (2) Install the thermostat assembly into the
thermostat shield of cylinder body as shown in Fig.
7-2-23.

Installing the thermostat cap ②

(1) Install the thermostat cap onto the thermostat seat
Thermostat Thermostat shield on the left side of cylinder body.
(2) Mount 2 hexagon flange bolts (M6×20) used to
Thermostat cap
fasten the thermostat cap, and tighten these bolts by
the required torque. See Fig. 7-2-24.

thermostat cap:
9 N·m ± 3 N·m
Fig. 7-2-24 Installing the thermostat and its cap Attention: After the installation, the pipe orifice
of thermostat cap shall face the front bottom of diesel
engine, and there shall be no water leakage at the
joints.
Water inlet
pipe
Installing the water inlet pipe ①
(1) Fit water inlet pipe to the water inlet of thermostat
cap, and tighten the clip. See Fig. 7-2-25.
Cylinder body (2) After installation, check and ensure that the water
inlet pipe is sealed so strictly now water leakage will
occur.
Fig. 7-2-25Installing the water inlet pipe

Radiator cap (1) Connect the earthing cables of storage battery.
(2) Install the drain plug and tighten it.
(3) Fill the cooling system with sufficient coolant.
(4) Start the engine and check its working condition.
Ensure that there is no leakage in the cooling system.
Radiator
Drain plug
Fig. 7-2-26 Installing the drain plug

423
3. Radiator
Removal order
① Overflow tank hose
② Upper water rubber hose of radiator
③ Lower water rubber hose of radiator
④ Radiator fan
⑤ Radiator assembly
Installation order
removal.
Fig. 7-2-27 Removal and installation orders of radiator
Removal
Radiator cap
Preparation
(1) Disconnect the earthing cables of storage battery.
(2) Prepare a standby container for collecting the
discarded coolant, since the coolant is poisonous.
Properly dispose of the discarded coolant so as to
protect the environment.
(3) Loosen the drain plug to drain away the coolant
from the engine cooling system.
Radiator
Warning: when drain plug is opened to drain, pay
Drain plug
special attention to avoid being burnt by the machine
body, radiator and coolant.
Fig. 7-2-28 Removing the radiator drain plug Removing the overflow tank hose ①

Remove the overflow tank hose from the radiator. See

Fig. 7-2-29.
Overflow tank
Removing the upper water rubber hose of radiator
hose
②
(1) Loosen the clip at the connection between the
upper water rubber hose of radiator and the radiator.
(2) Remove the upper water rubber hose from its
installation position on the radiator as shown in Fig.
7-2-30.
Removing the lower water rubber hose of radiator
③
(1) Loosen the clips of the lower water rubber hose
Fig. 7-2-29 Removing the overflow tank hose which connect the engine water port and the radiator
water port. See Fig. 7-2-30.
Upper water
rubber hose (2) Removing the lower water rubber hose from the
radiator water port.
Removing the radiator fan ④
(1) Remove the cooling fan and harness terminals.
(2) Remove the bolts fastening the cooling fan and the
radiator, and take off the cooling fan from the radiator.
See Fig. 7-2-30.
Caution: In removal operation, take care to

Lower water
rubber hose prevent the radiator core from being scratched by the
Fan assembly fan vanes.
Remove the radiator assembly ⑤
Fig. 7-2-30 Removing the radiator assembly
Remove the fastening bolts on the radiator which
connect the radiator support and the radiator, and take
down the radiator assembly. See Fig. 7-2-31.
Check and Repair
1. Checking the Radiator Cap

(1) Use radiator cap tester to determine the opening
pressure of pressure valve as shown in Fig. 7-2-32.If
the opening pressure exceeds the standard value, the
radiator cap shall be replaced.
Tester for the radiator filler cap: 5-8840-2036-0
Fig. 7-2-31 Removing the radiator Opening pressure of pressure valve for radiator cap
88~118 kPa
(2) Check the opening pressure of the vacuum valve

at the center part of valve seat for radiator cap. If the
vacuum valve can not move smoothly owning to the
corrosion or dust, the radiator cap shall be cleaned or

425
replaced.
Opening pressure of vacuum valve:
12.8~17.0 kPa
2. Checking the Radiator Core

(1) The deformation of radiator fins will lower the effect
of heat dissipation and causes the overheat to the
cooling system. Level the radiator fins, but do not
damage the roots of radiator fins.
(2) Remove all dust and other foreign matters from the
radiator core.
Fig. 7-2-32 Determining the opening pressure
of Pressure Valve for radiator cap 3. Rinsing the Radiator
Rinse the radiator inside and the coolant passage by
the water and neutral cleaning solution. Remove all
incrustation and scale.
4. Checking the coolant leakage
Send the compressed air with a pressure of 196.9 kPa
from the radiator filling hole into the radiator inside by
using the radiator cap tester, and check the cooling
system for leakage. See Fig. 7-2-33.
Tester for the radiator filler cap: 5-8840-2036-0
Installation
Fig. 7-2-33 Checking the coolant leakage Installing the radiator assembly ⑤
(1) Install the radiator assembly which has some
hoses. See Fig. 7-2-34.
(2) Use the specified torque to tighten the bolts
connecting the radiator with the upper support.

radiator:
23 N•m ± 3 N•m
Caution: Do not let the fan vanes scratch the

radiator core during the installation.
Installing the radiator fan ④
(1) Install the radiator fan to the radiator, and tighten
the fastening bolts by the specified torque. See Fig.
7-2-35.

radiator fan:

23 N•m ± 3 N•m
Upper water
rubber hose
(2) Connect the radiator fan and the harness
terminals.
Caution: Do not let the fan vanes scratch the

radiator core during installation.
Installing the lower water rubber hose of radiator
③
(1) Install the lower water rubber hose of radiator to
Lower water the engine water port and radiator water port.
rubber hose
Fan assembly (2) Tighten the clips at both ends of the lower water
rubber hose of radiator
Installing the upper water rubber hose of radiator
②
(1) Connect the upper water rubber hose of radiator to
Overflow tank the radiator.
hose
(2) Install the clip at the connection point between the
upper water rubber hose of radiator and the radiator,
and tighten the clip. See Fig. 7-2-35.
Installing the overflow tank rubber hose ①
(1) Fit the overflow tank hose to the overflow tank, and
clamp the hose by a clip as shown in Fig. 7-2-36.
(2) Add the qualified coolant until to the neck of the
Fig. 7-2-36 Installing the overflow tank hose radiator filling hole and to the MAX mark of the
overflow tank.
(1) Connect the earthing cables of storage battery.
(2) Fill coolant into the cooling system. Coolants of
different grades can not be mixed to use, since the
preservatives selected may differ from each other. So,
pay attention to the grade of the coolant which has
been added.
(3) Start and warm up the engine.
(4) Check the level of engine coolant.
(5) Check whether there is any leakage in the cooling
system.

427
Chapter VIII Lubrication System

Section I General
The combined force-feed and splash lubrication is adopted for turbocharged diesel engine
GW4D20/GW4D20B.
The lubrication system of diesel engine includes oil pan, oil collector, oil pump, oil filter, oil cooler, main
oil duct of cylinder, oil pressure sensor and oil alarm, etc. See Fig. 8-1-1.
Storage
battery Alarm
Oil pressure switch
Main oil duct of cylinder
Oil filter and cooler assembly
Filter core
Piston Crank Camshaft Vacuum
cooling bearing journal pump
Oil filter Safety valve
Oil cooler Safety valve

Turbochar
ger
Rocker
Connecting arm
rod bearing
Pressure Engine Adjustment
limiting oil pump valve
valve
Oil
Throttle
collector
hole
Oil pan
Fig. 8-1-1 Schematic diagram of lubrication system of turbocharged diesel engine

Diesel engine’s parts which need the force-feed lubrication
Turbocharger include the turbocharger, main bearing shell, connecting rod
bearing shell, camshaft journal, hydraulic clearance adjuster
and rocker arm, etc.
Turbocharger needs the force-feed lubrication. Its function is to
make sure that the rotor and bearing are lubricated and cooled
sufficiently under the normal operation. Lubricating oil circuit of
turbocharger: the lubricating oil flows into the turbocharger
Oil inlet pipe from the main oil duct of diesel engine cylinder through the oil
inlet pipe and flows back to the oil pan through the oil return
hose. Turbocharged diesel engine is equipped with the piston
Lubricating oil cooling system and the oil is sprayed to the top of piston from
Lubricating oil Oil return hose the spray pipe through the main oil duct to cool the piston.
To avoid the oil leakage of turbocharger and ensure the normal
operation, it is necessary to ensure the smooth oil inlet and
Fig. 8-1-2 Lubrication for turbocharger return without leakage. The section shape of oil return hose
should not be changed.
Diesel engine’s parts which need the splash lubrication include
piston, piston ring, piston pin and cylinder.

Section II On-board Repair

1. Oil Filter
Removal procedure
① Air intake pipe of turbocharger
② Oil filter
Fig. 8-2-1 Removal and installation procedures of oil filter
Removal
Preparation
Air flow sensor
(2) Place a container under the oil filter to receive the
spilled oil.
Warning: Hot oil may cause burn, so please

environment.
Fig. 8-2-2 Removing the air intake pipe of

turbocharger

429
Removing the air intake pipe of turbocharger①

Loosen the clamps on both ends of turbocharger to take
off the air intake pipe of turbocharger as shown in Fig.
8-2-2.
Removing the oil filter ②
Special tool (1) Screw off the oil filter from the pipe connector with
special tool as shown in Fig. 8-2-3.
Remove and install
with the special tool. Filter spanner: 5-8840-0020-0
(2) Take off the seal ring of oil filter.

Fig. 8-2-3 Oil filter
Installation
Installing the oil filter ②

Prompt: Oil filter core is a disposable part and should
not be reused.
(1) Coat the O-ring of oil filter with a thin layer of oil as
Mobil API C1 – 4 lubricating oil.
(2) Check if the seal ring of oil filter assembly is installed

correctly, and then screw down the filter on the pipe
connector. When the rubber ring of oil filter contacts the
oil cooler, screw it down for 3/4 ~ 1 circle.
(3) Check the seal ring of filter for oil leakage after the
installation.
Filter spanner: 5-8840-0020-0

Installing the air intake pipe of turbocharger ①

(1) Install the air intake pipe of turbocharger and fasten
the clamp as shown in Fig. 8-2-6.
Air flow sensor
(2) Check the seal of turbocharger air intake pipe
connector for leakage after the installation.
Fig. 8-2-6 Installing the air intake pipe of

turbocharger

operations.
Fig. 8-2-7.
(2) Add the lubricating oil into the lubrication system to
the specified level.
(3) Start the engine and check its working and check the
lubrication system for leakage.

storage battery

431
2. Engine Oil Pump
Removal procedure
③ Timing system
④ Engine oil dipstick guide
subassembly and the engine oil
dipstick
⑤ Oil pan lower body assembly
⑥ Oil pump assembly
Fig. 8-2-8 Removal and installation procedures of oil pump

Removal
Preparation
(2) Drain out the lubricating oil in the engine lubrication
system.
Warning: Risk of burn from the engine body and

the hot engine oil. Properly handle the waste engine oil
and protect the environment.
with a tool to take off the generator belt after it is
loosened enough.
(2) Remove the tension pulleys.
Damping pulley
(3) Remove the wedge idle wheel assembly.
(4) Remove the flat idle wheel assembly.
Timing pulley of
crankshaft (5) Remove the power steering pump assembly and
bracket as shown in Fig. 8-2-6.
(6) Remove the generator and its bracket.
(1) Remove the 4 hexagon flange bolts (M8×20) for
fastening damping pulley at the front end of crankshaft.
Fig. 8-2-10 Removing the damping pulley See Fig. 8-2-10.
assembly (2) Remove the damping pulley assembly from the front
end of the crankshaft.
Removing the timing system ③.
(1) Remove the timing hood components I and 11, as
well as the timing hood. See Fig. 8-2-11.
(4) Remove the timing idle wheel: unscrew the bolts for
fastening the timing idle wheel to take off the timing idle
wheel.
(5) Remove the crankshaft timing pulley: unscrew the
Removing the engine oil dipstick guide
subassembly and the engine oil dipstick ④
(1) Pull out the oil dipstick assembly from the guide.
(2) Remove a hexagon flange bolt (M8x22) of oil

433
dipstick subassembly fastening on the timing hood.

(3) Pull out the oil dipstick guide subassembly from the
oil pan as shown in Fig. 8-2-12.
Removing the lower body assembly of oil pan ⑤
(1) Remove 14 hexagon flange bolts (M6 x 12)
fastening the lower and upper bodies of oil pan with
spanner orderly as shown in Fig. 8-2-13.
Removing the oil pump assembly ⑥
(1) Remove 10 hexagon bolts and flat ring components
(M8×40, M8×25 and M8×20) fastening the engine oil
Fig. 8-2-12 Removing the engine oil dipstick pump assembly and cylinder body in proper order, and
and its guide take off the engine oil pump assembly. See Fig. 8-2-14.
See Fig 8-2-14.
Upper body of
oil pan
Lower body of
oil pan Inspection and repair
(1) Replace the oil pump assembly when the rotor is

found to be seriously worn or damaged. See Fig.
8-2-15.
Fig. 8-2-13 Removing the lower body of oil (2) Replace the oil pump assembly if the pressure
pan limiting valve is found to be blocked.
Installation
Installing the oil pump assembly ⑥
Outer rotor (1) Apply a little lubricating oil on the seal ring of oil
Seal ring pump and insert the seal ring into the end of
corresponding groove of oil pump housing without
scratch, deflection and misplacement.
Front oil seal (2) Coat the front oil seal of crankshaft with an
installation, there should not be any scratch, deflection
or misplacement.
Fig. 8-2-14 Removing the oil pump assembly Installer of front oil seal: 5-8840-2361-0.


(4) Install the oil pump assembly and cylinder body

together. Tighten 10 hexagon bolts and plain washer
components (M8×40, M8×25 and M8×20) according to
the specified torque and order.
Fuel pump
pulley Outer rotor There should be no stagnation when the oil pump
Oil pump Tightening torque for fastening bolt of oil pump

Pressure housing
limiting 23 N • m± 3 N • m
valve
Installing the lower body assembly of oil pan ⑤
(1) Check the junction surface between the lower and
内转子及主动轴 Internal rotor and drive upper bodies of oil pan for dirt and scratch, and then
bearing apply the silicon sealant on the junction surface
between the lower and upper bodies of oil pan.
Fig. 8-2-15 Installing the oil pump assembly
Apply the sealant (2) Install the lower body of oil pan to the upper body
and screw down 6 hexagon flange bolts (M6x12)
according to the specified torque and order as shown in
Fig. 8-2-16.

of oil pan
9 N • m±3 N • m
and the engine oil dipstick ④
(1) Check if the seal ring of oil dipstick guide connector
Fig. 8-2-16 Installing the lower body assembly is in good condition.
of oil pan (2) Insert one end with the seal ring of oil dipstick guide
assembly into the upper body hole of oil pan, and fix the
other on the timing hood with a hexagon flange bolt
(M10x35). See Fig. 8-2-17.
Tightening torque for fastening bolt of engine oil
dipstick guide
45 N • m± 3 N • m
oil dipstick assembly.
After the assembling, keep it under good sealing

condition to prevent leakage.
Fig. 8-2-17 Installing the engine oil dipstick Installing the timing system ③.
and its guide (1) Install the timing pulley of crankshaft. Install the
woodruff key and the crankshaft timing pulley to the
crankshaft, and tightly tighten the fastening bolt
pulley should be properly fitted. See Fig. 8-2-18.

435

timing pulley
185 N • m〜195 N • m
(2) Install the timing idle wheel assembly and tighten the
fastening bolts according to the specified torque.
Tightening torque for fastening bolt of timing idle
wheel
22 N • m〜26 N • m
Fig. 8-2-18 Installing the timing system head and camshaft bearing cap. See Fig. 8-2-19.
mark on the pulley is aligned with the arrow on the oil
pump housing.
Timing mark
Bone-line (6) Install the timing tension pulley: Embed the limit
Camshaft mounting the bowl-shaped plug onto the cylinder head.
timing pulley After the mounting pin of the timing tension pulley is
adjusted by a hexagon socket head spanner so that it is
aligned with the notch position, screw the tension pulley
Fig. 8-2-19 Installing the camshaft timing bolts with specified torques. See Fig. 8-2-20.
pulley
Tightening torque for fastening bolt of timing
tension pulley
22 N • m~26 N • m
(7) Install the timing hood components 1 and 11 and the
timing hood.
——Install the timing hood components to the cylinder
body, and screw down 5 hexagon flange bolts (M10×35
and M10x50) as per the specified torque. See Fig.
Use a hexagon 8-2-21.
socket spanner
to adjust the Analog Tightening torque for fastening bolt of timing hood
mounting hole. Notch
component.
45 N • m± 3 N • m
——Embed the sealing strips I and II of timing hood
respectively into the corresponding sealing grooves.
See Fig. 8-2-21.
——After aligning the mounting holes of timing hood
components 1 and 11, tighten 10 hexagon flange bolts
(M6x16). See Fig. 8-2-21.

pulley
9 N • m±3 N • m
Sealing (1) Fit the elastic cylindrical pin into the pin hole of the
strip
crankshaft timing pulley.
Sealing damping pulley to the front end of crankshaft, and screw
strip
Fig. 8-2-21 Installing the timing hood pulley
component 23 N • m± 3 N • m
Crankshaft Attention: Put the timing mark of damping pulley
forwards.
Installing the engine accessories ①.
(1) Install the flat idle wheel assembly and wedge idle
wheel assembly and tighten the bolts as per the
Timing specified torque. See Fig. 8-2-23.
pulley
After the installation, the belt pulleys must be in
the same plane by visual check.
Damping pulley Tightening torques for the flat idle wheel and
wedge idle wheel
22 N • m〜26 N • m
assembly
(2) Align the tension pulley bolt to the mounting hole of
generator bracket. After the limit boss of tension pulley
is aligned with the mounting hole of generator bracket,
tighten the tensioner with fixing bolts. See Fig. 8-2-24.
Tightening torque for fastening bolt of tension
pulley
53 N • m〜57 N • m
(3) Install the generator belt to make each pulley install
the belt in place except the flat idle wheel and make
sure that the belt wedge-shaped teeth perfectly match
Fig. 8-2-23 Installing the engine accessories (4) Rotate the tension pulley with tool to insert the flat
idle wheel into the belt after the generator belt is
enough loose.
After the installation, check the generator belt for
any excessive tension or any insufficient tension.
operations.

437

(2) Fill lubricating oil to the lubrication system.
Rotary lubrication system for leakage.
installation
position of
belt

3. Oil Collector
Oil pan upper part

assembly
Oil pan upper part

assembly
Removal procedure
Lower body assembly of oil pan
Oil collector
Fig. 8-2-25 Removal and installation procedures of oil filter

439
Removal
Preparation
Upper body of
oil pan
Lower body of system.
oil pan
Warning: Risk of burn from the engine body and
the hot engine oil. Properly handle the waste engine oil
and protect the environment.
Removing the lower body assembly of oil pan ①
Oil pan upper part fastening the lower and upper bodies of oil pan with
assembly spanner orderly as shown in Fig. 8-2-26.
Removing the oil filter ②
(1) Remove 2 hexagon flange bolts (M6x16) fastening
oil pipe with spanner. See Fig. 8-2-27.
(2) Remove 2 hexagon flange bolts fastening the oil
collector bracket with spanner.
Oil collector
(3) Take off the oil collector from the upper body of oil
Fig. 8-2-27 Removing the oil collector Installation

Installing the oil collector ②
(1) Align the oil collector with the oil suction hole of oil
pan and install the gasket of oil collector. Install 2
hexagon flange bolts (M6x16) and screw them down as
(2) Add appropriate volume of lubricating oil to the oil
collector screen.
Attention: Screw down and install 2 hexagon

flange bolts (M8×12) on the oil collector after installing
the upper body of oil pan.
Fig. 8-2-28 installing the oil collector assembly
M6 9 N • m±3 N • m
M8 23 N • m± 3 N • m

Installing the lower body assembly of oil pan ①

Apply the sealant
(1) Check the junction surface between upper and lower
bodies of oil pan for dirt and scratch.
(2) Apply the silicon rubber sealant on the junction
surface between the lower and upper bodies of oil pan.
See Fig. 8-2-29.
Install the lower body of oil pan to the upper body and
screw down 14 hexagon flange bolts (M6x12) according
to the specified torque and order as shown in Fig.
8-2-30.
Fig. 8-2-29 Installing the lower body assembly Tightening torque of fastening bolt at lower body of
of oil pan
oil pan
9 N • m±3 N • m
Attention:
leakage may occur.
junction surface between upper and lower bodies of oil
pan is clean.
operations.
Fig. 8-2-30 Tightening the fastening bolts of (1) Connect the earthing cable for the storage battery.
lower body of oil pan according to the See Fig. 8-2-31.
specified order

storage battery

441
4. Oil Pan
Removal procedure
① Engine oil dipstick guide subassembly and
the engine oil dipstick
② Oil pan lower body assembly
③ Oil collector
④ Oil pan upper part assembly
Fig. 8-2-32 Removal and installation procedures of oil pan

Removal
Preparation
system.
Warning: Hot oil may cause burn, handle the used

oil properly and protect the environment.
Removing the engine oil dipstick guide
subassembly and the engine oil dipstick ①
Fig. 8-2-33 Removing the engine oil dipstick (1) Pull out the oil dipstick assembly from the guide.
and its guide
(2) Remove a hexagon flange bolt (M10x35) of oil
dipstick subassembly fastening on the timing hood.
Apply the sealant
(3) Pull out the oil dipstick guide assembly from the
upper body hole of oil pan as shown in Fig. 8-2-33.
Removing the lower body assembly of oil pan ②
fastening the lower and upper bodies of oil pan with
spanner orderly as shown in Fig. 8-2-34.
Removing the oil collector ③
(1) Remove 2 hexagon flange bolts (M6x16) fastening
Fig. 8-2-34 Removing the lower body oil pipe with spanner. See Fig. 8-2-35.
assembly of oil pan (2) Remove 2 hexagon flange bolts (M8 X12) fastening
the oil collector bracket with spanner.
Upper body of
oil pan (3) Take off the oil collector from the upper body of oil
Removing the upper body assembly of oil pan ④
(1) Screw down 15 hexagon flange bolts （M6 x20 & M6
X 110 & M8 x25 & M8 x45) on the oil pan orderly with
Oil collector spanner.
Lower body of
(2) Take out the dowel pin of upper body of oil pan and
oil pan take off the upper body of oil pan from the lower cylinder
Installation
Fig. 8-2-35 Removing the oil collector
Installing the upper body assembly of oil pan ④
(1) Check if the dowel pin of upper body of oil pan is
installed correctly, and then apply the silicon rubber
sealant on the junction surface of oil pan and cylinder
body. Install the upper body of oil pan on the cylinder

443
Cylinder body LOCTITE587 flat sealant.
Attention: Make sure the joint surface between

the upper body of oil pan and the cylinder body is clean
before reapplying sealant.
(2) Screw down 12 hexagon flange bolts（M6 X20 & M8
Upper body of
X45) fastening the upper body of oil pan according to
oil pan the specified torque and order as shown in Fig. 8-2-37.
The upper body of oil pan and cylinder body

should fit closely after the installation.
Tightening torque of fastening bolt of oil pan upper
body
Fig. 8-2-36 Removing and installing the upper
body of oil pan Bolt specification Tightening torque
M6 9 N • m±3 N • m
M8 23 N • m± 3 N • m
Installing the oil collector ③

(1) Apply appropriate volume of lubricating oil to the oil
collector seal.
Mobil API CI4 lubricating oil
(2) Align the oil collector with the oil suction hole of oil
pan and put the oil collector gasket into it and tighten it
with 2 hexagon flange bolts (M8 x 16).
Fig. 8-2-37 Installing the upper body of oil pan
Attention: Screw down and install 2 hexagon
Upper body of
flange bolts (M6×12) on the oil collector after installing
oil pan the upper body of oil pan as shown in Fig. 8-2-38.
M6 9 N • m±3 N • m
M8 23 N • m± 3 N • m
Oil collector
Lower body of Installing the lower body assembly of oil pan ②

oil pan
(1) Check the junction surface between upper and lower
bodies of oil pan for dirt and scratch.
(2) Apply the silicon rubber sealant on the junction
Fig. 8-2-38 installing the oil collector surface between the lower and upper bodies of oil pan.
assembly
(3) Install the lower body of oil pan to the upper body
and screw down 14 hexagon flange bolts (M6x12)
according to the specified torque and order as shown in

Fig. 8-2-39.

of oil pan
9 N • m±3 N • m
Attention:
(1) Many fastening bolts are installed on the oil pan, and
all the bolts should be tightened. Otherwise, oil leakage
may occur.
Fig. 8-2-39 Installing the lower body assembly (2) Before applying sealant again, make sure the
of oil pan junction surface of upper and lower bodies of oil pan is
clean.
and the engine oil dipstick ①
(1) Check if the seal ring of oil dipstick guide connector
is in good condition and install it in place.
Oil dipstick (2) Insert one end with the seal ring of oil dipstick guide
assembly assembly into the upper body hole of oil pan, and fix the
other on the timing hood with a hexagon flange bolt
(M10x35). See Fig. 8-2-40.
oil dipstick assembly.
Tightening torque of fastening bolt of engine oil

Fig. 8-2-40 Installing the engine oil dipstick dipstick guide
and its guide
23 N • m± 3 N • m
After the assembling, keep it under good

sealing condition to prevent leakage.
operations.

445
Chapter IX Turbocharging System

Section I General
1. Turbocharging system composition
The turbocharging system is made up of the intake and
exhaust systems and the turbocharger. Based on
different configuration requirements, GW4D20
turbocharged diesel engine is equipped with the VGT
turbocharger (variable geometry turbocharger, see Fig.
9–1-1), while GW4D20B turbocharged diesel engine is
equipped with the WGT turbocharger (turbocharger with
bypass valve, see Fig. 9–1-2).
2. Turbocharger structure
The turbocharger is generally made up of the following
three parts: the turbine, the intermediate body and the
Fig. 9-1-1 VGT turbocharger assembly gas compressor. The VGT turbocharger is equipped
with the VGT actuator while the WGT turbocharger is
equipped with the bypass valve.
2.1 Turbine part
The turbine part mainly consists of the turbine housing
and the turbine, which act as energy converters.
Through the turbine housing, the exhaust gas produced
by the diesel engine enters the nozzle and injects to the
turbine impeller with a certain angle. Thus the heat and
pressure energies of the exhaust gas are converted into
kinetic energy, which rotates the turbine at a high
speed, as shown in Fig. 9-1-3.
2.2 Intermediate body
The intermediate body is the middle support used to
Fig. 9-1-2 WGT turbocharger assembly support the rotor assembly and fix the turbine housing
and the gas compressor housing, and the lubricating oil
Turbine housing tank used for lubricating and cooling floating bearing, as
Turbine exhaust
outlet shown in Fig. 9-1-4.
Gas compressor 2.3 Gas compressor part

housing
The gas compressor part mainly consists of the gas
compressor impeller, the diffuser, and the housing of the
gas compressor, as shown in Fig. 9–1–3.Through the
Turbine Turbine air cleaner, the air is sucked into the gas compressor
exhaust inlet impellor impeller rotating at a high speed so that the air flow
Air outlet of the velocity and pressure are boosted. Through the diffuser
gas compressor and the gas compressor housing, the kinetic energy of
Air inlet of the Gas the air flow is converted into the pressure energy, which,
gas compressor after further boosting, will enter the cylinder via the air
compressor impellor intake manifold pipe of the diesel engine, so as to
increase the density of its inlet air.
Fig. 9-1-3 Gas compressor and turbine of the
turbocharger The turbine shaft and the turbine are connected by
friction welding. The impeller of the gas compressor is
installed at the turbine shaft by means of transition fit

Rotor assembly and is pressed tightly by the self-locking nut. Subject to

Turbine impellor the precise dynamic balancing, the whole rotor
Lubricating
oil inlet assembly is ensured to be working normally in case of
high-speed rotation.
2.4 VGT Adjuster (VGT Turbocharger)By changing the
flow geometry of the turbine, VGT turbocharger
(variable geometry turbocharger) realizes its optimal
match with the diesel engine under different working
conditions. All operating points match well with the
Gas Floating shaft diesel engine to make the diesel engine performs in an
compressor Lubricating
bearing
impellor
oil outlet optimal condition.
Intermediate housing
As the diesel engine speed declines, the outlet area of
the turbine nozzle ring will be reduced to increase the
Fig. 9-1-4 Turbocharger intermediate housing
rotation speed of the turbine and the outlet pressure of
and rotor assembly
the gas compressor; While the diesel engine speed
increases, the outlet area of the turbine nozzle ring will
be expanded to reduce the outlet pressure of the gas
compressor and the maximum ignition pressure so as to
VGT actuator
prevent overspend of the diesel engine mechanical
load.
The structure of the VGT adjuster is shown in the Fig.
9-1-5.
2.5 Bypass valve (WGT Turbocharger)
Adjusting rod
Nozzle ring
In case of high rotation speed, WGT turbocharger
(turbocharger with the bypass valve) will release a
Nozzle ring portion of the exhaust gas from the turbine front via the
blade exhaust valve. The air release valve in front of the
turbine is automatically controlled by the turbocharged
pressure. When the diesel engine speed exceeds a
Fig. 9-1-5 VGT Adjuster (VGT turbocharger)
certain value, the turbocharged pressure will open the
Turbocharged air air release valve to release the air by overcoming the
Turbine Gas
reaction of the spring.
compressor
Exhaust head pipe impellor
The structure of the WGT turbocharger with bypass
valve is shown in Fig. 9-1-6.
Exhaust
outlet
Fresh air Attention:
(1) The specified value of the start pressure of the air

Axis pin release valve is set by the manufacturer and no
Rocker arm adjustment should be conducted by the user, namely,
Bypass valve
Diaphragm the adjusting nut at the linkage push rod should not be
Linkage push
rod Spring
Sealed pressure screwed. Otherwise, the performance regarding
Adjusting nut chamber
Exhaust inlet dynamic, economy and reliability will be seriously
damaged.
Fig 9-1-6 Turbocharger structure
(2) Under no circumstances, linkage push rod should be
(WGT turbocharger with bypass valve) used as the handle or the bench for loading or stepping.
(3) If the air induction pipe is found to be leaking or the
linkage push rod to be inflexible during the usage, the
operator should stop the vehicle for troubleshooting.
(4) The air release valve and the sealed pressure

447
chamber can not be maintained. If there is any damage,

the whole turbine housing device should be replaced.
2.6 Identification of the subassembly
The manufacturing data and other important information
required for maintenance are provided on the
nameplate of the turbocharger. See Fig. 9-1-7.
Fig. 9-1-7 Identification of the subassembly

Section II On-board Maintenance
WGT turbocharger
Removal procedure
① Turbocharger intake hose
② Air cleaner
③ Catalytic converter pipe
④ Turbocharger heat shield
⑤ Turbocharger fuel inlet bolt
⑥ Turbocharger fuel return
hose subassembly
Install them in the opposite order of removal
⑦ Turbocharger assembly
VGT turbocharger
Fig. 9-2-1 Removal and installation procedures of the turbocharging system

449
Removal
Preparation
Air flow sensor Disconnect the earthing cable of the storage battery.
Removing the turbocharger intake hose ①
(1) Loosen the clamps at the intake hose and the air
gas compressor housing of the turbocharger. See Fig
9-2-2.
(2) Pull out the connector of crankcase vent hose
Fig. 9-2-2 Removing the turbocharger intake Removing the air cleaner ②
hose
(1) Remove the air cleaner harness connector.
(2) Remove the hose connected with the intake pipe of
the turbocharger.
Filter core (3) Remove the fastening bolt connecting the air
cleaner and the body and take off the air cleaner. See
Fig. 9-2-3.
The air cleaner filter core should be replaced in the
following cases:
Turbocharger -——Maintenance and replacement period is due
intake hose
-——The filter core is seriously polluted and the dirts
are difficult to remove.
-——The filter core is deformed and damaged.
Fig. 9–2-3 Removing the air cleaner
Removing the catalytic converter pipe ③

Catalytic
converter (1) Remove the bolt and nut connecting the catalytic
converter pipe and the turbocharger or the front
exhaust pipe.
Front exhaust Mounting support for
pipe the front exhaust pipe (2) Remove the catalytic converter pipe and the sealing
gaskets at its both ends. See Fig. 9-2-4.
(3) Check the sealing gasket of the catalytic converter
pipe, and replace those damaged or deformed ones.
Fig. 9-2-4 Removing the Catalytic Converter

Pipe

Removing the turbocharger heat shield ④

(1) Loosen 3 hexagon flange face bolts (M6×12)
Heat shield
fastening the turbocharger heat shield. See Fig. 9-2-5.
(2) Take off the heat shield (VGT turbocharger) from the
outside of turbocharger.
Turbocharger
Fig. 9-2-5 Removing the turbocharger heat

shield
Removing the turbocharger fuel inlet bolt ⑤
(1) Remove the fuel inlet bolt at the turbocharger fuel
Turbocharger
fuel inlet pipe
inlet. See Fig. 9-2-6.
(2) If not necessary, the fuel inlet bolt connecting the
turbocharger fuel inlet pipe and the cylinder should not
be removed.
Removing the turbocharger fuel return hose
Turbocharger component ⑥
(1) Remove 2 hexagon flange face bolts (M6×16)
fastening the turbocharger fuel return hose component
and the turbocharger. See Fig. 9-2-7.
(2) Remove the single-ear stepless clip fastening the
Fig. 9-2-6 Removing the turbocharger fuel turbocharger fuel return hose component and the fuel
inlet bolt return hose.
(3) Take off the turbocharger fuel return hose
component and the packing.
Check the packing, and replace those damaged
Fuel return hose
or deformed ones.
Removing the turbocharger assembly ⑦
(1) Pull out the turbocharger harness plug.
Fuel return hose (2) Remove 1 connecting bolt and 2 fastening nuts
component
fixing the turbocharger assembly, and take off the
turbocharger assembly and the turbocharger gasket.
See Fig. 9-2-8.
Check the turbocharger gasket and replace those

Fig. 9-2-7 Removing and installing the
deformed and damaged ones.
turbocharger fuel return hose component
Installation
Installing the turbocharger assembly ⑦
(1) Install the turbocharger gasket.

451
(2) Install the turbocharger and fix tight 1 connecting

bolt and 2 fastening nuts as per the specified torque.
Turbocharger See Fig. 9-2-8.
(3) Connect the turbocharger harness plug.
Tightening torque for the turbocharger connecting
bolt and fastening nut.
45 N • m±3 N • m
Fuel return hose Heat shield Installing the turbocharger fuel return hose
component ⑥
(1) Install the packing of the fuel return hose component
and fasten 2 hexagon flange face bolts (M6 x 16) to the
lower body of the turbocharger. See Fig. 9-2-7.
Fig. 9-2-8 Removing the turbocharger
assembly
Tightening torque for the fastening bolt of the
turbocharger fuel return hose component
Turbocharger 9 N • m±3 N • m
fuel inlet pipe
(2) Cover the single-ear stepless clip at the fuel return
hose, connect the hose to the fuel return hose
component and the cylinder fuel return connector and
properly install the single-ear stepless clip in place. See
Fig. 9-2-7.
Turbocharger Installing the turbocharger fuel inlet bolt ⑤
(1) Check the gasket of the turbocharger fuel inlet bolt
and replace those damaged ones.
(2) Install the turbocharger fuel inlet bolt and gasket to
the turbocharger and tighten them as per the specified
Fig. 9-2-9 Installing the turbocharger fuel inlet
bolt
Tightening torque for the turbocharger fuel inlet
bolt
Heat shield
22 N • m± 3 N • m
Attention: There is one fuel inlet bolt gasket on

the turbocharger fuel inlet pipe ball head and one below
it. Take care to avoid omission during installation.
Installing the turbocharger heat shield ④
(1) Install the turbocharger heat shield at the heat shield
Turbocharger position of the turbocharger exhaust manifold pipe.
(2) Tighten 3 hexagon flange face bolts (M6×12)
fastening the turbocharger heat shield as per the
Fig. 9-2-10 Installing the turbocharger heat specified torque. See Fig. 9-2-10.
shield Tightening torque for the fastening bolt of the
turbocharger heat shield
9 N • m±3 N • m

Installing the catalytic converter pipe ③

Catalytic (1) Install the catalytic converter pipe and the packing at
converter its both ends, and connect it to the turbocharger or the
front exhaust pipe.
Front exhaust Mounting support for (2) Install the bolt and the nut fastening the catalytic
the front exhaust pipe
pipe converter pipe and tighten them as per the specified
of the catalytic converter pipe.
23 N • m± 3 N • m
(3) Check after installation and make sure that the
Fig. 9-2-11 Installing the catalytic converter catalytic converter pipe is sealed without air leakage.
pipe
Air cleaner cover Installing the air cleaner ②

(1) Install the air cleaner and fasten the bolt connecting
the air cleaner housing and the machine body. See Fig.
Filter core
9-2-12.
(2) Install the air intake hose connecting the air cleaner
and the turbocharger and fasten it with the clip. See Fig.
9-2-12.
(3) Connect the air cleaner harness plug.
Turbocharger
intake hose (4) After installation, check the air cleaner for any
Air cleaner leakage at the connections between its cover and
housing housing and of all the pipelines, and make sure there is
no air-leakage.
Fig. 9-2-12 Installing the air cleaner
Installing the turbocharger intake hose ①

(1) Install the turbocharger intake hose and tighten the
clip. See Fig. 9-2-13.
Air flow sensor
(2) Check the connector of the turbocharger intake pipe
after the installation and make sure that it is sealed
without any leakage.
operations.
make sure both the intake and exhaust systems and
Fig. 9-2-3 Installing the intake hose of the the turbocharging system are in normal operation.
turbocharger

453
Section III Inspection and Repair
The turbocharger is a precision machine rotating at a high speed. Its maximum rotation speed can reach
210000 r/min or more and its normal speed is always above 10000 – 100000 r/min. Therefore, if not
necessary, the turbocharger assembly should not be disassembled arbitrarily. When the turbocharger
rotator rotates inflexibly or the diesel engine performance deteriorates due to dust and carbon deposits,
simple clearing and cleaning can be conducted to the turbocharger without complete disassembling. The
detailed methods are as follows :
(1) Clean the dust and fuel dirts on the surface of the turbocharger.
(2) Remove the turbocharger from the diesel engine and pay attention not to lift the turbocharger by
utilizing the linkage push rod as a handle.
(3) Remove the air guide pipe first and then the adjusting device of the air release valve.
(4) Remove the gas compressor housing, the turbine housing, and the parts connecting the fuel inlet
pipe and return hose and the coolant pipe.
(5) Clear and clean the gas compressor housing, the turbine housing and 2 turbine impeller surfaces.
(6) Fill an appropriate amount of the cleaning agent via the fuel inlet port, and rotate the impeller by
hands repeatedly till it rotates flexibly.
(7) Assemble the turbocharger and install it in the diesel engine. When installing the turbocharger, all the
packings connected with the turbocharger should be replaced and the clean lubricating oil should be
filled through the turbocharger fuel inlet port for lubrication.
Caution: Do not touch and strike the impeller during the removing and cleaning for the
turbocharger. If there is any touch, the deformed impeller blade can not continue to be used even after
the correction. The cleaning agent can be kerosene, gasoline or diesel of good quality.
If excessive abrasion and damage of the turbocharger are found during checking, the wear and
damaged parts should be adjusted, repaired or replaced.
1. Checking the working condition of the

exhaust outlet
(1) Remove the hose between the exhaust outlet
and the intake pipe.
(2) Connect the pressure gauge.
Connecting rod
(3) Check whether the connecting rod starts to
move or not when an approximate 0.088Mpa
pressure is applied at the exhaust outlet. See Fig.
9-3-1.
Pressure
Attention: For this kind of check, the
pressure should not be above 0.1Mpa.
Fig. 9-3-1 Checking the working condition of the
exhaust outlet

2. Checking the working condition of the

turbocharger
Check whether the pressure for moving the control rod
for 2 mm is within the following limit value.
Working pressure of the control rod
About 0.118Mpa
For the turbocharger maintenance, please contact with
the “Great Wall Baoding Internal Combustion Engine
Manufacturing Company Limited” service station.
The following standard value and limit value for the
important axial clearance and bearing clearance of the
Fig. 9-3-2 Checking the working condition of impeller shafts are for reference only.
the turbocharger
3. Checking the axial clearance of the

impeller shaft.
Measure the axial clearance of the impeller by dial
indicator. See Fig. 9-3-3.Apply a 0.12N force on the gas
compressor impeller and the turbine impeller
alternately.
Axial clearance of the impeller shaft
Standard value Limit value
0.06 ~ 0.09mm 0.11 mm
Fig. 9-3-3 Measuring the axial clearance of

the impeller shaft
4. Checking the axial clearance of the rotor
During the inspection, fix the magnetic base on the
turbine housing outlet flange surface to connect the dial
indicator to the turbine rotor shaft end face, and then
push or pull the turbine rotor axially. The measured
difference value is the axial clearance value.
Rotor of the new turbocharger
Axial clearance 0.01 mm
Operation limit ≤0.25mm
Fig. 9-3-4 Checking the turbocharger When the axial clearance of the turbocharger rotor
exceeds the operation limit, please disassemble the
assembly and replace the wearing parts.

455
5. Checking the clearance between the

Oil return port impeller shaft and the bearing
Measure the clearance between the impeller shaft and
the bearing by the dial indicator. See Fig. 9-3-5.
Bearing clearance of the impeller shaft
Standard value Limit value
Limit value 0.215mm

Oil supply port
Fig. 9-3-5 Measuring the clearance between

the impeller shaft and the bearing
6. Checking the radial clearance of the rotor
During the inspection, press the gas compressor
impeller radially and measure the minimal clearance
between the gas compressor impeller and the housing
by thickness gauge.
Minimal clearance
No less than 0.10mm
If the clearance is below the value, replace the floating

bearing.
Prompt: Before figuring out or excluding the causes of
Fig 9-3-6 Checking the turbocharger turbocharger damages, do not adopt a new one.

Chapter X Electronic Control EGR System

Section I General
The electronic control EGR technology is adopted in GW4D20/GW4D20B turbocharged diesel engine so
that its overall emission can reach National Ⅳ standard.
EGR system can be used to control the exhaust gas recirculation (EGR system) for modern engine.
Through introducing a small amount of the exhaust gas produced by the engine into the cylinder and
blending it with the fresh air, the exhaust gas recirculation system reduces the emission of the pollutant.
Through reducing the combustion rate to decrease the peak value of the combustion temperature, the
emission amount of Nox can be reduced.
The EGR rate should be adjusted precisely according to different working conditions of the engine in the
EGR system.
As the engine load changes, the exhaust gas amount introduced into the cylinder should also be
adjusted accordingly to always allow the EGR system to work under the condition of good emission
control and good engine power.
If the introduced exhaust gas is too much, the engine power will decrease, the smoke will increase and
the engine will produce louder noise. If the introduced exhaust gas is too little, the emission requirement
can not be met for the engine. Therefore, for each working condition (load, rotation speed and water
temperature) of the engine, there is always an optimal EGR rate (the ratio of the exhaust gas
recirculation mass to the fresh air mass).
The EGR system of the engine is equipped with the EGR cooler, whose function is to cool the exhaust
gas entering the cylinder to reduce the intake air temperature so as to reduce the Nox as well as the CO
and HC emission volumes.
When the EGR valve, the vacuum adjuster and the EGR cooler are damaged, timely replace them
according to the manufacturer’s requirement and the specification.
EGR valve Vehicle speed

signal
Cooling water
temperature signal
Recirculated exhaust gas
Air flow sensor signal
EGR Engine speed signal

condenser
Footboard signal
Exhaust gas Air intake
Fig. 10-1-1 Schematic diagram of the EGR electronic control system

457
Removal procedure
① EGR valve harness plug
② EGR condenser component
③ EGR valve assembly
Intake manifold pipe
Fig. 10-2-1 Installation and removal procedures of EGR System

Removal
Preparations:
Removing the harness plug of the EGR valve ①
(1) Loosen the plug connecting the harness connector
and the EGR valve.
EGR valve
(2) Hold the plug and pull out the harness plug
connected with the EGR valve. See Fig. 10-2-2.
Caution: Pull the plug connector instead of the

Fig. 10-2-2 Removing the harness plug of the harness (the wire) when separating the circuit
EGR valve connector.
Removing the EGR condenser component ②

Air intake Water outlet pipe
pipe (1) Remove 2 hexagon flange face bolts (M8 x16) from
the air outlet pipe of the EGR condenser. See Fig.
EGR condenser 1-2-3.
(2) Remove 2 hexagon flange bolts (M8 x20) from the
intake pipe of the EGR condenser. See Fig. 1-2-3.
(3) Loosen the single-ear stepless clip fastening the
water inlet pipe and the water outlet pipe of the EGR
Air outlet pipe condenser. See Fig. 10-2-3.
Water inlet (4) Remove 1 hexagon flange face bolt (M10x16)

pipe fastening the EGR condenser bracket and the cylinder
head.
Fig. 10-2-3 Removing the EGR condenser (5) Take off the EGR condenser from the cylinder head.
Removing the EGR valve assembly ③

(1) Remove 2 hexagon flange face nuts fastening the
EGR valve
assembly EGR valve. See Fig. 10-2-4.
(2) Remove 2 hexagon flange face bolts (M8x20)
fastening the EGR valve and the EGR condenser intake
pipe, and the condenser intake pipe gasket. See Fig.
10-2-4.
(3) Take off the EGR valve assembly and the air outlet
gasket.
(4) Check the packing, and replace it if damaged or
deformed.
Fig. 10-2-4 Removing the EGR valve

459
EGR valve
assembly Installation
Installing the EGR valve assembly ③
Air intake
manifold pipe (1) Install 2 double end stud bolts at the air intake
manifold pipe. See Fig. 10-2-5.
(2) Install the EGR valve assembly at the air intake
manifold pipe and tighten 2 hexagon flange nuts as per
the specified torque.
Tightening torque for the fastening nut of the EGR
valve.
Fig. 10-2-5 Installing the EGR valve 23 N • m± 3 N • m
Installing the EGR condenser component ②
Air intake Water outlet pipe (1) Install the EGR condenser component at the rear
pipe end of the cylinder head and untighten the bolt
temporarily.
EGR condenser (2) Install the double end stud bolts at the exhaust
manifold pipe, the EGR condenser gasket at the EGR
condenser component, and the EGR condenser air
intake pipe gasket at the exhaust manifold pipe. Install
the EGDD condenser air intake pipe and tighten 2
hexagon flange face nuts and 2 hexagon flange face
Air outlet pipe bolts (M8x20) as per the specified torque. See Fig
Water inlet 10-2-6.
pipe (3) Install the EGR condenser gasket at the EGR
condenser component and the EGR condenser exhaust
Fig. 10-2-6 Installing the EGR condenser pipe gasket at the EGR valve seat. Install the EGR
condenser exhaust pipe and tighten 2 hexagon flange
face bolts (M8x16) as per the specified torque. See Fig.
10-2-6.
Tightening torque for the fastening bolt of the EGR
condenser air intake/outlet pipes.
23 N • m± 3 N • m
(4) Install the EGR condenser water inlet pipe and water
outlet pipe, and fix them tight with the single-ear
stepless clip. See Fig. 10-2-6.
EGR valve
(5) Install 1 hexagon flange face bolt (M10x16)
fastening the EGR condenser bracket and the cylinder
head. Fasten the EGR condenser.
Tightening torque for the fastening bolt of the EGR
Fig. 10-2-7 Installing the harness plug of the condenser bracket.
EGR valve
45 N • m± 3 N • m

Installing the harness plug of the EGR valve ①

(1) Connect the EGR valve harness connector to the
EGR valve. See Fig. 10-2-7.
(2) Check the EGR valve harness plug to ensure it is
firmly connected.
operations.
(1) Connect the earthling cable of storage battery. See
Fig. 10-2-8.
make sure the electronic control EGR system is in
normal operation.
Fig. 10-2-8 Connect the earthing cable of

storage battery

461
Chapter XI Electrical System

Section I Storage Battery
1. Storage Battery Performance Parameters
When the dry charged storage battery is urgently needed, fill the prepared electrolyte into the battery
and rest it for 30 min, and after that the battery can be used. However, generally it can only be used in 3
to 5 h after being charged. The storage battery has been charged for 4 h before delivery.
Table 11-1-1 Storage Battery Performance Parameters
Item Parameter
Storage battery model 6-QA-80
Number of cells 6
Rated voltage (V) 12
Rated capacity (A.H. 20 discharge rate) 90
Height of the electrolyte level over the polar plate (mm) 10~15
Overall dimension (mm) (length×width×height) 300 x 170 x220
Electrolyte specific gravity See Table 11-1-2 and Table 11-1-3
Table 11-1-2 Electrolyte specific gravity in different areas and temperature conditions (g/cm3)
Electrolyte specific gravity of fully charged

storage battery at 15°C
Climate condition (ambient temperature)
In winter In Summer
Area where temperature is below -40℃ in winter 1.31 1.27
Area where temperature is above -40℃ in winter 1.29 1.25
Area where temperature is above 0℃ in winter 1.24 1.24
Table 11-1-3 Correction value of electrolyte specific gravity at different temperatures
Electrolyte temperature
+ 45 + 30 + 15 0 -15 -30 -45
measured (℃)
Correction value of
specific gravity meter + 0.02 + 0.01 0 -0.01 -0.02 -0.03 -0.04
readings

2. Preparing Electrolyte
2.1 Electrolyte Preparation Methods
(1) The lead-acid storage battery electrolyte is made of pure water and concentrated sulphuric acid. The
density of electrolyte used for starting an automobile is 1.280g/cm3±0. 005g/cm3 (25°C).
(2) The container where electrolyte is prepared should be acid and heat resistant glazed ceramic, glass
jar, trough or leadwork torque. Operation staff should be equipped with protective appliance when
preparing electrolyte.
(3) Brush off the container and wash it with pure water before preparing electrolyte.
(4) Fill the pure water needed for preparing electrolyte into the container and then mix the concentrated
sulphuric acid into the pure water and keep stirring. It is forbidden to fill water into sulphuric acid because
it will cause burns as a result of spattering fluid.
Reduction formula d25 = dt + 0. 0007 (t-25)
In this formula: d25=the electrolyte density at 25°C; dt: the electrolyte density at temperature of t; 0.0007:
temperature factor; t: the electrolyte temperature practically measured.
The proportion of pure water (or distilled water) to the sulphuric acid in electrolyte is shown in Table
11-1-4.
Table 11-1-4 Proportion of pure water (or distilled water) to sulphuric acid in electrolyte
Volume ratio of Mass ratio of Volume ratio of Mass ratio of

Electrolyte pure water (or pure water (or Electrolyte pure water (or pure water (or
specific gravity distilled water) distilled water) specific gravity distilled water) distilled water)
at 20°C (g/cm3) to sulphuric to sulphuric at 20°C (g/cm3) to sulphuric to sulphuric
acid acid acid acid
1. 10 9.80:1 6.28:1 1.21 4.07:1 2.22:1
1. 11 8.80:1 5.84:1 1.22 3.84:1 2.09:1
1. 12 8.00:1 5.40:1 1.23 3.60:1 1.97:1
1. 13 7.28:1 4.40:1 1.24 3.40:1 1.86:1
1. 14 6.68:1 3.98:1 1.25 3.22:1 1.76:1
1.15 6.15:1 3.63:1 1.26 3.05:1 1.60:1
1. 16 5.70:1 3.35:1 1.27 2.80:1 1.57:1
1. 17 5.30:1 3. 11:1 1.28 2.75:1 1.49:1
1. 18 4.95:1 2.90:1 1.29 2.60:1 1.41:1
1. 19 4.63:1 2.52:1 1.30 2.47:1 1.34:1
1.20 4.33:1 2.36:1
Note: The table values are calculated on a specific gravity of 1.83 of pure sulphuric acid at 20°C.

463
2.2 Filling Electrolyte

(1) Make sure the vent holes on the story battery plug
are penetrated. Remove the packing and sealing paper
under the exhaust cock after filling electrolyte.
(2) Do not fill the electrolyte into the storage battery
until the liquid temperature cools down below 30℃.
(3) Fill the prepared electrolyte into each cell till the
liquid level in plastic container is parallel to the mark of
“Max” on the housing, and the liquid level in rubber
container is 10 to 15 mm above the baffle plate.
(4) Tighten the exhaust cock to avoid leakage.
3. Charging the Storage Battery
3.1 Charging Equipment
Caution: Only DC power supply is applicable for

Fig. 11-1-1 Checking the storage battery
electrolyte level charging storage battery.
(1) Rectifier
The widely used rectifiers are dry type rectifiers (copper-oxide rectifier, selenium rectifier, silicon rectifier),
gaseous rectifier (tungsten lamp rectifier) and mercury rectifier. Their input AC voltage is generally 110 V
or 220 V, and the nominal output voltages are 6 V, 12 V and 24 V. Dry type rectifiers are convenient to
use and can be unattended during charging, therefore are widely used.
(2) Controlled silicon voltage regulation charger
The controlled silicon voltage regulation charger applies power supply of 220 V AC which is transformed
to direct current through controlled silicon rectifier and charges storage battery from output end. The DC
output voltage is 0 to 220V and the electric current is 0 to 40 A.
3.2 Detecting Instruments
Densimeter, thermometer, voltmeter, amperemeter and other detecting instruments and necessary tools
are generally used for storage battery charging and daily maintenance.
3.3 Charging the Storage Battery
(1) Preparations before charging
——Check if the electrolyte or pure water complies with related prescription.
——Remove the exhaust cock on storage battery.
——Fill the electrolyte or pure water up to the specified level line.
(2) Charge connection
The positive pole of the charger is connected with that of the storage battery, and the negative pole of
the charger is connected with that of the storage battery. Don’t reverse the connection. For most storage
batteries, the charge can be determined according to the charger power. The charge connection must be
firm and reliable.
(3) Charging modes
Generally there are constant-current charge, constant-voltage charge and quick charge.
The constant-current charge includes initial charge, supplementary charge, normal charge and
equalizing charge.

——Initial charge: it is the first charge for dry discharged storage battery before being used. Fill
electrolyte into dry discharge storage battery and rest the battery for 1 to 6 h, and do not start charging
until the liquid temperature lowers below 35°C.For initial charge, the electric current is generally 0.07
C20 A, and after the single cell voltage reaches 2.4 V, cut the electric current in half for subsequent
charging.
——Supplementary charge: it is used for dry charged storage battery of poor dry charging performance
and long storage time, or for storage battery unused for about 1 month after being sufficiently charged
with electrolyte filled. The electric current applied for supplementary charge is 0.1 C20 A, and the
charging time is about 5 h or determined by the storage period.
——Normal charge: it is the charge for storage battery being used after initial charge. In the first stage of
normal charge for automobile storage battery, the electric current applied is 0.1 C20 A, and after
charging of 8 to 12 h till the single cell voltage reaches above 2.4 V, the electric current is cut in half for
the subsequent charging of about 10 hither charge capacity is generally 1.5 times of discharge capacity,
or 1.3 to 1.5 times of rated charge capacity.
——Equalizing charge: it is the sufficient charge for storage battery by means of normal charge and
electric current of 0.035 C20 A in order. When there are even bubbles in storage battery with
temperature increasing, stop charging for 1 h and repeat such operation 3 to 4 times. Single cell can
produce plenty of bubbles. The equalizing charge stops when the storage battery voltage and electrolyte
density tend to be stable.
——Constant-current charge: it is the charge applying constant voltage all through. In the beginning, the
charge current is high and then progressively weakened, and the charge constant voltage is generally
2.3 to 2.4 V. Such charge produces little gas and consumes little water. Therefore, constant-voltage
charge is usually used for seal lead-acid storage battery free from maintenance.
——Quick charge: it is the charge for storage battery applying high electric current and pulse current as
well as intermittent charge with short time discharge. The quick charge applies 1 to 2 times of C20 A high
electric current. The quick charge is implemented by a purpose-made quick charger.
(4) How to judge whether storage battery is sufficiently charged or not
There are plenty of bubbles in a single cell, cell voltage is between 2.6 to 2.8 V and is measured to stay
constant after charging 2 h, and the electrolyte specific gravity reaches 1.280g/cm 3 ±0.01g/cm3 (25°C)
and stays constant after 2 h.
(5) Preparations of charging
The liquid temperature can not exceed 45°C, if not, take measures to lower it down (to reduce charge
current or stop charging or put it in a trough for cooling), and the ventilation should be good, and fire
source be prevented.
(6) Fault diagnosis of lead-acid storage battery
The fault diagnosis methods commonly used for lead-acid storage battery are shown in Table 11-1-5,
11-1-6 and 11-1-7.
Table 11-1-5 Specific gravity measurement
Specific gravity value (25°C) Judgement Treatment
High concentration of electrolyte, Using deionized water to adjust

Above 1.300
and incorrect filling the specific gravity
1.250~1.280 Good
1.250~1.220 Undercharging Recharging

465
Overdischarging, low
Below 1.220 to 1.100 Check after charging
concentration, or other faults
Specific gravity difference for

Possible fault of single cell Check after charging
each cell being above 0.04
Table 11-1-6 Voltage measurement
Voltage Judgement Treatment
Above 12.5 V Normal
12.5 to 11.5 V Undercharging Recharging
Below 11.5 V Overcharging or internal fault Check after charging
Table 11-1-7 Capacity measurement
Capacity detector showing Judgement Treatment
White area Sufficient
Green area Normal
Yellow area Recharging required Recharging
Red area Fully discharged Check after charging
4. Checking the Storage Battery

Remaining Capacity
(1) Checking the electrolyte specific gravity with a
Rubber ball specific gravity meter
Rubber tube
As the electrolyte specific gravity increases after
Specific gravity charging and decreases after discharging, the
meter core remaining capacity can be estimated according to
Electrolyte Glass tube the specific gravity. Based on experience, 0.01g/
Storage battery cm3 of specific gravity decrease equals to 6% of
the discharging capacity of storage battery, so if
the specific gravity is known when storage battery
is sufficiently charged, the discharging rate can be
roughly calculated according to the electrolyte
specific gravity measured. 如 :For example: the
specific gravity is 1.28 when the storage battery is
sufficiently charged, but the measured value is
Fig. 11-1-2 Checking the electrolyte specific gravity
1.20, so the storage battery has been discharge by
of storage battery
48%.

(2) Checking single cell voltage with a high rate

discharge gauge
High rate discharge gauge is also called
discharge tongs which consists of one 3 V DC
voltmeter and one loadresistor. Press the points
of two contact pins firmly on the positive and
Voltmeter
negative poles of storage battery for 5 s to
observe the terminal voltage that storage battery
Resistor can maintain under high load discharging. By
Discharge tongs doing this, the storage battery discharging rate
contact pin and starting ability can be judged.
Storage battery
For high rate discharge gauges produced by
different factories, read their electric current and
voltage readings according to corresponding
instructions. For storage battery of good
technical conditions, single cell voltage should be
Fig. 11-1-3 Checking storage battery with a pair of
higher than 1.5 V and stays constant in 5 s. If the
discharge tongs
voltage drops quickly in 5 s or the voltage of one
single cell is lower than others by more than 0.1
V, there is something wrong with this battery and
measures shall be taken to repair it.

467
Section II Starting System

1. General
1.1 Starting System
The starting system consists of storage battery, starter, starting switch, ignition lock, starter relay and
other components which are connected according to Fig. 11-2-1.
Starter relay
Starter
Starting switch
Holding coil
Contact point
“50” terminal
“30”
terminal
Magnetic switch
Pinion clutch Storage battery
Attraction coil
Fig. 11-2-1 Starting system
The starter is installed on the cylinder body on the

left side of the engine.
Starter technical parameters:
Cylinder body
Voltage: 12 V.
Output power: 2 kW.
Rotation direction: clockwise (view from the drive
gears).
1.2 Starter
The magnetic gear-reduction starter is adopted in
the starting system, and the starter shaft is used as
pinion shaft as well. When the starting switch is on,
the magnetic switch contact point is turned on so
as to drive the armature to rotate. At the same time
the movable core is attracted, and the shifter lever
drives the pinion forward to engage with gear ring.
Fig. 11-2-2 Starter Then the gear ring rotates to start the engine.
When the engine is started and the starting switch

is cut off, the movable core returns to its original

position, the pinion separates from the gear ring
and the armature stops rotating. When the engine
speed is higher than that of the pinion, the latter
will be idling so as not to drive the armature to
rotate.
1.3 Starting Circuit
Starting switch
Storage
battery
Fuse Fuse
Fuse
Starter relay
Quick starting element

0.5BW
Attraction
Holding coil
coil
Magnetic switch
Starter
Fig. 11-2-3 Starting circuit of engine

469
2. On-board Maintenance
Removal procedure
① Terminal
② Harness plug
③ Starter assembly
Starter
Reinstall
Reinstall them
themin the
in opposite order oforder
the opposite removal
of
removal
Fig. 11-2-4 Removal and reinstallation procedures of the starter assembly
Removal
Preparations:
Disconnect the earthing cable of the storage
battery. See Fig. 11-2-5.
Removing terminal ①
Remove the fastening nut for tightening the
starting switch wire terminal, and then remove the
wire.
Removing the harness plug ②

Fig. 11-2-5 Removing the storage battery cables
Hold the plug and pull out the harness plug
connected with the starter.
Caution: Pull the circuit connector instead of

the harness (the wire) when separating the
connector.

Removing the engine assembly ③

at the rear end of air intake side of the cylinder
body (the bolts are used for fastening the starter).
See Fig. 11-2-6.
(2) Take out the starter from the starter mounting
hole at the rear end of the cylinder body.
Reinstallation
Cylinder body
Reinstalling the starter assembly ③
(1) After installing the transmission, install the
starter assembly into the mounting hole at the rear
end of the cylinder body. The rabbet of the starter
should be accurate.
(2) Install the 2 hexagon flange bolts (M10×115)
fastening the starter to the cylinder body, and
tighten them according to specified torque. See
Fig. 11-2-7.
starter
Fig. 11-2-7 Reinstalling the starter assembly
50 N • m± 3 N • m
Reinstalling the harness plug ②

Hold the starter harness plug, and insert the
harness connectors into it. See Fig. 11-2-8.
Reinstalling the terminal ①
Connect the terminal of earthing cable for storage
battery with the terminal of starting switch wire,
and then tighten the fastening nut according to
specified torque.
Tightening torques for the fastening bolt of the
terminals
Starter 23 N • m± 3 N • m
Fig. 11-2-8 Reinstalling the starter assembly

471

operations.
(1) Connect the earthling cables for the storage
battery. See Fig. 11-2-9.
(2) Start the engine and check the working
condition of the starting system.
Fig. 11-2-9 Installing the storage battery cables

Section III Charging System

1. Generator
AC generator is adopted in the GW4D20/
GW4D20B turbocharged diesel engine. The former
is installed on the right side of the engine and driven
by generator belt. See Fig. 11-3-1.
Generator technical parameters:
Nominal voltage: 12 V.
Generator Rated speed: 5000 r/min.

Speed range: 900 to 11000 r/min.
Rotation direction: clockwise (view from the pulley).
Polarity: negative earthing.
Working mode: rated connection.
Adjuster regulation voltage: 14.5 V±0.3 V.
Fig. 11-3-1 Engine Generator and generator circuit are shown in Fig.
11-3-2 and Fig. 11-3-3.
1.1 Precautions for Generator Maintenance
(1) Negative earthing is adopted for the generator,
therefore the storage battery earthing pole should
be the same, otherwise the battery will discharge
through silicon diode and burn out the latter.
(2) After the generator is started, check whether the
generator is generating electricity with a bulb or
multimeter instead of spark test, otherwise the diode
will be easily damaged.
(3) When checking the silicon rectifier elements of
the generator, it is definitely forbidden to use a
tramegger (megger) or 220 V AC to check the
generator insulation, otherwise the diode will be
Fig. 11-3-2 Generator assembly damaged.
(4) When the diesel engine is stopped, disconnect
Generator the power switch, otherwise the storage battery
current will pass the field winding and adjuster for a
long period, and make the storage battery
discharged accordingly and burn out the coils.
1.2Maintenance of the Generator and Adjuster
(1) When disassembling the generator for repair, do
remove the bolts first and then the bearing shroud
Storage
battery
on the rear cover, after that remove other parts.
(2) Maintenance items
——After the generator is disassembled, first blow
off the dust in it by compressed air, wipe out grease
stain with gasoline, and then polish the slip ring on
Fig. 11-3-3 Circuit diagram of generator the rotor with No. 00 sand paper.

473
——Clean the bearings, and check them for any

looseness. Replace them if any.
——Check if the weld of the field coil with the slip
ring is reliable (the field coil resistance is 5~6
Ω).Check if the weld of the stator lead wires with the
diode is reliable.
——Check the diodes, remove the connecting wires

Above 10000Ω of the stator winding with diodes, and then check
one diode after another with a multimeter
（resistance×1 scale）. See Fig. 11-3-4.
Check the diodes on the rear cover according to the
following methods. Rest the multimeter negative
testbar on the rear cover and the positive testbar on
the out terminal of the diode, and the value shown
on the electric meter should be no more than 10Ω.If
the ohm value shown is low, it indicates the diode
has been broken down; if the ohm value is high, it
indicates the diode circuit has been broken and the
diodes should be replaced. Then rest the negative
testbar on the out terminal of the diode, and the
positive testbar on the rear cover. The value shown
Fig. 11-3-4 Checking the generator diode on the ammeter should be above 10000Ω.If the ohm
value is very low, it means the diode has been
Above 10000Ω damaged.
As the 3 diodes inserted on another element board
conduct electricity in the reverse direction, the
measured result should be the opposite. The
method is shown in Fig. 11-3-5.
Caution: It is definitely forbidden to check the
insulation of the diodes or generator with a
tramegger (megger) or 220 V AC.
(3) Reinstalling the generator after repair: combine
the rotor with the drive end cover and stator cover,
and then connect the diodes with the stator winding.
Then install the rotor, drive end cover and the rear
Fig. 11-3-5 Checking the generator diode cover. Fit 3 bolts and tighten them according to
required torque. After that, the reinstallation is
finished.
(4) Set the generator in no-load and generating
tests, and the performance should comply with
related requirements.
1.3 Maintenance of the Generator belt
The generator belt is used to transmit the crankshaft
torque which is output by the damping pulley to the
generator assembly, power steering pump and
refrigerating compressor assembly, and thus makes
them work normally.

Keep the front end of the diesel engine clean to

avoid the generator belt slip or abnormal sound, etc.
as a result of grease stain, water or other foreign
substances on the belt.
The generator belt is made of rubber and should be
kept away from heat.
2. Diagnosis
On-board comprehensive checking
The charging system working condition is shown by
the charging indicator installed on the vehicle
dashboard. See Fig. 11-3-7.The indicator is on
when the starting switch is turned to “ON” position. If
the indicator is off after the engine is started, it
means the charging system is working normally. If
the indicator displays abnormally, it means possible
Fig. 11-3-6 Generator and generator belt undercharge or overcharge of the storage battery,
and following checks and diagnosis should be
carried out on the charging system:
(1) Visually check the generator drive belts and wire
connector.
(2) With the engine being shut down, turn the
starting switch to the “ON” position and observe the
indicator.
——If the indicator is still off: remove the wire
connector from the generator, and ground the “L”
terminal on the connector.
——If the indicator is on: repair or replace the
generator.
Fig. 11-3-7 Charging system indicator

475
Charging circuit
Starting switch
Storage battery
Fuse Fuse
Oil seal Fuse
Generator “s” terminal

“W” terminal
“W” terminal Charging relay
“L” terminal
Engine “IG” terminal Charging alarm

lamp
tachometer
Charging signal
Fig. 11-3-8 Generator charging circuit
Storage Resistor
battery
Charging Resistor
Ignition switch alarm lamp
“s” terminal
Generator
“W” terminal
Engine tachometer
“L” terminal Charging relay
“IG” terminal
Fig. 11-3-9 On-board checking of the charging system

3. On-board Maintenance
Removal procedure
① Generator terminals and
harness plug
② Generator belt
③ Generator assembly
Reinstalling them in the
opposite order of removal
Fig. 11-3-10 Removal and reinstallation procedures of the generator assembly

477
Removal
Preparations:
Remove the earthling cables for the storage battery.
See Fig. 10-3-11.
Removing the generator terminals and harness

connector①
Fig. 11-3-11 Removing the earthing cables of
storage battery (1) Remove the generator terminal
Loosen the nut fastening the generator terminal,
and remove the generator connecting wires.
(2) Pull out the generator harness plug.
Hold the plug, and pull out the harness plug
connected with the generator.
Caution: Pull the plug connector instead of the

Generator
Removing the generator belt ②
Turn the tension pulley with a tool till the generator
belt is loose enough, and then remove the
generator belt. See Fig. 11-3-13.
Fig. 11-3-12 Removing the generator harness
plug
Removing the generator assembly ③
(1) Remove the 3 hexagon flange bolts (M10 x45,
M8 x30) fastening the generator from the front end
of the engine cylinder body.
(2) Take out the generator assembly from the
generator bracket on the right side of the cylinder
Reinstallation
Reinstalling the generator assembly ③
(1) Set the generator assembly at the front end of
Fig. 11-3-13 Removing the generator belt the cylinder body and set it aligned to the generator
bracket and cylinder body mounting hole, then
install 3 hexagon flange bolts (M10x45, M8x30),

and tighten them according to specified torque. See

Fig. 11-3-14.

generator
Bolt specification Tightening torque
M8 23 N • m± 3 N • m
M10 45 N • m± 3 N • m
(2) Connect the generator connecting wires.
Fig. 11-3-14 Removing and reinstalling the

generator assembly
Installing the generator belt ②

(1) Set the generator belt at position so as to make
sure that the belt wedge teeth fit well with the pulley
wedge slot. See Fig. 11-3-15.
(2) Turn the tension pulley with a tool till the
generator belt is loose enough and then fit the
accessory flat idle wheel into the belt. Make sure
there is no excessive tension or insufficient tension.
After the installation, check the generator belt to
make sure the belt wedge teeth fit well with the
pulley wedge slot.
Installing the generator terminals and harness

plug ①
(1) Inserting the generator harness plug
Hold the generator harness plug and insert it into
the harness connector.
(2) Connecting the generator terminal
Install the generator harness onto the terminal, and
tighten the fastening nut according to specified
torque.
Tightening torques for the fastening bolt of the

terminal
Fig. 11-3-16 Installing the generator terminals and
harness plug 23 N • m ± 3 N • m

479

operations:
(1) Connect the storage battery cable with the
negative cable connected last. See Fig. 11-3-17.
Attention: The storage battery wires should

be reliable, firmly fixed and underlain by shock
pads.
(2) Start the engine and check the working condition
of the charging system.
Fig. 11-3-17 Installing the earthing cable of the

storage battery

Chapter XII Exhaust System

Section I General
Attention: It is necessary to keep a sufficient distance between the exhaust system assembly and
the floor so as to protect the floor base from being overheated and protect the heat insulation and
trimming materials in the passenger compartment from being damaged.
When checking or replacing the exhaust system assembly, you need to keep a sufficient distance
between the exhaust system assembly and the floor so as to protect the floor base from being
overheated and protect the heat insulation and trimming materials in the passenger compartment from
being damaged.
Check the overall exhaust system and the body surface around it as well as the rear compartment cover
for any crack, damage, missing or displaced parts, and check them for separated junction, eyelet, loose
connections or other damaged that may result in exhaust leakage into the rear compartment or the
passenger compartment. If there is dust or water in the rear compartment, it means that there is a
problem in this area. Any malfunction should be eliminated immediately.
The specific structure of the exhaust system varies depending on the vehicle model, so before
maintenance, you should well knew its structure for the model involved and then take corresponding
measures.
Fig. 12-1-1 Schematic Diagram of Exhaust System (for reference only)

The explosion sound and vibration noise generally occur when some parts are not well centered. For the
adjustment of the exhaust system, first unscrew all bolts and nuts until all parts are well centered, and
then screw down them from front to rear.
Check items:
(1) Check the connections for looseness or damage, especially check for exhaust leakage.
(2) Check the holding plate and the rubber for defective, crack or damage.
(3) If any part of the catalytic converter heat insulation cover is damaged or its depression extends to the

481
catalyst, repair or replace it.

(4) Check for depression, damage, or the eyelet or crack due to corrosion.
Section III Front Exhaust Pipe
Removal procedure
①Catalytic converter pipe
②Front exhaust pipe
③Muffler
④Rear exhaust pipe
Fig. 12-3-1 Removal procedure for front exhaust pipe

Removal
Preparation
Removing the catalytic converter pipe ①
(1) Remove 3 high temperature resistant hexagon
flange nuts which fasten the catalytic converter
pipe and the VGT turbocharger; then remove 2
fixing bolts and nuts which connect the catalytic
converter pipe and the exhaust elbow.
(2) Remove 2 fastening bolt nuts which connect
the catalytic converter pipe and the front exhaust
pipe; then take off the catalytic converter pipe and
the sealing gaskets of its both ends. See Fig.
Fig. 12-3-2 Removing the catalytic converter pipe 12-3-2.
Removing the Front Exhaust Pipe ②

(1) Remove the fastening bolt and nut which
connect the front exhaust pipe and the muffler. See
Mounting bracket Fig. 12-3-3.
for front exhaust
Front exhaust manifold pipe (2) Take off the front exhaust pipe from its bracket.
manifold pipe
Removing the Muffler ③
(1) Remove the fastening bolt, nut and gasket
which connect the muffler and rear exhaust pipe.
See Fig. 12-3-4.
(2) Take off the muffler from its bracket.
Fig. 12-3-3 Removing the front exhaust pipe
Removing the Rear Exhaust Pipe ④
Loosen the clamp fastening bolt, and then remove
the rear exhaust pipe from the bracket of this pipe.
See Fig. 12-3-5.
Installation
Installing the Rear Exhaust Pipe ④

(1) Connect the rear exhaust pipe with the muffler,
install the sealing gasket, and screw down the bolt
and nut as per the specified torque. See
Fig.12-3-6.
Tightening torque for the fastening bolt and
nut of rear exhaust pipe:
Fig. 12-3-4 Removing the muffler
45 N • m ± 3 N • m

483
(2) Install the rear exhaust pipe on its bracket and

tighten the clamp. See Fig. 12-3-6.
Installing the Muffler ③
(1) Install the muffler on its bracket. See Fig.
12-3-6.
(2) Connect the rear exhaust pipe with the muffler,
and nut as per the specified torque.
Tightening torque for the connecting bolt and
nut of muffler and rear exhaust pipe:
45 N • m ± 3 N • m
Fig. 12-3-5 Removing the rear exhaust pipe
Installing the Front Exhaust Pipe ②
(1) Install the front exhaust manifold to the bracket
of front exhaust pipe. See Fig. 12-3-7.
Muffler
(2) Connect the front exhaust pipe with the muffler,
and nut as per the specified torque. See Fig.
12-3-7.
Tightening torque for the connecting bolt and

nut of muffler and front exhaust pipe:
45 N • m ± 3 N • m
Rear exhaust pipe
Fig. 12-3-6 Installing the rear exhaust pipe and

muffler
Install the Catalytic Converter Pipe ①

(1) Connect the catalytic converter pipe with the
Front exhaust pipe
turbocharger and the front exhaust pipe, install the
sealing gasket to both ends, and then use the
specified tightening torque to screw down the bolt
and nut which connect with the front exhaust pipe.
Tightening torque for the bolt and nut of

Muffler catalytic converter pipe and front exhaust pipe:
45 N • m ± 5 N • m
(2) For the engine equipped with a VGT

turbocharger, you screw down the fastening nuts
Fig. 12-3-7 Installing the front exhaust pipe which connect with the catalytic converter pipe and
the turbocharger as per the specified torque.

Tightening torque for the connecting nuts of

Catalytic catalytic converter pipe and turbocharger:
converter
23 N • m ± 3 N • m
Mounting
Front exhaust bracket for front (3) For the engine equipped with a WGT
pipe turbocharger, screw down the fastening bolts
exhaust pipe
which connect with the catalytic converter pipe and
the exhaust elbow as per the specified torque.
Tightening torque for the bolt and nut of

catalytic converter pipe and exhaust elbow:
45 N • m ± 3 N • m
Fig. 12-3-8 Installing the catalytic converter pipe

operations:
(1) Connect the earthling cable of storage battery.
See Fig. 12-3-9.
(2) After installing all parts and confirming that
there is no error, start the engine and check every
joint for gas leakage.
Fig. 12-3-9 Installing the earthing cable of storage

battery

485
Appendix
Appendix I Engine Malfunction Code
Engine
Exhaust-related
Malfunction Malfunction
Part / System Malfunction Description Malfunction Action
Code Indicator
Indicator Lamp
Lamp
Air System Management
Malfunction of the air flow sensor
P0102
(low)
Malfunction of the air flow sensor Lit up in the
P0103
(high) third driving Lit up
circle
Malfunction of the air flow sensor Slightly
P1100 (malfunction of the supply voltage reduce the
Air flow
or the analog-to-digital converter) torque (by
sensor
about
Malfunction related to the
10%)
P1102 reasonableness of the air flow
sensor (low) Lit up in the
third driving Not lit up
Malfunction related to the circle
P1103 reasonableness of the air flow
sensor (high)
Excessive control error of EGR Lit up in the
P0400 valve air flow third driving Not lit up
circle
Malfunction of EGR valve position
Lit up in the
control (the absolute value of the
P1404 third driving Not lit up
drive duty circle exceeding the limit
circle
for too many times) Slightly
Drive malfunction of the EGR valve reduce the
P1490 (short circuit between forward drive torque (by
and reverse drive) about
10%)
Drive malfunction of the EGR valve Lit up in the
P0487
Exhaust gas (broken circuit) third driving Lit up
recirculation circle
Drive malfunction of the EGR valve
(EGR) valve P0489
(short circuit to ground)
Drive malfunction of the EGR valve
P0490
(short circuit to the supply)
Drive malfunction of the intake
P2103 throttle valve (short circuit to the
supply)
P2100 Not lit up Not lit up
throttle valve (broken circuit)
P2102 throttle valve (short circuit to
ground)

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of the turbocharger
P0237
pressure sensor (low)
Malfunction of the turbocharger
P0238 Lit up in the
pressure sensor (high) Moderately
third driving Lit up
Turbocharger Malfunction of the turbocharger reduce the
circle
pressure pressure sensor (malfunction of the torque (by
P1235
sensor supply voltage or the about
analog-to-digital converter) 20%)
Malfunction related to the Lit up in the
P0236 reasonableness of the third driving Not lit up
turbocharging pressure circle
Excessive control error of the VGT Lit up in the
P0046 actuator turbocharging pressure third driving Not lit up
VGT circle Moderately
Variable Drive malfunction of the VGT reduce the
P0048
geometry actuator (short circuit to the supply) torque (by
Lit up in the
turbocharger Drive malfunction of the VGT about
P0045 third driving Lit up
(VGT) actuator (broken circuit) 20%)
circle
Drive malfunction of the VGT
P0047
actuator (short circuit to ground)
Fuel Injection System
Broken circuit to 1# fuel injector (the Lit up in the first
P0201 Lit up
high end or the low end) driving circle
P0204 Lit up
P0202 Lit up
P0203 Lit up Slightly
reduce the
Short circuit to the high / low end of Lit up in the first
P1201 Lit up torque (by
1# fuel injector driving circle
about
Short circuit to the high / low end of Lit up in the first
P1204 Lit up 10%) /
Increase
Fuel injector Short circuit to the high / low end of Lit up in the first
P1202 Lit up the idle
speed to
Short circuit to the high / low end of Lit up in the first 1000 r/min
P1203 Lit up
2# fuel injector driving circle / Disable
Drive malfunction of the 1st group the air
P2147 of fuel injectors (short circuit to the conditioner
supply) Lit up in the first
Lit up
Drive malfunction of the 1st group of driving circle
P2148 fuel injectors (short circuit to
ground)
Drive malfunction of the 2nd group
Lit up in the first
P2150 of fuel injectors (short circuit to the Lit up
driving circle
supply)

487
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Drive malfunction of the 2nd group
P2151 of fuel injectors (short circuit to
ground)
Communication malfunction of the
P1146 serial peripheral interface for the 1st Not lit up Not lit up
group of fuel injectors
Communication malfunction of the
P1149 serial peripheral interface for the 2nd Not lit up Not lit up
group of fuel injectors
Signal malfunction of 1# knock
sensor (the sensor not installed or
P0325 Not lit up Lit up
ineffective signals caused by
malfunctions)
Malfunction of the minimum drive
pulse (MDP) drift for 1# fuel injector
(the correction value of MDP lower
than the limit value)
(the correction value of MDP higher
Knock pulse (MDP) drift for 4# fuel injector
sensor (the correction value of MDP lower
than the limit)
P0269 Not lit up Not lit up Slightly
(the correction value of MDP lower
reduce the
torque (by
about
P0263 Not lit up Not lit up 10%)
Slightly
reduce the
Knock Malfunction of the minimum drive
torque (by
sensor pulse (MDP) drift for 2# fuel injector
P0269 Not lit up Not lit up about
10%)
The corrected minimum drive pulse
(MDP) for 1# fuel injector too short

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of the rail pressure
P0192
sensor (low)
Malfunction of the rail pressure Delay the
P0193 stop for
sensor (high)
60s
Malfunction of the rail pressure
/ Largely
sensor (malfunction of the supply
P1190 reduce the
voltage or the analog-to-digital
Lit up in the first torque (by
converter) Lit up
driving circle about
Malfunction of the rail pressure 50%)
P1194 sensor (abnormal variation / Increase
gradient) the idle
Malfunction related to the speed to
reasonableness of the rail pressure 1000 r/min
P0194
(unreasonable fall of the rail
pressure)
Malfunction of the rail pressure Delay the
P1192 sensor drift (lower than the min. stop for
limit value) 60s
Rail pressure Malfunction of the rail pressure / Limp
sensor P1193 sensor drift (higher than the max. home
limit value) (1400
Not lit up Lit up
r/min)
Malfunction of the rail pressure / Largely
sensor drift (exceeding the reduce the
P1191 torque (by
intermediate limit value for too
many times) about
50%)
Delay the
stop for
60s
/ Largely
reduce the
Rail pressure too high (exceeding torque (by
the max. limit value) about
50%)
/ Increase
the idle
speed to
1000 r/min

489
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
P0087 Rail pressure not built up normally Not lit up Not lit up
Excessive control error of the rail
P1254 pressure (the error higher than the Largely
limit value) reduce the
Not lit up Lit up torque (by
Excessive control error of the rail about
P1253 pressure (the error lower than the 50%)
limit value)
Drive malfunction of the inlet Delay the
P0255 metering valve (IMV) (broken stop for
circuit) 60s
Drive malfunction of the inlet / Largely
P0253 metering valve (IMV) (short circuit reduce the
Inlet
to ground) Lit up in the first torque (by
metering Lit up
Drive malfunction of the inlet driving circle about
valve (IMV)
metering valve (IMV) (short circuit 50%)
to the supply) / Increase
P0254 the idle
speed to
1000 r/min
The correction value of the IMV
P1256 control current too low (low fuel
volume) Limp
The correction value of the IMV home
P1257 control current too low (high fuel (1400
volume) r/min)
Not lit up Lit up / Largely
The correction value of the IMV reduce the
P1258 control current too high (low fuel torque (by
volume)
about
The correction value of the IMV 50%)
P1259 control current too high (high fuel
Inlet volume)
metering Malfunction related to the return
P0258
valve (IMV) value of the IMV drive current (low)
Malfunction related to the return
P0259 value of the IMV drive current
(high) Not lit up Not lit up
Malfunction related to the return
value of the IMV drive current
P1260
(malfunction of the analog-to-digital
converter)
Control malfunction of the IMV
P1251
drive current (low)
Not lit up Not lit up
Control malfunction of the IMV
P1252
drive current (high)

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
The characteristic correction data
P1624 (C21) of 1# fuel injector not written Not lit up Lit up
or the check code incorrect
Characteristic
The characteristic correction data Limp home
correction
P1624 (C21) of 3# fuel injector not written Not lit up Lit up (1400
data of fuel
or the check code incorrect r/min)
injectors
P1625 (C21) of the fuel injector copied Not lit up Lit up
from NVM to RAM incorrect
Camshaft position signal not within
Camshaft P0341 the normal range, thus cannot be Not lit up Lit up
position received
sensor Camshaft position signal
completely lost
Crankshaft position signal pitch too
wide to be received
Crankshaft position signal pitch too
Crankshaft P0371 Not lit up Not lit up
narrow
position
sensor Crankshaft position signal failing to
detect the tooth loss position
Crankshaft position signal
completely lost
Malfunction of cylinder balance
(the first cylinder): the fuel injector
stuck, or instantaneous rotation Moderately
P0263 Not lit up Lit up reduce the
speed difference of the two
adjacent cylinders lower than the torque (by
limit value due to other troubles about
Cylinder 20%)
balance Malfunction of cylinder balance / Increase
(the third cylinder): the fuel injector the idle
stuck, or instantaneous rotation speed to
speed difference of the two 1000 r/min
adjacent cylinders lower than the
limit value due to other troubles

491
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of cylinder balance
(the fourth cylinder): the fuel
injector stuck, or instantaneous
P0266 rotation speed difference of the Not lit up Lit up Moderately
two adjacent cylinders lower than reduce the
the limit value due to other torque (by
troubles about
Cylinder
20%)
balance Malfunction of cylinder balance / Increase
(the second cylinder): the fuel the idle
injector stuck, or instantaneous speed to
P0269 rotation speed difference of the Not lit up Lit up 1000 r/min
two adjacent cylinders lower than
the limit value due to other
troubles
The harness resistance value too
P1286
low (1# fuel injector)
Not lit up Lit up
P1287
high (1# fuel injector)
P1292
Compensation low (3# fuel injector)
Not lit up Lit up
between the The harness resistance value too
P1293
battery high (3# fuel injector)
voltage and The harness resistance value too
P1288
the harness low (4# fuel injector)
resistance Not lit up Lit up
P1289
P1290
low (2# fuel injector)
Not lit up Lit up
P1291
Stopping of Overspeeding of the engine
the engine
Basic Input Signal
Malfunction of the coolant
P0117
temperature sensor (low) Slightly
Malfunction of the coolant Lit up in the reduce the
P0118
temperature sensor (high) third driving Lit up torque (by
Malfunction of the coolant circle about
Coolant 10%)
temperature P1115 temperature sensor (malfunction
sensor of the analog-to-digital converter)
Malfunction related to the Slightly
reasonableness of the coolant Lit up in the reduce the
P0116 temperature sensor third driving Not lit up torque (by
circle about
10%)

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of the air pressure
P0107
sensor (low) Slightly
Malfunction of the air pressure Lit up in the reduce the
Air pressure P0108
sensor (high) third driving Lit up torque (by
sensor
Malfunction of the air pressure circle about
P1105 sensor (malfunction of the 10%)
analog-to-digital converter)
Malfunction of the intake
P0112
temperature sensor (low)
Slightly
Malfunction of the intake
Intake P0113 Lit up in the reduce the
temperature sensor (high)
temperature third driving Lit up torque (by
sensor Malfunction of the intake circle about
temperature sensor (malfunction 10%)
P1110
of the analog-to-digital
converter)
Malfunction of the oil
P0182
temperature sensor (low)
Slightly
Malfunction of the oil
P0183 Lit up in the reduce the
Oil temperature temperature sensor (high)
third driving Lit up torque (by
sensor Malfunction of the oil circle about
temperature sensor (malfunction 10%)
P1180
of the analog-to-digital
converter)
Moderately
Alarm for the water volume in the reduce the
Oil water
P2269 oil water separator exceeding Not lit up Not lit up torque (by
separator
the limitation about
20%)
Malfunction related to the signal
uniformity of the brake pedal
two-way switch detected during
Brake pedal speed increase of the vehicle
switch Malfunction related to the signal
uniformity of brake pedal
two-way switch detected during
speed reduction of the vehicle
Signal malfunction of the clutch
pedal high-way switch
Signal malfunction of the clutch
Clutch pedal P0833 Not lit up Not lit up
pedal low-way switch
switch
Malfunction related to the signal
P083F uniformity of clutch pedal Not lit up Not lit up
two-way switch

493
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of the accelerator
P0122 pedal position sensor in the 1st
way (low)
P0123 pedal position sensor in the 1st
way (high)
pedal position sensor in the 1st Largely
P1120 way (malfunction of the supply reduce the
voltage or the analog-to-digital torque (by
converter) about 50%)
Not lit up Lit up
Malfunction of the accelerator / Increase
P0222 pedal position sensor in the 2nd the idle
way (low) speed to
1000 r/min
P0223 pedal position sensor in the 2nd
way (high)
pedal position sensor in the 2nd
P1220 way (malfunction of the supply
Accelerator
voltage or the analog-to-digital
pedal position
converter)
sensor
Signals of accelerator pedal
position sensors in the two ways Largely
P1123 not uniform (signal level in the 1st reduce the
way higher than that in the 2nd torque (by
way) about 50%)
Not lit up Lit up
Signals of accelerator pedal / Increase
position sensors in the two ways the idle
P1223 not uniform (signal level in the speed to
2nd way higher than that in the 1st 1000 r/min
way)
Malfunction of the accelerator Limp home
P2299 pedal position sensor (the pedal Not lit up Lit up (1400
stuck) r/min)
Malfunction of the accelerator Limp home
Lit up in the first
P0120 pedal position sensor (triggering Lit up (1400
driving circle
the mode “limp home”) r/min)
Malfunction of the accelerator Largely
pedal position sensor (triggering reduce the
the mode “reduce the torque”) torque (by
about 50%)

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Delay the
stop for 60s
/ Limp
home
Malfunction of the
Analog-to-digital (1400
P0606 analog-to-digital converter for Not lit up Lit up
converter (ADC) r/min)
the electronic control unit
/ Slightly
reduce the
torque (by
about 10%)
Complete Vehicle Function
Malfunction of the battery Slightly
P0562
voltage (low) reduce the
Malfunction of the battery torque (by
P0563
Battery voltage voltage (high) Not lit up Lit up about 10%)
Malfunction of the battery / Disable
P1560 voltage (malfunction of the the air
analog-to-digital converter) conditioner
Malfunction of 1# supply voltage Delay the
P0642 (the supply cut off due to stop for 60s
overheating) / Slightly
reduce the
torque (by
Not lit up Lit up
Malfunction of 1# supply voltage about 10%)
P0643 (the voltage exceeding the / Increase
normal range) the idle
speed to
1000 r/min
Malfunction of 2# supply voltage Moderately
P0652 (the supply cut off due to reduce the
overheating) torque (by
External supply about 20%)
voltage
/ Increase
Not lit up Lit up the idle
Malfunction of 2# supply voltage speed to
P0653 the voltage exceeding the normal 1000 r/min
range)
/ Disable
the air
conditioner
Malfunction of 2# auxiliary supply
P0698 voltage (the supply cut off due to
overheating)
Not lit up Lit up
Malfunction of 2# auxiliary supply
P0699 voltage (the voltage exceeding
the normal range)

495
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
Malfunction of the speed signal
P0500 from the speed sensor or CAN Not lit up Not lit up
bus
Signals from the speed sensor
lost
Malfunction related to the
Speed sensor P0501 reasonableness of the speed Not lit up Not lit up
sensor
The signal value from the speed
sensor too high
Malfunction of the mileage
P1500 signal from the speed sensor or Not lit up Not lit up
CAN bus
Drive malfunction of 1# electric
P0692
fan (short circuit to the supply)
Moderately
Drive malfunction of 1# electric reduce the
fan (broken circuit) torque (by
about 20%)
Fan drive P0691
fan (short circuit to ground)
P0694
fan (short circuit to the supply) Moderately
Drive malfunction of 2# electric reduce the
fan (broken circuit) torque (by
Drive malfunction of 2# electric about 20%)
P0693
fan (short circuit to ground)
Drive malfunction of the A/C
P0647
relay (short circuit to the supply)
/ Disable
A/C relay drive P1646 Not lit up Lit up the air
relay (broken circuit)
conditioner
P0646
relay (short circuit to ground)
Malfunction of glow plug drive
P0384
(short circuit to the supply)
Drive malfunction of the glow
Glow plug drive P1383 Not lit up Lit up
plug (broken circuit)
P0383
plug (short circuit to ground)
Drive malfunction of the engine
malfunction indicator lamp
(broken circuit, or short circuit to
ground or the supply)
Indicator lamp
Drive malfunction of the
drive
exhaust-related malfunction
P0650 indicator lamp (broken circuit, or Not lit up Not lit up
short circuit to the supply or
ground)

Appendix
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
plug indicator lamp (broken
circuit, or short circuit to the
supply or ground)
Drive malfunction of the alarm
lamp for water volume in the oil
P1269 water separator exceeding the Not lit up Not lit up
limitation (broken circuit, or short
circuit to the supply or ground)
Related to the engine management system
Malfunction of the ECU internal Slightly
non-volatile memory reduce the
torque (by
about 10%)
Malfunction related to integrity of
P1603 the ECU internal memory Not lit up Lit up
Internal (integrity of the program codes)
memory
Malfunction related to integrity of Stop the
P1604 the ECU internal memory Not lit up Lit up engine
(integrity of the rated data) immediately
Malfunction related to integrity of
P1605 the ECU internal memory Not lit up Lit up
(integrity of RAM)
P0685 The main relay stuck Not lit up Lit up
Main relay Supply of the main relay cut off
abnormally
U0001 Malfunction of CAN bus Not lit up Not lit up
CAN communication
U0155 malfunction of the instrument Not lit up Not lit up
system control unit
CAN communication
U0100 malfunction of the engine Not lit up Not lit up
system control unit
CAN communication
U0122 malfunction of the TCS system Not lit up Not lit up
control unit
CAN network
CAN communication
U0101 malfunction of the automatic Not lit up Not lit up
gearbox system control unit
Malfunction related to the OBD
sent by the automatic gearbox
system control unit through CAN
message
CAN communication
U0151 malfunction of the airbag system Not lit up Not lit up
control unit

497
(Continued)
Engine
Exhaust-related
Code Indicator
Indicator Lamp
Lamp
CAN communication
U0140 malfunction of the body system Not lit up Not lit up
control unit
Vehicle collision signal sent by
P1946 the airbag system control unit Not lit up Not lit up
through CAN message received
The key for the anti-theft chip
not written
Response from the anti-theft
Anti-theft chip chip not received
(ATC) Passport check by the anti-theft
chip failing
The anti-theft chip control unit
continuing not to respond
Electronic Monitoring malfunction of the
control unit electronic control safety
safety P0606 Not lit up Not lit up
monitoring
(ESM)

Appendix
Appendix II Conversion Table of Common Measurement Units for

Engines
Engineering Unit Statutory Measurement Unit
Measurement
Code Name Symbol Name Symbol
L(l) Kilometer km Kilometer km
Meter m Meter m
Length Centimeter cm Centimeter cm
Millimeter mm Millimeter mm
Micron μm Micron μm
S Square meter m2 Square meter m2
Square cm2 Square cm2
Area centimeter mm2 centimeter mm2
Square Square
millimeter millimeter
V Cubic meter m3 Cubic meter m3
Cubic centimeter cm3 Cubic centimeter cm3
Cubic millimeter mm L(l)
Volume
Kiloliter kL(kl)
liter L(l) Liter
Milliliter mL (ml)
G Ton t Ton t
Weight Kilogram kg Kilogram kg
Gram g Gram g
F Kilogram force kgf kg Newton N
Force g 1kgf = 9.81N
1kg • m/s = IN
P Kilogram force kgf/ cm2 Pascal Pa
Pressure per square N/m2 = 1 Pa
centimeter 1 kgf/cm2 =9. 81 x104m2
M Kilogram force kgf/m Newton meter N•m
Torque per meter 1kgf • m =9. 81N • m
A Kilogram force • kgf • m Joule J
meter Kilowatt-hour kW • h
Work
IN • m = lJ
1kgf ——m=9. 81J
Q Kilocalorie kcal 1kW • h=3.6 xl06J
Heat 1kJ= 1000 J
1 kcal =4. 187 kJ
N Metric horse PS Watt W
power Kilowatt kW
Power
1N • m/s = 1J/s = 1W
1PS =736W

499
Continued
Engineering Unit Statutory Measurement Unit
Measurement
Code Name Symbol Name Symbol
Temperature t Celsius ℃ Kelvin K
Fahrenheit ℉ Celsius ℃
1°C =1K
1°F =0. 556 K
Voltage U Kilovolt kV Volt V
Volt V
Current I Ampere A Ampere A
Milliampere mA
Rotation n Revolution per r/ min Revolution per r/ min
speed minute r/ s minute 1 r/min = ( 1/60) s -1
Revolution per
second
Speed V Meter per m/ s Meter per m/ s
second second
Specific fuel ge Gram per g/PS • h Gram per g/kW • h
consumption horsepower hour kilowatt hour
Time t Hour(h) h Hour h
Minute(m) m( min) Minute min
Second(s) s(sec) Second s
Dynamic Pascal Pa • s Pascal-second Pa • s
viscosity Poise P 1P=0. 1 Pa • s
1kgf • s/m2 =9. 81Pa • s
Kinematic V Stokes St Square meter m2/s
viscosity Square meter m2/s per second 1St = 10-4m2/s
per second Cst 1Cst = 10-2st = 10-6m2/s
Centistokes


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长城内燃机

GREAT WALL ENGINES

Great Wall Baoding Internal Combustion Engine

Great Wall Baoding Internal Combustion Engine

Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited

Great Wall Baoding Internal Combustion Engine

Chapter I Introduction .............................................................................................................................. 1

Great Wall Baoding Internal Combustion Engine

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

Great Wall Baoding Internal Combustion Engine

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

Great Wall Baoding Internal Combustion Engine

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

Great Wall Baoding Internal Combustion Engine

Section XII Oil Filter and Oil Cooler ....................................................................................................... 303

Great Wall Baoding Internal Combustion Engine

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

Great Wall Baoding Internal Combustion Engine

The repair procedure is introduced in the following sequence:

Great Wall Baoding Internal Combustion Engine

Title of work task: the content of repair

Mounting the clutch assembly

Front bearing installer: 5-8522-0024-0

Torque: 23 N·m ± 3 N·m Specification

Check the assembly quality.

Fig. 1-1-2 Mounting the Clutch Assembly

Great Wall Baoding Internal Combustion Engine

Washing, cleaning: clean up; without dust, oil stain, etc.

Great Wall Baoding Internal Combustion Engine

Section II Main Contents of Civilized Production for Maintenance

Section III Fire Control Measures for Maintenance Workshop

Great Wall Baoding Internal Combustion Engine

Section IV Dress Security Requirements for Maintenance Personnel

Section V Main Contents of Maintenance Process Regulation

Section VI Identification Marks

Fig. 1-6-1 Serial Number

Great Wall Baoding Internal Combustion Engine

Section VII General Repair Instructions

1. When carrying out repair, use the baffle, seat and

Great Wall Baoding Internal Combustion Engine

7. When necessary, apply sealant to gaskets to prevent

Great Wall Baoding Internal Combustion Engine

Section VIII Precautions for

If the vehicle is equipped with the mobile

Great Wall Baoding Internal Combustion Engine

Chapter II Technical Information of Engine

The diesel engine is a kind of complex machinery that

Great Wall Baoding Internal Combustion Engine

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

Air intake manifold

Fig. 2-1-4 Intake/Exhaust System

Fig. 2-1-5 Turbocharging System

Oil inlet pipe Oil return hose 5. Fuel Supply System

Great Wall Baoding Internal Combustion Engine

Great Wall Baoding Internal Combustion Engine

Section II View of Engine

1. Front View of Engine

Fig. 2-2-1 Front View of GW4D20 Turbocharged Diesel Engine Assembly

Great Wall Baoding Internal Combustion Engine

2. Rear View of Engine