User Manuals: Great Wall GW4D20 Diesel Engine

Manuals and User Guides for Great Wall GW4D20 Diesel Engine. We have 1 Great Wall GW4D20 Diesel Engine manual available for free PDF download: Maintenance Manual

Great Wall GW4D20 Maintenance Manual (510 pages)

TURBOCHARGED DIESEL ENGINES

Brand: Great Wall | Category: Engine | Size: 28.08 MB

Table of Contents
5
Chapter I Introduction
11
Section I How to Use this Manual
11
Section II Main Contents of Civilized Production for Maintenance
14
Section III Fire Control Measures for Maintenance Workshop
14
Section IV Dress Security Requirements for Maintenance Personnel
15
Section V Main Contents of Maintenance Process Regulation
15
Section VI Identification Marks
15
Section VII General Repair Instructions
16
Section VIII Precautions for Maintenance Operation
18
Chapter II Technical Information of Engine
19
Section I Structure of Engine
19
Cylinder Head and Cylinder Body
19
Crank and Connecting Rod Mechanism
19
Valve Actuating Mechanism and Intake/Exhaust System
19
Turbocharging System
20
Fuel Supply System
20
Lubrication System
21
Cooling System
21
Startup Device
21
Section II View of Engine
22
Front View of Engine
22
Rear View of Engine
23
Left View of Engine
24
Right View of Engine
25
Vertical View of Engine
26
Section III Main Performance Indexes of Engine
27
Power Performance Index
27
Economical Efficiency Index
27
Reliability and Durability Index
28
Low Public Hazard Index
28
Section IV Engine Property Curves
29
Section V Technical Data and Specifications of Engine
31
Technical Parameters of Engine
31
Various Temperature and Pressure Ranges of Engine
33
Specifications of Main Engine Accessories
34
Specifications of Main Parts of Fuel Supply System
35
Section VI Maintenance Standard for Engine
36
Tightening Torque of Main Fasteners of Engine
36
Fit Clearance of Main Parts of Engine
38
Section VII Running-In of Engine
42
Preparation before Running-In
42
Running-In
42
Precautions for Running-In
43
Technical Maintenance after Running-In
43
Precautions for Usage of New Vehicles
43
Section VIII Technical Maintenance for Engine
44
Technical Maintenance Cycle
44
Technical Maintenance Contents
47
Technical Maintenance for Air Cleaner
50
Technical Maintenance for Oil Supply System
51
Technical Maintenance for Fuel Lubrication System
53
Technical Maintenance for Cooling System
56
Additional Maintenance in Severe Driving Conditions
58
Technical Maintenance During Storage
58
Precautions in Technical Maintenance
58
Section IX Repair Process for Diesel Engine
58
Repair Process for Diesel Engine
58
Engine Handover and Repair Class Identification
59
Exterior Washing for the Engine
60
Section X Technical Requirements for Engine Removal and Reinstallation
61
General Technical Requirements for Assembling
61
General Technical Requirements for Removal
63
Section XI Special Tools and Instruments for Repair
64
Section XII Repair Operation for Engine
66
Model Mark
66
Air Cleaner
66
Lubrication System
67
Fuel System
68
Cooling System
69
Engine Control
71
Great Wall Baoding Internal Combustion Engine
71
Quick Start-Up System
72
Section XIII Engine Parts and Tightening Torques
73
Engine Bracket Mounting Assembly
73
Cylinder Body Mounting Assembly
74
Cylinder Body Component
75
Cylinder Head Mounting Assembly --1
76
Cylinder Head Mounting Assembly --2
77
Cylinder Head Mounting Assembly --3
78
Piston Connecting Rod Mounting Assembly
79
Crankshaft Flywheel and Clutch Mounting Assembly
80
Air Intake and Exhaust Systems Mounting Assembly --1
81
Air Intake and Exhaust Systems Mounting Assembly --2
82
Oil Pan and Engine Oil Collector Mounting Assembly
83
Engine Oil Pump Mounting Assembly
84
Engine Oil Cooler and Cooling Pipelines Mounting Assembly
85
Timing Mechanism Mounting Assembly --1
86
Timing Mechanism Mounting Assembly --2
87
Fuel Supply System Mounting Assembly --1①
88
Fuel Supply System Mounting Assembly --2①
89
Fuel Supply System Mounting Assembly --3①
90
Turbocharger Mounting Assembly --1①
91
Turbocharger Mounting Assembly --2①
92
EGR System Mounting Assembly
93
Electronic Control System Sensor
94
Generator Mounting Assembly
95
Throttle Mounting Assembly
96
Thermostat and Water Pump Mounting Assembly
97
Engine and Compressor Mounting Assembly
98
Vacuum Pump and Steering Pump Mounting Assembly
99
Chapter III Malfunction Diagnosis and Troubleshooting
100
Section I Troubleshooting
100
Failure to Start the Diesel Engine
101
Difficulty in Starting the Diesel Engine at a Low Temperature
101
Insufficient Power in the Diesel Engine
102
Excessive Fuel Consumption of Diesel Engine
103
Abnormal Noise During the Diesel Engine Running
103
Abnormal Noise from Diesel Engine
105
Abnormal Smoke from Diesel Engine
105
Heavy Oil Consumption and Low Pressure of the Diesel Engine Lubrication System
106
Abnormal Coolant Temperature, Lack of Coolant in the Diesel Engine Cooling System
108
Malfunction of the Diesel Engine Turbocharging System
109
Malfunction of the Diesel Engine Oil Supply System
110
Diesel Engine Wobble During Idling
113
Diesel Engine Running at a High Idle Speed
114
Starter Not Working, Lacking Power, and Making Noise
114
Working Starter but Non-Working Diesel Engine
115
Diesel Engine Rotating but Unable to be Started
116
Difficulty in Starting Due to Malfunction in the Quick Start-Up System
117
No Power Generation, Undercharge or Overhigh Charging Current of Generator
118
Insufficient Capacity, Difficulty in Starting or Overhigh Self Discharge of the Storage Battery
119
Section II Malfunction Diagnosis
120
Start-Up System Malfunction Diagnosis
120
Turbocharging System Malfunction Diagnosis
124
Chapter IV Mechanical System
129
Section I Cylinder Head
129
Section II Camshaft
147
Section III Valve, Valve Spring, Valve Oil Seal, Rocker Arm and Hydraulic Clearance Adjuster
158
Section IV Crankshaft
167
Section V Piston and Connecting Rod Assembly
188
Section VI Engine Oil Pump Assembly
206
Section VII Cylinder Body Assembly
211
Chapter V GW4D20 / GW4D20B Turbocharged Diesel Engine
225
Section I General
225
Section II Engine Assembly
226
Section III Engine Brackets
235
Section IV Air Intake Manifold Pipe
245
Section V Exhaust Manifold Pipe
250
Section VI Cylinder Cover
256
Section VII Camshaft
263
Section VIII Rocker Arms and Hydraulic Clearance Adjusters
273
Section IX Valve Oil Seal and Valve Spring
283
Section X Cylinder Head Assembly and Cylinder Head Gasket
296
Section XI Timing Pulley
308
Section XII Oil Filter and Oil Cooler
313
Section XIII Primary Shaft Front Bearing of the Flywheel and Transmission
316
Section XIV Oil Pump Assembly
320
Section XV Oil Pan Assembly
328
Section XVI Piston and Connecting Rod Assembly
333
Section XVII Front Oil Seal of Crankshaft
347
Section XVIII Rear Oil Seal of Crankshaft
352
Section XIX Crankshaft
356
Section XX Cylinder Body Assembly
374
Chapter VI Fuel System
394
Section I General
394
Components of Fuel Supply System
394
Components of High Pressure Common Rail System
396
Section II On-Board Maintenance
410
Fuel Filter Assembly
410
Fuel Injector Assembly
413
High-Pressure Fuel Pump Assembly
417
Chapter VII Cooling System
421
Section I General
421
Water Pump
421
Thermostat
422
Radiator
422
Antifreeze Fluid
422
Section II On-Board Maintenance
424
Water Pump Assembly
424
Thermostat
430
Radiator
434
Chapter VIII Lubrication System
438
Section I General
438
Section II On-Board Repair
439
Oil Filter
439
Engine Oil Pump
442
Oil Collector
449
Oil Pan
452
Chapter IX Turbocharging System
456
Section I General
456
Turbocharging System Composition
456
Turbocharger Structure
456
Section II On-Board Maintenance
459
Section III Inspection and Repair
464
Checking the Working Condition of the Exhaust Outlet
464
Checking the Working Condition of the Turbocharger
465
Checking the Axial Clearance of the Impeller Shaft
465
Checking the Axial Clearance of the Rotor
465
Checking the Clearance between the Impeller Shaft and the Bearing
466
Checking the Radial Clearance of the Rotor
466
Chapter X Electronic Control EGR System
467
Section I General
467
Section II On-Board Maintenance
468
Chapter XI Electrical System
472
Section I Storage Battery
472
Storage Battery Performance Parameters
472
Preparing Electrolyte
473
Charging the Storage Battery
474
Checking the Storage Battery Remaining Capacity
476
Section II Starting System
478
General
478
On-Board Maintenance
480
Section III Charging System
483
Generator
483
Diagnosis
485
On-Board Maintenance
487
Chapter XII Exhaust System
491
Section I General
491
Section II On-Board Maintenance
491
Section III Front Exhaust Pipe
492
Appendix
496
Appendix I Engine Malfunction Code
496
Appendix II Conversion Table of Common Measurement Units for Engines
509

Great Wall Categories

Engine Digital Photo Frame Automobile

Laptop Tablet

More Great Wall Manuals

User Manuals: Great Wall GW4D20 Diesel Engine

Great Wall GW4D20 Maintenance Manual (510 pages)

Table of Contents

Related Products

Great Wall Categories