Page 2 Model GW4D28 diesel engine is suitable for light truck, Pickup, SUV business car, light passenger car and other machine powered by diesel engine.
Page 4 Model GW 4D28 diesel engine Service Manual Maintenance documents Mechanical system 4D28 engine Fuel system Cooling system Starting system Charging device Exhaust system...
Page 5 IN-1 Maintenance documents-Fault diagnosis and troubleshooting Maintenance documents Page Fault diagnosis and troubleshooting ......IN-2 Main data and specifications ........IN-11 Maintenance standard ..........IN-13 Maintenance work ............IN-15 Fault diagnosis and troubleshooting ......IN-23 Special tools ..............IN-31...
Page 6 IN- Maintenance documents-Fault diagnosis and troubleshooting Fault diagnosis and troubleshooting 1.Difficult to start the engine Examination Causes Corrections 1. The starter does not work Contact failure of the storage battery terminals because of Clean and refasten the terminals of storage battery. oxidization corrosion.
Page 7 Maintenance documents-Fault diagnosis and troubleshooting IN-3 Examination Causes Corrections 4. Fast startup system Preparations: 1.Disconnect lead socket joint of the temperature switch. 2.Determine if the preheating plug is switching (a)Ensure the starting switch is “opened” (b)Connect the cylinder wall and any preheating plug with a voltmeter (c)Turn the starting switch to “close”...
Page 8 Maintenance documents-Fault diagnosis and troubleshooting IN- Examination Causes Corrections Delivery pump Delivery pump damage Repair or replace the fuel delivery pump Fuel sprayer seized Replace the fuel sprayer Fuel sprayer Injection starting pressure too low or bad Adjust or replace the sprayer atomization of the oil sprayer Delivery valve damaged causing fuel oil Replace the delivery valve...
Page 9 Maintenance documents-Fault diagnosis and troubleshooting IN- 4.Fuel consumption too large Examine Causes Corrections Repair or change the according spare part of Fuel system Fuel leakage fuel system air filter Air filter elements blockage Clean or replace the air filter elements Idle speed Improper adjustment of the idle speed Adjust the idle speed...
Page 10 Maintenance documents-Fault diagnosis and troubleshooting IN-6 8.Smoke arises from the engine Examine Causes Correction Air filter Air filter elements blockage Clean or replace the air filter elements Injection starting pressure too low or bad atomization Injector Adjust or replace the injector of the injector Injection timing Injection timing incorrect...
Page 11 Maintenance documents-Fault diagnosis and troubleshooting IN-7 Examination Causes Corrections 4.Flapping noise valve clearance Improper adjustment of valve clearance Adjust the valve clearance rockshaft Rockshaft bearings wear Replace the rockshaft bearings Flywheel Flywheel bolts loose Fasten flywheel bolts crankshaft and/or thrust Wear of crankshaft and/or thrust bearing Replace the crankshaft and/or thrust bearing bearing...
Page 12 Maintenance documents-Fault diagnosis and troubleshooting IN-8 Examine if the storage battery is normal and then diagnose as follow: starter do not rotate starter do not rotate Examine the storage battery Examine the storage battery Storage battery failure or life Storage battery failure or life Storage battery is normal Storage battery is normal replace the storage battery...
Page 13 Maintenance documents-Fault diagnosis and troubleshooting IN- Engagement failure of the pinion and gear ring Engagement failure of the pinion and gear ring When the starting switch turns to “start” position, When the starting switch turns to “start” position, examine if there is voltage on the electromagnetic examine if there is voltage on the electromagnetic switch terminals switch terminals...
Page 14 Maintenance documents-Fault diagnosis and troubleshooting IN-10 Although the starting switch turns to “start” position, Although the starting switch turns to “start” position, but the electromagnetic switch does not work but the electromagnetic switch does not work when the starting switch turns to “start” position, when the starting switch turns to “start”...
Page 15 Maintenance documents-Main data and specifications IN-11 Main data and specifications Main data and specifications Engine model D8 Items Four strokes, valve-in-head, straight, Engine style water cooling Combustion chamber style ω style Cylinder bush style Dry, chroming stainless steel tube Cylinder number=cylinder diameter×stroke 4—93×102 Piston ring number Air ring: 2 Oil ring: 1...
Page 16 Maintenance documents-Main data and specifications IN-1 Cooling system Cooling method Closed forced circulation Radiator type Tube-band Heat transfer kcal/h 71400 Heat transfer area 11.78 Front face area 0.216 Net weight 10.71 Valve opening pressure 88—118 Capacity of coolant Coolant pump type Centrifugal wheel Transmission ratio of the belt Thermostat type...
Page 17 Maintenance documents-Maintenance standard IN-13 Maintenance standard Unit: mm Engine mechanical system Parts Items Standard value Operating limit Notes Flatness of the cylinder cover and outlet manifolds ≤0.05 mating surfaces. 92±0.05 —— Cylinder cover height Can not be ≤0.05 0.20 Cylinder cover Angularity of cylinder cover bottom surface reground ≤0.05...
Page 18 Maintenance documents-Maintenance standard IN-1 Maintenance standard (Supplement) Unit: mm Parts Items Standard value Operating limit Notes Axial gap Radial jumping of the main journal and the 0.30 0.10 connecting rod journal 0.08 ≤0.05 Main journal diameter 69.91 Connecting rod journal diameter 52.90 Crankshaft Non-uniform wear of the main journal and...
Page 19 Filter core blockage with carbon and dust (a) Prepare original air filter core cleaning solution produced by the Great Wall Car Company, and dilute it with water. (b) Immerse the filter core into the cleaning solution for about 20 minutes.
Page 20 IN-16 Maintenance documents-Maintenance work Lubricating system Main oil filter ( paper type filter core) replacement procedure (a) Loose oil drain plug and drain oil. (b) Tighten again the oil drain plug after several minutes. (c) wist off used filter counter clockwise with filter wrench. (d) Clean the mating surface of oil cooler.It can make new oil filter assembly suitable.
Page 21 (g) Retighten the vent plug. (h) Start injection pump up and down several times and check if there is any leakage of fuel. Attention: Original fuel filter produced by the Great Wall Car Company is recommended. Blowdown procedure of water separator. water quantity indicator...
Page 22 IN-18 Maintenance documents-Maintenance work Mixing ratio of cooling water vs. anti-freezing liquid shall long-acting coolant always be determined according to the left diagram. mixing ratio Inspection of cooling system Mount the tester of the radiator water filling port onto the radiator.
Page 23 IN-19 Maintenance documents-Maintenance work Engine control Examine the idle speed (a) Operate car hold-up brake and retard driving wheel. (b) Set the gearbox in free position. (c) Start the engine and warm it. (d) Remove engine control pull wire from the control rod. (e) Mount the revolution indicator onto the engine.
Page 24 IN-20 Maintenance documents-Maintenance work (b) Examine if the support nuts of oscillating beam shaft loosed. Screw down any loosed support nuts of oscillating beam shaft before valve space adjustment. Tighten torque: 54N m (c) Examine the space between the push beams of air intake valve and exhaust valve in the first cylinder.
Page 25 IN-21 Maintenance documents-Maintenance work (f) Set the micrometer gauge on 0 position. Measurement device: 5-8840-0145-0 (g) Turn the crankshaft right and left slightly, examine if the pointer of the micrometer is at the position of 0 . (h) Turn the crankshaft along operating direction and read out the measurement device when the crankshaft is at the top dead point.
Page 26 IN-22 Maintenance documents-Maintenance work (e) Repeat procedure (c) and procedure (d) for the other cylinders. If the measurement value is less than prescribed value, refer to section ìFault diagnosis and debugging ìin this manual. Fast start II system Fast start system examination procedure Disconnect the water temperature sensor wires of thermostat.
Page 27 IN-23 Maintenance documents-Fastening torque Fastening torque Cylinder cover shield Rockshaft assembly Cylinder cover The first step The second step The third step 60-75 60-75 :prescribed torque...
Page 28 IN-24 Maintenance documents-Fastening torque Crankshaft. Main bearing cover .Connecting rod bearing cover.Crankshaft vibra- tion absorber pulley .Flywheel. Oil bottom casing The first step The second step 60-90 :prescribed torque...
Page 29 IN-25 Maintenance documents-Fastening torque Timing gear Timing gear chamber Back plate of the machine body :prescribed torque...
Page 30 IN-26 Maintenance documents-Fastening torque Cooling system and lubricating system :prescribed torque...
Page 31 IN-27 Maintenance documents-Fastening torque Air inlet manifold Exhaust manifold Front exhaust pipe :prescribed torque...
Page 32 IN-28 Maintenance documents-Fastening torque Engine electrical system preheating plug cold area excluded :prescribed torque...
Page 33 IN-29 Maintenance documents-Fastening torque Engine fuel system :prescribed torque...
Page 34 IN-30 Maintenance documents -Fastening torque Installation support of the engine :prescribed torque...
Page 35: Table Of Contents
EM-1 Mechanical system Page Cylinder cover ............. EM-2 Crankshaft shaft assembly .......... EM-6 Air valve assembly ............EM-8 Camshaft and erection pole ........EM-13 Crankshaft ..............EM-19 Piston and connecting rod assembly ......EM-28 Engine oil pump assembly .......... EM-34 Engine body ..............
Page 36: Cylinder Cover
EM-2 Mechanical system-Cylinder cover Cylinder cover Disassembly procedure 1. thermostat body assembly 2. oil sprayer body 3. preheating plug and plug link plate 4. rockshaft assembly 5. push rod 6. cylinder cover Reassembly procedure Reassemble according to the reverse procedure of disassembly. Attention: When disassembly, the parts of air valve assembly shall be collected in a place and marked with identification sign...
Page 37 EM-3 Mechanical system-Cylinder cover 6. Cylinder cover Loose the cylinder cover bolts gradually for several times according to the order number shown in the diagram, each for a little. Attention: If you fail to do so, the bottom surface of the cylinder cover will be damaged.
Page 38 EM-4 Mechanical system-Cylinder cover (6) Examine the mating surface of water jacket sealing plugs. Measure angularity of the mating surface between the exhaust manifold and the cylinder cover with a ruler and a feeler gauge. The mating surface shall be reground if the measurement value is between the prescribed limit value and standard value.
Page 39 EM-5 Mechanical system-Cylinder cover (6) Air valve door lock (a) Press the valve spring in position with spring compressor. (b) Mount the air valve door lock into the valve spring seat. (c) Tap around of the door lock with rubber hammer. Valve spring compressor: 9-8523-1423-0 J-29760 2.
Page 40 EM-6 Mechanical system-Rockshaft assembly Rockshaft assembly Disassembly procedure 1. rockshaft assembly 2. rockshaft elastic collar 3. rocker 4. rockshaft support 5. rocker 6. rockshaft spring 7. rockshaft Reassembly procedure Reassemble according to the reverse procedure of disassembly. Disassembly 1. Rockshaft assembly 2.
Page 41 EM-7 Mechanical system-Rockshaft assembly (c) Examine the oil hole of the rocker to ensure it not blocked. Sweep the oil hole of the rocker with compressed air if necessary. Rocker correction Examine step abrasion and scoring condition of the contact surface of the rocker top valve rod If there is any light step abrasion or scoring on the contact surface, rub it with oil stone.
Page 42: Air Valve Assembly
EM-8 Mechanical system-Air valve assembly Air valve assembly Disassembly procedure 1. rockshaft assembly 2. air valve door lock 3. air valve spring 4. air valve 5. air valve oil seal 6. air valve guide pipe Reassembly procedure Reassemble according to the reverse procedure of disassembly. Disassembly 1.
Page 43 EM-9 Mechanical system-Air valve assembly Verticality (a) Measure the verticality of the air valve spring with a right-angle steel ruler. (b) The air valve spring must be replaced if the measurement value exceeds the prescribed limit value. Limitation: 1.7mm 3. Spring tension (a) Compress the spring to its installation height with a spring testing instrument.
Page 44 EM-10 Mechanical system-Air valve assembly 2. Replace the air valve guide pipe Knock the air valve guide pipe out of the combustion chamber use special tool. Valve guide pipe replacer: 9-8523-1212-0 (b) Coat the air valve guide pipe outer surface with engine oil. (c) Mount new air valve guide pipe form one side of cylinder cover top surface with special tool;...
Page 45 EM-11 Mechanical system-Air valve assembly Air valve seat 1. Air valve seat contact taper-face angle (a) Measure the air valve seat contact taper-face angle (b) The air valve, air valve guide pipe and air valve seat must be replaced as a pair if the measured value exceeds prescribed limit.
Page 46 EM-12 Mechanical system-Air valve assembly (e) Knock the air valve up and down slightly and turn the air valve at the same time to be fitted with the air valve seat. Examine if the air valve contact width is proper. (g) Examine if the air valve seat surface can contact with overall air valve circumference.
Page 47 EM-13 Mechanical system-Camshaft and transverse member Camshaft and transverse member Disassembly procedure 1. cylinder cover assembly 2. flywheel 3. back plate of the machine body 4. oil bottom casing assembly 5. engine oil pump assembly 6. camshaft timing gear 7. camshaft thrust plate 8.
Page 48 EM-14 Mechanical system-Camshaft and transverse member Camshaft 1. Camshaft axial clearance Measure the camshaft axial clearance with a dial gauge. This task must be carried out before disassembling camshaft timing gear. The thrust plate must be replaced if the axial clearance of camshaft exceeds the prescribed limit value.
Page 49 EM-15 Mechanical system-Camshaft and transverse member Camshaft bearing Disassemble camshaft bearing (a) Dismount the bowl plug of machine body. (b) Disassemble the camshaft bearing with bearing replacer. bearing replacer: 5-8840-2038-0 Assemble camshaft bearing (a) Align the oil hole on the bearing with that on the engine body.
Page 50 EM-16 Mechanical system-Camshaft and transverse member (b) Measure the inner diameter of installation hole on the transverse member, calculate for clearance. The transverse member and/or engine body must be replaced if the gap between the transverse member and its installation hole exceeds the prescribed limit value. Clearance between the transverse member and its installation hole mm Limit Standard...
Page 51 EM-17 Mechanical system-Camshaft and transverse member 5. Engine oil pump assembly (a) Smear the oil pipe O-ring with engine oil and mount the O-ring into its groove in the engine body. (b) Install the engine oil pump assembly and the oil pipe onto the engine body and screw down the fixing bolts to prescribed torque.
Page 52 EM-18 Mechanical system-Camshaft and transverse member (2) Measure the piston top projection (a) Measure the piston projection with a micrometer. (b) Refer to the illustration for measuring position of the piston top projection. All the measuring positions shall be as adjacent to the cylinder bush as possible.
Page 53: Crankshaft
EM-19 Mechanical system- Crankshaft Crankshaft Disassembly procedure 1. cylinder cover assembly 2. oil bottom casing assembly 3. timing gear 4. injection pump assembly 5. timing gear chamber 6. engine oil pump assembly 7. piston and connecting rod assembly 8. flywheel 9.
Page 54 EM-20 Mechanical system- Crankshaft Inspection and maintenance Parts must be adjusted, repaired or replaced when excess wear or damage is found in examination. 1. Crankshaft thrust clearance Mount dial gauge as shown in the diagram and measure the crankshaft thrust clearance. The thrust bearings must be replaced as a whole if thrust clearance exceeds the prescribed limit value.
Page 55 EM-21 Mechanical system- Crankshaft Measure the diameter and non-uniform wear of the crankshaft main journal and the crankpin. The crankshaft must be replaced if non-uniform wear of the crankshaft exceeds the prescribed limit value. Standard Limit Main journal diameter 69.917-69.932 69.91 52.915-52.930 52.90...
Page 56 EM-22 Mechanical system- Crankshaft Attention: Pay attention to distinguish top bearing (engine body side) form bottom bearing (main bearing cover side) of the main journal even though there are oil groove and hole on the main journal top bearing (engine body side) and not on the main journal bottom bearing (main bearing cover side).
Page 57 EM-23 Mechanical system- Crankshaft (c) Coat the fifth bearing cover with recommended liquid sealant and the similar as shown in the diagram. Attention: Ensure there is not any oil dust on the bearing cover mating surface before coating liquid sealant. Cylinder screw thread hole and bearing blockage by liquid sealant is not permitted.
Page 58: Piston And Connecting Rod Assembly
EM-24 Mechanical system- Crankshaft 6. Piston and connecting rod assembly (a) Mount the connecting rod bearing onto the connecting rod body and its bearing cover. (b) Smear the cylinder bush hole, connecting rod bearing and the crankpin with new engine oil. (c) Examine if the opening position of piston ring is correct.
Page 59 EM-25 Mechanical system- Crankshaft 10. Timing gear (1) Crankshaft timing gear Mount the camshaft timing gear with camshaft erector The mark X-X on the camshaft timing gear must face outside. Camshaft gear erecter: 9-8522-0020-0 (2) camshaft timing gear (a) Install the camshaft thrust plate onto the engine body and screw down the camshaft thrust plate to prescribed torque.
Page 60 EM-26 Mechanical system- Crankshaft (5) Injection pump (a) Mount the O-ring onto oil injection pump flange (b) Mount the oil injection pump onto the timing gear chamber. Align the positioning mark V-V of the idle gear B with the mark V of the o il injection pump timing gear A Screw down six oil injection pump bracket bolts temporarily.
Page 61 EM-27 Mechanical system- Crankshaft (8) Crankshaft vibration absorber pulley Screw down the fastening bolts of the crankshaft vibra- tion absorber pulley to prescribed torque. Tighten torque: 206N m Attention: Crankshaft rotation shall be prevented when screwing down the fastening bolts of the crankshaft vibration absorber pulley.
Page 62 EM-28 Mechanical system-Piston and the connecting rod assembly Piston and the connecting rod assembly Disassembly procedure 1. cylinder cover assembly 2. oil bottom casing assembly 3. engine oil pump assembly 4. connecting rod bearing cover 5. piston and connecting rod assembly 6.
Page 63 EM-29 Mechanical system-Piston and the connecting rod assembly Inspection and maintenance 1. Piston (a) Remove carbon deposit on top of the piston and on the piston ring grooves carefully. Attention: Do not clean the piston with a metal brush, or the piston may be damaged.
Page 64 EM-30 Mechanical system-Piston and the connecting rod assembly 3. Piston pin Examine the piston pin visually to find if there is any crack, scar or other damage on it, replace the piston pin when necessary. (a) Measure the outer diameter of the piston pin on three different positions and along two different directions with a spiral micrometer.
Page 65 EM-31 Mechanical system-Piston and the connecting rod assembly (2) Axial gap of the connecting rod Measure the thrust clearance of the large end of connecting rod with feeler gauge. The connecting rod must be replaced if the measurement value exceeds the prescribed limit value. Axial gap of the connecting rod Limit Standard...
Page 66 EM-32 Mechanical system-Piston and the connecting rod assembly 3. Piston pin (a) Smear the piston pin and its seat hole with machine oil. Push the piston pin into the hole of piston pin seat hole. (b) Weight the assembly of each piston and connecting rod. Weight difference of difference cylinder and same as- sembly shall be limited to prescribed range when select- ing the assembly of piston and connecting rod.
Page 67 EM-33 Mechanical system-Piston and the connecting rod assembly 7. The connecting rod bearing cover. (a) Align the stamped marks of the connecting rod and the connecting rod bearing cover. (b) Smear machine oil on the bolt threads and mating surface of the connecting rod bearing cover.
Page 68 EM-34 Mechanical systemJEngine oil pump assembly Engine oil pump assembly Disassembly procedure 1. flywheel 2. back plate of the machine body 3. oil bottom casing assembly 4. engine oil pump assembly 5. oil pipe 6. strainer 7. pump cover 8. driven gear and bush 9.
Page 69 EM-35 Mechanical system-Engine oil pump assembly Inspection and maintenance Parts must be adjusted, repaired or replaced when excess wear or damage is found in examination. Casing and gears The machine oil pump assembly must be replaced if following conditions are found in examination. (a) Excess wear or damage of driven gear shaft bush.
Page 70 EM-36 Mechanical system-Engine oil pump assembly Reassembly 1. Engine oil pump body 2. Main shaft 3. Pinion 4. Pinion pin (a) Mount the new transmission shaft onto the machine oil pump body. (b) Mount the pinion onto the driving shaft. (c) Drill a hole of 5mm diameter to let the pinion and transmission shaft through.
Page 71: Engine Body
EM-37 Mechanical system- Engine body Engine body Disassembly procedure 1. cylinder cover assembly 2. pil bottom casing assembly 3. timing gear 4. oil injection pump assembly 5. timing gear chamber 6. engine oil pump assembly 7. piston and connecting rod assembly 8.
Page 72 EM-38 Mechanical system- Engine body 11. Main bearing cover. 12. Crankshaft 13. Transverse member 14. Camshaft 15. Engine body Inspection and maintenance Parts must be adjusted, repaired or replaced when excess wear or damage is found in examination. (a) Remove the gasket and any attachment on the surfaces of the machine body.
Page 73 EM-39 Mechanical system- Engine body Measurement of the Inner diameter of cylinder casing hole Measure the cylinder bush hole diameter of measurement point along thrust direction and crankshaft axial direction Height of measurement point :20mm The cylinder bush must be replaced if the measurement value exceeds the prescribed limit value.
Page 74 EM-40 Mechanical system- Engine body Installation of the cylinder bush Clean thoroughly surfaces of the cylinder bush and cylinder hole with fresh kerosene or diesel oil. (b) Blow surfaces of the cylinder bush and cylinder hole to dry with compressed air. (c) Mount the cylinder bush with special tool.
Page 75 EM-41 Mechanical system- Engine body 9. Piston and connecting rod assembly (a) Smear the piston pin and its seat hole with machine oil. Push the piston pin into the hole of piston pin seat hole. (b) Weight the assembly of each piston and connecting rod. Weight difference of difference cylinder and same as- sembly shall be limited to prescribed range when select- ing the assembly of piston and connecting rod.
Page 76 EM-42 Mechanical system- Engine body (h) Coat the piston ring surface with engine oil. Mount three piston rings with a piston ring replacer. Piston ring replacer: 5-8840-9018-0 The piston ring shall be assembled as following procedures. Oil ring The second air ring The first air ring Attention: The marked face shall be toward upside when mounting...
Page 77 EM-43 Mechanical system- Engine body (n) Place the connecting rod bearing cover in position. The front mark on top of the piston must face the direction of engine. Align the cylinder serial number on the connecting rod bearing cover with that on the connecting rod. front mark (o) Smear machine oil on the bolt threads and mating surface of each connecting rod bearing cover.
Page 78 EN-1 4D28 Engines Page General description ............. EN-2 Engine assembly ............EN-3 Engine bracket ............EN-7 Intake manifold ............EN-9 Exhaust manifold ............EN-11 Cylinder cover cap ............EN-13 Rockshaft assembly ............ EN-14 Valve oil seal and valve spring ........EN-16 Cylinder cover assembly and sealing washer .....
Page 79: General Description
Take care not to damage the oil nozzle when disassembling and assembling piston and rod assembly. The GW4D28 diesel engine is a direct injection diesel engine. The injector has four orifices and then this may obtain the optimal mixture ratio of the admission and fuel injection.
Page 80: Engine Assembly
EN-3 GW4D28 Diesel engines-Engine assembly Engine assembly Disassembly sequence 1. transmission assembly and clutch assembly 2. radiator assembly 3. air intake guide 4. heater hose 5. engine control cable 6. preheating plug wire 7. fuel oil hose 8. oil pressure switch wire 9.
Page 81 EN-4 GW4D28 Diesel engine-Engine assembly 2. Radiator assembly (a) Demount the upper and lower hoses of the radiator (b) Disassemble overflow tank hose (c) Disassemble the radiator assembly 3. Air intake guide 4. Heater hose 5. Engine control cable Release the cable bracket fixing bolts and demount the valve control cable from the control lever of the injection pump 6.
Page 82: 13. Engine Bracket
EN-5 GW4D28 Diesel engine-Engine assembly 13. Engine bracket Disassemble the engine bracket and engine jaw pads from both sides of the housing. 14. Engine assembly (a) Lift the engine with a crane carefully (b) The front should be higher than the rear after lifting the...
Page 83 EN-6 GW4D28 Diesel engine- Engine assembly 6. Air-conditioning compressor assembly (a) Mount the air-conditioning compressor and screw the fixing bolts to the specified torque screw down torque :19N (b) Connect the wire connector of the magnetic clutch (c) Mount driving belts of the air-conditioning compressor...
Page 84 EN-7 GW4D28 Diesel engine- Engine assembly Engine assembly Disassembly sequence 1. air intake guide 2. fan guide shield 3. engine jaw pad Assemble in the reverse order of disassembling. Disassembly Preparation work Break the grounding cable of the storage battery Drain off coolant 1.
Page 85 EN-8 GW4D28 Diesel engine-Engine assembly Assembly 1. Engine jaw pad (a) Lift the engine to mount the engine jaw pad (b) Tight the engine jaw pad fixing nuts and connecting bolts to the specified torque screw down torque of the engine jaw pad fixing nuts: 82N.m...
Page 86: Intake Manifold
EN-9 GW4D28 Diesel engine-Intake manifold Intake manifold Disassembly sequence 1. air intake guide 2. crankcase vent hose 3. fuel injection pipe 4. oil measuring scale guide pipe 5. oil radiator cooling water pipe 6. intake manifold Assembly sequence Carry out assembly in the reverse order...
Page 87 EN-10 GW4D28 Diesel engine-Intake manifold Assembly 1. Intake manifold Screw the fixing bolts and nuts of the intake manifold tight to the specified torque screw down torque :19N m 2. Oil radiator cooling water pipe (a) Assemble the oil radiator cooling water pipes...
Page 88: Exhaust Manifold
EN-11 GW4D28 Diesel engine-Intake manifold Exhaust manifold Assembly sequence 1. front exhaust pipe fixing nut 2. fixing bolt of the front exhaust pipe mounting bracket 3. heat insulation board 4. exhaust manifold Assembly sequence Carry out assembly in the reverse order...
Page 89 EN-12 GW4D28 diesel engine-Exhaust mainfold Assembly 1. Exhaust manifold Screw the fixing bolts and nuts of the exhaust manifold tight to the specified torque screw down torque :26N m 2. Heat insulation board Install the heat insulation board and tight the fixing bolts to the...
Page 90: Cylinder Cover Cap
EN-13 GW4D28Diesel engine- Cylinder cover cap Cylinder cover cap Disassembly sequence 1. crankcase vent hose 2. cylinder cover cap 3. cylinder cover cap seal.ring Assembly sequence Carry out assembly in the reverse order of disassembly Disassembly Preparation work Break the grounding cable of the storage battery 1.
Page 91: Rockshaft Assembly
EN-14 GW4D28 Diesel engine-Rockshaft assembly Rockshaft assembly Disassembly sequence 1. crankc ase vent hose 2. cylinder cover cap 3. rockshaft assembly Assembly sequence Carry out assembly in the reverse order of disassembly Disassembly Preparation work Break the grounding cable of the storage battery 1.
Page 92 EN-15 GW4D28 Diesel engine-Rockshaft assembly Valve clearance adjustment (a) Rotate the crankshaft till the TDC ruling of the crankshaft vibration damper pulley aligns with the timing pointer. At this time either the first or the fourth cylinder piston locates at the top dead center (TDC) of the upstroke.
Page 93: Valve Oil Seal And Valve Spring
EN-16 GW4D28 Diesel engine-Valve oil seal and valve spring Valve oil seal and valve spring Disassembly sequence 1. cylinder cover cap 2. rockshaft assembly 3. valve spring 4. valve oil seal Assembly sequence Carry out assembly in the reverse order of disassembly...
Page 94 EN-17 GW4D28 Diesel engine-Valve oil seal and valve spring Assembly 1. Valve oil seal Install new valve oil seals with a special tool special tool: 5-8840-2033-0 2. Valve spring Mount a bracket to the valve spring Note: The painted end of the valve spring should be underneath...
Page 95: Cylinder Cover Assembly And Sealing Washer
EN-18 GW4D28 Diesel engine-Cylinder cover assembly and sealing washer Cylinder cover assembly and sealing washer Disassembly sequence 1. radiator hose 2. heater hose 3. engine wire 4. engine oil radiator cooling water pipe 5. by-pass hose 6. fuel injection pipe 7.
Page 96 EN-19 GW4D28 Diesel engine-Cylinder cover assembly and sealing washer 5. By-pass hose 6. Fuel injection pipe (a) Release the turnbuckle of the fuel injection pipe (b) Release the conical nuts at the side of the injection pump (c) Unscrew the conical nuts at the side of the injector and...
Page 97 EN-20 GW4D28 diesel engine-Cylinder cover assembly and sealing washer 14. Cylinder cover Release the cylinder cover bolts, a little each time. The sequence is shown in figure Note: If the cylinder cover bolts are not unscrewed a little each time,...
Page 98 EN-21 GW4D28 diesel engine-Cylinder cover assembly and sealing washer 3. Tappet Oil the tappet and insert it into the cylinder cover 4. Rockshaft assembly see page EN-14 5. Cylinder cover cap (a) Oil the rocker arm and valve spring (b) Install the cylinder cover cap seal ring to the cylinder...
Page 99 EN-22 GW4D28 Diesel engine-Cylinder cover assembly and sealing washer 12. Engine oil radiator cooling water pipe Screw the water pipe bracket bolts to the specified torque screw down torque :19N m 13. Engine wire Connect the wires of the coolant temperature sensor and the thermometer assembly 14.
Page 100: Timing Gear
EN-23 GW4D28 Diesel engine-Timing gear Timing gear Disassembly sequence 1. fan guide shield 2. power steering pump driving belt 3. AC-generator driving belt 4. cooling fan assembly 5. crankshaft vibration damper pulley 6. acoustic hood 7. acoustic hood gasket 8. timing gear cover 9.
Page 101 EN-24 GW4D28 Diesel engine-Timing gear 10. Idle gear (a) Measure the clearance of the camshaft timing gear and crank- shaft timing gear before disassembling the idle gears (b) Measure the axial clearance of the idle gears before disassem- bling them...
Page 102 EN-25 GW4D28 Diesel engine-Timing gear 13. Camshaft timing gear (a) Measure the axial clearance of camshaft with a dial measuring gauge Do this work before disassembling camshaft timing gear If the clearance of the camshaft exceeds the specified limit, the thrust plate must be replaced.
Page 103 EN-26 GW4D28 Diesel engine-Timing gear (c) Tight six injection pump bracket bolts5)temporarily After screwing the injection pump rear bracket bolts, tight the bracket bolts of the injection pump at last (d) Install the injection pump rear bracket 6) and rear bracket...
Page 104 EN-27 GW4D28 Diesel engine-Timing gear 6. Timing gear pipe. (a) Install the timing gear pipe to the timing gear housing and idle gear A Tight the pipe eye bolt 1) and fixing bolt 2) to the specified torque screw down torque of the pipe eye bolt:13N m 7.
Page 105: Oil Filter Assembly
EN-28 GW4D28 Diesel engine-Engine oil filter assembly Engine oil filter assembly Disassembly sequence 1. water tube hose 2. engine oil filter 3. engine oil radiator fixing nut 4. engine oil radiator Assembly sequence Carry out assembly in the reverse order of...
Page 106 EN-29 GW4D28 Diesel engine-Engine oil filter assembly (2) Engine oil radiator Check whether there is leakage of the radiator water channel (a) Plug up one end of the engine oil radiator water channel (b) Submerge the engine oil radiator into water. Aerate the other end of the engine oil radiator water channel with compressed air (19.60kPa), if there are bulbs rising to the...
Page 107: Flywheel And Transmission Primary Shaft Front-Bearing
EN-30 GW4D28 Diesel engine- Flywheel and transmission primary shaft front-bearing Flywheel and transmission primary shaft front-bearing Disassembly sequence 1. transmission assembly and clutch assembly 2. transmission primary shaft front-bearing 3. flywheel Assembly sequence Carry out assembly in the reverse order of disassembly...
Page 108 EN-31 GW4D28 Diesel engine- Flywheel and transmission primary shaft front-bearing 3. Flywheel (a) Assemble flywheel retaining device (b) Unscrew fixing bolts of the flywheel and then disas- semble the flywheel Assembly 1. Flywheel (a) Cover the flywheel bolts with engine oil...
Page 109: Oil Pump Assembly
EN-32 GW4D28 Diesel engine- Engine oil pump assembly Engine oil pump assembly Disassembly sequence 1. vacuum pump engine oil hose 2. enginge bracket bolt 3. stiffening plate and rubber packing 4. oil pan 5. engine oil pump assembly Assembly sequence...
Page 110: Oil Pan Assembly
EN-33 GW4D28 Diesel engine- Engine oil pump assembly Assembly 1. Engine oil pump assembly (a) Oil the O-ring of oil hose and install the O-ring to the O- ring groove of the housing (b) Install the engine oil pump assembly with engine oil hose...
Page 111 EN-34 GW4D28 Diesel engine- Oil pan assembly Oil pan assembly Disassembly sequence 1. vacuum pump engine oil hose 2. enginge bracket bolt 3. stiffening plate and rubber packing 4. oil pan assembly Assembly sequence Carry out assembly in the reverse order...
Page 112 EN-35 GW4D28 Diesel engine- Oil pan assembly 4. Oil pan assembly (a) Lift the engine for about 50 mm (b) Disassemble the oil pan from the housing Assembly 1. Oil pan assembly (a) Cover the fifth bearing cap arched area ,gutter and timing...
Page 113: Camshaft And Tappet Stem
EN-36 GW4D28 Diesel engine-Camshaft and tappet stem Camshaft and tappet stem Disassembly sequence 1. transmission assembly and clutch assembly 2. engine assembly 3. cylinder cover assembly 4. camshaft timing gear 5. oil pan assembly 6. engine oil pump assembly 7. camshaft and tappet stem...
Page 114 EN-37 GW4D28 Diesel engine-Camshaft and tappet stem (6) Camshaft timing gear (a) Measure the camshaft axial clearance with a dial measur- ing gauge Do this work before disassembling camshaft timing gear If the camshaft clearance exceeds the speci- fied limit, the thrust plate must be replaced.
Page 115 EN-38 GW4D28 Diesel engine-Camshaft and tappet stem Assembly 1. Camshaft and tappet stem (a) Oil the tappet stem and tappet stem mounting hole (b) Place the tappet stem according to the position mark made when disassembling(if the tappet stem is ready to use again)
Page 116 EN-39 GW4D28 Diesel engine-Camshaft and tappet stem (2) Timing gear cover (a) Align the timing gear cover set pin with the timing gear cover,and then assemble the timing gear cover (b) Screw the fixing bolts of the timing gear cover to the...
Page 117: Piston And Connecting Rod Assembly
EN-40 GW4D28 Diesel engine-Piston and connecting rod assembly Piston and connecting rod assembly Disassembly sequence 1. cylinder cover assembly 2. oil pan assembly 3. engine oil pump assembly 4. connecting rod bearing cap 5. piston and connecting rod assembly Assembly sequence...
Page 118 EN-41 GW4D28 Diesel engine-Piston and connecting rod assembly 5. Piston and connecting rod assembly (a) Clean the carbon of the upper part of the cylinder wall with a doctor knife before disassembling the piston and connecting rod (b) Move the piston to the top of the cylinder, push the end of the rod with the shaft of a hammer or its equivalent,and take out the piston and connecting rod.
Page 119 EN-42 GW4D28 Diesel engine-Piston and connecting rod assembly (g) Knock out the piston pin with hammer and copper bar If the piston and piston pin are to be reinstalled,please tag each bearing and piston pin with a label, recording the...
Page 120 EN-43 GW4D28 Diesel engine-Piston and connecting rod assembly (f) Press the retainer hard into the groove with fingers. Check whether the connecting rod spins freely on the pin (g) Mount the piston ring with a piston ring expander The N shaped mark on the gaseous ring must be upward.
Page 121 EN-44 GW4D28 Diesel engine-Piston and connecting rod assembly (1) Eliminate carefully all kinds of sundries on the back of rod bearings and fitting surface of the rod bearings (m) Cover the upper bearing surface with engine oil Cover the cylinder wall with engine oil...
Page 122: Crankshaft Front-Seal
EN-45 GW4D28 Diesel engine-Crankshaft front-seal Crankshaft front-seal Disassembly sequence 1. fan guide shield 2. power steering pump driving belt 3. AC-generator driving belt 4. cooling fan assembly 5. crankshaft vibration damper pulley 6. crankshaft front-seal Assembly sequence Carry out assembly in the reverse order...
Page 123 EN-46 GW4D28 Diesel engine-Crankshaft front-seal Assembly 1. Crankshaft front-seal (a) Install the front-seal to the gear cover with an oil seal assembler Front-seal assembler:5-8840-2361-0 (b) Pay attention to the mounting depth of the oil seal in figure Depth value:1mm 2. Crankshaft vibration damper pulley...
Page 124: Crankshaft Rear-Seal
EN-47 GW4D28 Diesel engine- Crankshaft rear-seal Crankshaft rear-seal Disassembly sequence 1. transmission assembly and clutch assembly 2. flywheel 3. crankshaft rear-seal Assembly sequence Carry out assembly in the reverse order of disassembly Disassembly Preparation work Break the grounding cable of the storage battery 1.
Page 125 EN-48 GW4D28 Diesel engine- Crankshaft rear-seal Assembly 1.Crankshaft rear-seal (a) Install the rear-seal to the block with an oil seal assembler rear-seal assembler:5-8840-2359-0 Note: Scrape the rust and chippings of the oil seal press-in part thoroughly. Pay attention to the press-in direction of the oil seal...
Page 126 EN-49 GW4D28 Diesel engine-Crankshaft and main bearing Crankshaft and main bearing Disassembly sequence 1. transmission assembly and clutch assembly 2. engine assembly 3. cylinder cover assembly 4. crankshaft timing gear 5. oil pan assembly 6. engine oil pump assembly 7. piston and connecting rod assembly 8.
Page 127 EN-50 GW4D28 Diesel engine-Crankshaft and main bearing 4. Crankshaft timing gear (See page EN-23 5. Oil pan assembly See page EN-34 6. Engine oil pump assembly See page EN-32 7. Piston and connecting rod assembly See page EN-41 8. Timing gear housing 9.
Page 128 EN-51 GW4D28 Diesel engine-Crankshaft and main bearing (d) Install the crankshaft main bearing to the housing and main bearing cap . The main bearing must be installed in the right position (e) Assemble the crankshaft carefully (f) Cover the thrust plate with engine oil...
Page 129 EN-52 GW4D28 Diesel engine-Crankshaft and main bearing 2. Crankshaft rear-seal (see page EN-48) 3. Flywheel and engine body backboard (a) Align the back plate with set pin of the housing (b) Screw the back plate fixing bolts to the specified torque...
Page 130: Housing
EN-53 GW4D28 Diesel engine-Housing Housing Disassembly sequence 1. transmission assembly and clutch assembly 2. engine assembly 3. cylinder cover assembly 4. AC-generator 5. engine bracket 6. engine oil filter assembly 7. timing gear 8. oil pan assembly 9. engine oil pump assembly 10.
Page 131 EN-54 GW4D28 Diesel engine-Housing 1. Transmission assembly and clutch assembly (See page EN-30) 2. Engine assembly (See page EN-3) 3. Cylinder cover assembly (See page EN-18) 4. AC-generator (a)Remove AC-generator wire connector (b)Remove the engine oil hose from the oil pan...
Page 132 EN-55 GW4D28 Diesel engine-Housing 12. Water pump assembly (a) Remove the water pump assembly fixing bolts and detach the water pump assembly (b) Detach the O-ring from the water pump 13. Flywheel and engine body backboard (a) Install flywheel retaining device...
Page 133 EN-56 GW4D28 Diesel engine-Housing 4. Crankshaft rear-seal (see page EN-48) 5. Flywheel and engine body backboard 6. Water pump Timing gear housing (see page EN-52) 8. Piston and connecting rod assembly (see page EN-42) 9. Engine oil pump assembly (see page EN-33) 10.
Page 134 FU-1 Fuel system Page General ............... FU-2 Maintenance and repair on the car ......FU-6 Fuel filter assembly ............. FU-6 Filter element of the fuel filter ........FU-7 The injector ..............FU-8 The injector pump assembly ........FU-11 Oil injection timing adjustment ........FU-14 Parameters of the fuel injection pump ......
Page 135: General
FU-2 Fuel system-General General The following should be observed when being engaged in working on the fuel supply system: (1) Whenever the fuel supply system is working, earth wire of the battery should be cut off. (2) Dry chemical fire extinguishers (level B) should be kept around the work place. (3) Change all the removed oil pipes and attachments for new ones which are the same types as the removed.
Page 136 The Bosch distributor injection pump is used in the GW4D28 type diesel motor. The fuel is fed to each injector uniformly by a to-and- fro/rotary type plunger, which has nothing to do with the serial numbers.
Page 137 FU-4 Fuel system-General The fuel filter and Oil-and-moisture trap start the injection pump oil-and-moisture trap the fuel filter assembly the case drain level float filter element of the fuel filter level sensor drain plunger There is a fuel filter with filter element and an Oil-and-moisture trap, besides the distributor injection pump.
Page 138 FU-5 Fuel system-General The injector injector body pressure adjusting washer pressure adjusting spring of the injector pressure adjusting spring seat the injector hold-down nut The high pressure fuel, which is from the injection pump, is injected to combustion chamber by the injector through the injec- tion hole.
Page 139: Maintenance And Repair On The Car
FU-6 Fuel system-Maintenance and repair on the car Maintenance and repair on the car The fuel filter assembly Disassemble order 1. fuel hose 2. fuel filter 3. oil-and-moisture trap Assemble order The assemble order is adverse to the disassemble order. Disassemble Preparing work Cut off the earth wire of battery.
Page 140: Filter Element Of The Fuel Filter
FU-7 Fuel system-Maintenance and repair on the car Filter element of the fuel filter Disassemble Disassemble the filter element by filter wrench. Filter wrench: 5-8840-0253-0 (J-22700) Assemble (a) Clean the surface of filter element of fuel filter so the filter element can be well seated. (b) Paint thin motor oil on the O ring of new filter element.
Page 141: The Injector
FU-8 Fuel system-Maintenance and repair on the car The injector Disassemble order 1. high pressure oil pipe 2. oil return pipe 3. injector Assemble order The assemble order is adverse to the disassemble order. Disassemble Preparing work Cut off the earth wire of battery. 1.
Page 142 FU-9 Fuel system-Maintenance and repair on the car 3. Spacer ring 4. Pressure adjusting spring seat 5. Pressure adjusting spring 6. Pressure adjusting spacer 7. Injector body Check and repair Check the injector. If the injector is worn or damaged, it is necessary to adjust, repair or change.
Page 143 FU-10 Fuel system-Maintenance and repair on the car Injector adjustment (a) Install the injector on the tester. (b) Increase the test pressure and check the start condition under set pressure. Pressure: 18142KPa (1) If the injector can not work under set pressure, adjust it by adjusting spacer with suitable grade number.
Page 144 FU-11 Fuel system-Maintenance and repair on the car Injection pump assembly Disassembly order 1. the fan assembly 2. fan wind scooper 3. power steering pump and air-conditioning compressor belt 4. AC generator belt 5. sound barrier cover 6. spacer of sound barrier cover 7.
Page 145 FU-12 Fuel system-Maintenance and repair on the car 8. Control line of the injection pump Disassemble the screws on the line bracket and remove the control line. 9. Fuel hose Remove the fuel supply hose and return hose. 10. Line group of the injection pump tachometer sensor cold start solenoid valve Remove the tachometer sensor (with the tachometer), solenoid valve...
Page 146 FU-13 Fuel system-Maintenance and repair on the car 2. High pressure oil pipe (a) Connect the high pressure oil pipes at injection pump side and injector side, and tighten the conical nuts to set torque. Tightening moment: 29N m (b) Install oil pipe fastener at the original location. 3.
Page 147 FU-14 Fuel system-Maintenance and repair on the car 11. Fan wind scooper Install the fan wind scooper and overflow tank hose. 12. Fan assembly (a) Install the belt pulley and cooling fan onto the water pump, and tighten the lock screw to set torque. Tightening moment:8N m (b) Connect the earth wire of battery.
Page 148 FU-15 Fuel system-Maintenance and repair on the car Parameters of injector sspecification engine type GW4D28 injector(bisch) type p type:KBAL-P001A Start pressure of injector 18142 Size of high pressure oil pipe Inner diameter Outer diameter 6.35 Length Delivery pressure 19.61 Test fuel...
Page 149 FU-16 Fuel system-Maintenance and repair on the car Fuel tank Disassemble order 1. guard plate of fuel tank 2. cap fastener of tank filler 3. air hose of tank filler 4. hose of tank filler 5. oil drain block 6. fuel tank cushion 7.
Page 150: The Fuel Tank
FU-17 Fuel system-Maintenance and repair on the car Assemble 1. Fuel tank Notice: When install the fuel tank onto the frame, pay attention to set a cushion on the fuel tank of the frame. 2. Three-lined oil pipe fastener Tighten the fixing screws to set torque. Tightening moment: 19N 3.
Page 151: The Fuel Gauge
FU-18 Fuel system-Maintenance and repair on the car Fuel gauge Disassemble order 1. fuel sensor 2. fuel level gauge Assemble order The assemble order is adverse to the disassemble order. Disassemble Preparing work Cut off the earth wire of battery. 1.
Page 152: Control Line Of The Throttle Valve
FU-19 Fuel system-Throttle line Throttle line Control line of the throttle valve Disassemble order 1. control line of the throttle valve 2. bolts 3. spring washer 4. flat washer 5. throttle line frame (front) 6. bolts 7. throttle line frame (back) Assemble order The assemble order is adverse to the disassemble order.
Page 153 FU-20 Fuel system-Throttle line Throttle pedal Disassemble order 1. accelerator lever 2. bracket case 3. bracket of accelerator lever 4. torsion spring 5. cotter pin 6. throttle pedal Assemble order The assemble order is adverse to the disassemble order. Disassemble 1.
Page 154 FU-21 Fuel system-Throttle line The adjustment of down force of the throttle pedal (a) When finishing each control line, push the throttle pedal seat in order to press the pedal to end through full travel. (b) Adjust the catch bolts to leave the clearance 0-2mm between the seat back and the catch bolt.
Page 155 FU-22 Fuel system-Throttle line Air filter Disassemble order 1. snorkel tube 2. air filter cover 3. air filter element 4. air filter case Assemble order The assemble order is adverse to the disassemble order. Disassemble 1. Snorkel tube 2. Air filter cover 3.
Page 156 Fuel system-Throttle line Carbon deposition and dust blocking the filter element (a) Prepare the diluted cleaning liquid which is original of the Great Wall Company. (b) Dunk the filter element in cleaning liquid for about 20 minutes. (c) After taking out the filter element from cleaning liquid, flush it carefully by water.
Page 157 CO-1 Cooling system Page General ............... CO-2 On vehicle repair ............CO-4 Single piece repair ............CO-7 Thermostat ..............CO-9 Radiator ............... CO-10 Conveying belt adjustment .......... CO-11...
Page 158: General
CO-2 Cooling system -General General thermostat cylinder cover overflow tank engine oil cooler radiator cold startup device water pump fuel injction pump vehicle heater The cooling system of type 4D28 diesel engine is of pressured coolant forced circulating type. The system consists of water pump, thermostat, fan, radiator and other parts.
Page 159 CO-3 Cooling system -General Radiator Tube-band radiator for type 4D28 diesel engine. A valve with cover is equipped with thermostat body of cylinder cover to increase the boiling point of coolant which will open when the pressure reaches 88-118kPa. Anti-freeze fluid mixing ratio(%) (a) Relation between mixing ratio and freezing point The freezing point temperature of engine coolant changes...
Page 160: On Vehicle Repair
CO-4 Cooling system -On-vehicle repair On-vehicle repair Water pump Disassembly procedure 1. air guide cover of cooling fan 2. cooling fan assembly 3. drive belt of power steering pump and air-conditioned compressor 4. drive belt of alternating current generator 5. crankshaft vibration damper pulley 6.
Page 161 CO-5 Cooling system -On-vehicle repair 4. Drive belt of alternating current generator lock bolt Loose bottom set point of alternating current generator and lock bolt of adjusting plate, dismount drive belt. 5. Crankshaft vibration damper pulley 6. Timing gear house cover 7.
Page 162 Cooling system -On-vehicle repair CO-6 Assembly 1. Water pump assembly (a) mount O-ring into O-ring groove of water pump body. (b) Assemble water pump, screw down set bolt of water pump to prescribed torque: 20N m 2. Timing gear house cover Assemble gear house cover and screw down set bolt of gear house cover to prescribed torque: 19N m...
Page 163: Single Piece Repair
CO-7 Cooling system -Single piece repair Single piece repair Disassembly Disassembly procedure 1. set screw 2. centre flange of fan 3. water pump impeller 4. water seal assembly 5. oil slinger 6. bearing assembly 7. water pump body Reassembly procedure The disassembly procedure is reverse of assembly procedure.
Page 164 Cooling system -Single piece repair CO-8 Inspection and maintenance If heavy wear or damage is found in inspection, necessary adjustment, repair and replacement of parts shall be carried out. Bearing assembly Inspect if there is any noise, stagnant and other abnormal condition. Reassembly 1.
Page 165: Thermostat
CO-9 Cooling system -Thermostat Thermostat Disassembly procedure 1. socket joint part 2. thermostat top shell 3. thermostat gasket 4. thermostat Assembly procedure The assembly procedure is reverse of disassembly procedure. Disassembly Preparation Disconnect earthing cable of storage battery. Drain coolant. Inspection and maintenance 1.
Page 166: Radiator
CO-10 Cooling system -Adjustment of drive belt Radiator Disassembly procedure 1. overflow tank hose 2. radiator hose 3. condenser 4. radiator assembly Assembly procedure The assembly procedure is reverse of disassembly procedure. Disassembly Preparations Disconnect earthing cable of the storage Inspection and maintenance battery.
Page 167 CO-11 Cooling system -Adjustment of drive belt 4. Examine coolant leakage Press the compressed air of 196.9kPa from radiator filling hole into the radiator with radiator cover tester. Examine if there is any coolant leakage in the cooling system. Assembly 1.
Page 168 ST-1 Starting system Page Summary ..............ST-2 Service on the vehicle ..........ST-4 Single piece maintenance ........... ST-5...
Page 169 ST-2 Starting system- Summary Summary starting relay starting motor starting switch holder winding contact point 50 terminal connector 30 terminalconnector electromagnetic switch pinion shaft clutch storage battery suction winding Starting system Starting System is composed of storage battery, starting motor, starting switch, ignition lock, starting relay and so on.
Page 170 ST-3 Starting system- Summary Starting circuit starting switch storage battery fuse fuse fuse fuse starting relay quick start component suction winding. retaining coils electromagnetic switch starter...
Page 171 ST-4 Starting system-Service on the vehicle Service on the vehicle Starter Disassembly procedure 1. 50 wiring terminal 2. 30 wiring terminal 3. earthing cable wire terminal 4. engine assembly 5. isolation board (cold area excluded) Assembly procedure Assemble according to the reverse procedure of disassembly.
Page 172 ST-5 Starting system-Single piece maintenance Single piece maintenance Discomposition sequence 1. lead wire 2. through bolt 3. yoke assembly 4. yoke cover 5. carbon brush and Carbon brush holder 6. armature 7. driving box 8. overriding clutch 9. return spring 10.
Page 173 ST-6 Starting system-Single piece maintenance 3. Yoke assembly Separating the yoke from magnetic switch 4. Yoke cover 5. Carbon brush and Carbon brush holder Disassemble the brush and the holder from armature with shaft-mouth plier 6. Armature 7. Driving box spring carbon brush 8.
Page 174 ST-7 Starting system-Single piece maintenance 11. Pinion Disassemble the pinion from the box 12. Holder Disassemble the holder from the box 13. Roller 14. Magnetic switch. Checking and repairing If find abrasion, destroyed or any other unusual conditions in the checking, then need to repair or replace parts. Armature (a) Checking the quantity of radial runout of ring header, if it exceeds the provide limit, and then need to replace the...
Page 175 ST-8 Starting system-Single piece maintenance Armature short-circuited test Put the armature in the short-circuited test meter to check if it is short-circuited. When rotate the armature slowly, make the saw blade touch the armature core ,short-circuited armature makes the saw blade oscillating and attracted by core .if so , it indicates that armature has been short-circuited ,must be replaced.
Page 176 ST-9 Starting system-Single piece maintenance Carbon brush and carbon brush holder Measure the length of the carbon brush, if the abrasion exceeds the using limit, then the carbon brush should be replaced. Length of carbon brush Output(kw) Standard Limit 14.5 Insulation experiment of the carbon brush holder Check the carbon brush holder is insulated with the Multimeter.
Page 177 ST-10 Starting system-Single piece maintenance Note: Do not forget to mount the ball and spring between clutch and magnetic switch. Before this, mount the roller on the pinion. Magnetic switch Link the magnetic switch between clutch and box temporarily then do the following experiments. Each experiment must be completed in 3 to 5 seconds.
Page 178 CH-1 Charging appliance Page General ............... CH-2 Diagnosis ..............CH-4 On-vehicle maintenace ..........CH-5 Single piece maintenance ........... CH-8...
Page 179 CH-2 Charging appliance-General General Electric generator 14V-50A rotor carbon brush stator Integrated circuit(IC) adjuster rolling bearing rolling bearing oil seal vacuum pump pulley through bolt back cover front cover slide ring The charging appliance is of integrated circuit (IC) universe adjuster type.
Page 180 CH-3 Charging appliance-General Charging circuit startup switch storage battery fuse fuse oil seal fuse S wiring terminal generator charging relay W wiring terminal w i r i n g terminal speed indicator to charging alarm light w i r i n g of the generator terminal to charging signal...
Page 181 CH-4 Charging appliance-Diagnosis Diagnosis resistance storage battery resistance kindle switch charging alarm light S wiring terminal generator W wiring terminal speed indicator of the generator charging relay L wiring terminal IG wiring terminal On-vehicle comprehensive inspection The operating condition of the charging appliance is indicated with the charging alarm light.when the starting switch is turned to ìcloseî...
Page 182 CH-5 Charging appliance-On vihicle maintenance On vihicle maintenance Disassembly procedure 1. power steering pump and air conditioning compressor 2. air conditioning compressor assembly 3. lead socket joint 4. vacuum hose 5. engine oil hose lock nut 6. driving belt of AC electric generator 7.
Page 183 CH-6 Charging appliance-On vihicle maintenance 6. Driving belt of AC electric generato (a) Loose the fastening bolts of adjusting plate. (b) Dismount adjusting bolts. (c) Loose the fastening bolts of AC electric generator and dismount the driving belt. 7. Power steering pump assembly (a) Loose the adjusting bolts and dismount the driving belt.
Page 184 CH-7 Charging appliance-On vihicle maintenance 5. Engine oil hose (a) Mount the engine oil hose onto the bottom case. (b) Mount the engine oil hose onto the body engine oil hose engine oil hose 6. Vacuum hose Mount the vacuum hose to the vacuum pump of the electric generator.
Page 185 CH-8 Charging appliance-Single piece maintenance Single piece maintenance Disassembly procedure 1. vacuum pump 2. lead 3. through bolt 4. rotor and front cover assembly 5. stator and back cover assembly 6. rotor 7. back bearing 8. terminal bolts and nuts 9.
Page 186 CH-9 Charging appliance-Single piece maintenance 6. Rotor Grip the rotor with nip, dismount belt nut , remove the pulley , fan , front cover and the rotor 7. Back bearing 8. Terminal bolts and nuts 9. Back cover (a) Dismount the nuts fastening B terminal and diode. (b) Separate stator and back cover.Pay attention to the loca- tion of insulating spacer so that they can be mounted to their original location when reassembly.
Page 187 CH-10 Charging appliance-Single piece maintenance `eJNM (c) Examine if the circuit between the slide rings is closed, multimeter replace them if circuit is open. slide ring (d) Examine if the circuit between the slide ring and rotor multimeter iron core or rotor axis is closed. If the circuit is closed, replace the rotor assembly.
Page 188 CH-11 Charging appliance-Single piece maintenance Diode multimeter (a) Examine if the circuit between terminals (for example: BAT and U) is closed.If the circuit is closed, that means the diode is ok; if the circuit is open, that means the diode is unqualified.
Page 189 CH-12 Charging appliance-Single piece maintenance The adjuster shall be replaced if the voltage breaks in any point. V4 is the voltage between middle tap of variable resistor and is the votage on BAT1-BAT2 terminal E when the resistance value of the resistor not Standard 20-26 changed.
Page 190 CH-13 Charging appliance-Single piece maintenance Vacuum pump reassembly (a) Position the stator on the center plate and the case when the fine-pitch spline upward.Align the holes of center plate and the rotor. (b) Mount the blade into the slots of rotor.Blade chamfer shall face outward when assembly.
Page 191 CH-14 Charging appliance-Single piece maintenance UK Rotor Wrap nip jaw, clamp the rotor with the nip and screw down pulley nuts to prescribed torque. Tighten torque: 90N m 9. Stator and back cover assembly 10. Rotor and front cover assembly 11.
Page 192 EX-1 Exhaust system Page General ............... EX-2 On-vehicle repair ............EX-3 Front exhaust pipe ............EX-4...
Page 193 EX-2 Exhaust system-General General Attention: There must be sufficient distance between exhaust system assembly and car body bottom board to prevent bottom board from overheat and damage to passenger carriage insulation and decorating material. When examine or replace exhaust system assembly, sufficient distance between exhaust system and any part of car body bottom board must be ensured to prevent bottom board from overheat and damage to passenger carriage insulation and decorating material.
Page 194 EX-3 Exhaust system-On-vehicle repair On-vehicle repair Detonation and vibration noise of exhaust system normally are caused by parts misalignment. When adjust the system, unlock all of the bolts and nuts first until all of the parts properly aligned, then tightening all of the bolts and nuts from front to end.
Page 195 EX-4 Exhaust system-Front exhaust pipe Front exhaust pipe Disassembly procedure 1. tightening nut of front exhaust pipe 2. set bolt of front exhaust pipe installation support 3. set bolt and tightening nut of front exhaust pipe 4. front exhaust pipe 5.

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