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MA NTENANCE MANUAL OF GW 2. 8TC TURBO —D IESEL ENG INE Edited by Research and Development Center of Great W all Baoding Intemal Con bustion Engine Manufacturing Company Limited GreatW all Baod ing Intemal Conbustion Engine Manufacturing Canpany Lim itedMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE BRIEF NTRODUCTION The main technical pammeters troubleshooting maintenance dis mounting adjusmen$ repairand so on of GW 2 8TC turbo—diesel engine are detailed intmduced in thismanual It can be used as working basis for the maintenance woukers and repaimen of the tutbo—diesel engine MAINTENANCE MANUAL OF GW 2, 8TC TURBO —D IESEL ENG NE Edited by Research and DevelonmentCenter of G wutW all Buoding Inwmul Combustion Engine Manufietu ring Can pany Lin ited Books Editorial Deparment ofAutimobila Chinese Acadamy of Agriculum|Machinery Sciences (CAAMS) (Add 1 Bebbuwun Deshengmen Wai BEUING+ Post coda 10008) Tel 86—19—G1882616 + E-mail qeib3@ 163. xm Copy Editor Gao Hai English Translate W ei Deshi Dawn and writen by Books Bdilpial Deparment of Autimebils CAMS: Fomat Deszner Xu Liunyh + CoverDesianer Yu Suying CompulerCampositions Luo Jian + Campuler Dawns Huang Qishers Printed in Beijhis Dad Press LAG + Paper wauited 3 Book sioe $n * 1250 + Wonks wal 360, 000 Tue 1st Fails Mah 2007 Being + The 1s: Pubibbed, Match 2007 Reting CAAMS—1034—92 /G + 346—QC—07~03—600, D0 | QFEBkwA eae zaMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE PREFACE GW 2. 8TC turbo —diesel engine is a product developed based upon the GW2. 8TDI turbo—diesel engine Apart from Hlinwing characteristic such as lower noise better econo my. starting quickly at lov tempemtura excellent performance both at high and at law speeds lightweight campact and high reliability this type turbo—d iesel engine also has mou powerful efficiency and achieve the standard of Eu Ul anission GW 2, 8TC tibo—diese! engine adopts CRS 2 0 high—pressure fuel rail fuel supply systan fim BOSCH Canpany ofGemany. This fuel supply system consists of various sen sors ECU, various actuators and connecting hamess The fuel supp Wing pressure of he system is 145 MPa and BOSCIT EDC16C39 type electric contml unit (ECU) will autmati cally control the fuel— supplying course Apart fim direct contmlling relevant actuators within fuel supply systm, ECU also contwols other sysiems working course such as EGR system, air conditioner systen, electric fan system and so forth concemed the operation of diese! engine GW 2, 8TC turbo—diesel engine mainly used on light trucks pick—up, SUV, cam mercial vehicle light bus and the mechanism with diesel engine as power GW 2, 8TC turbo —diesel engine is a power—mechanism with modem advanced tech nology and camplex stucture Therefore more sttict requirments for the coordinate anong materia \teclindbeies dnd the varibus assbriative parts are heeded. and mow highey levels , of opemtion, maintenance and repair ace Also needed carespond idgh: \ {MAINTENANCE MANUAL OF GW 2. 8'TC-IURBO~D IESEL ENG INEHIS a compre hensive manual ford ese! engine maintenance and it collects folkwing contents such as the man technical pammeters disassembly assanbl, adjusment detecting toub leshootng and soon of GW 2, 8TC tubo—diesel engine Reed thismanual carefully and mplenentev ery regu ations ih thismanual strictly so as to you could leam about tuble diagnosis tou bleshooting maintenance and repairmethods of diesel engine to ensure that the engine after maintenance can be at op tmalworking status and arrive ideal index of power and econany. Same contents concemed with vehicle and mechanica | chassis or the parts offered by ve hicle factory and machine mamufieturing enterprise in the process ofmaintenance, pair and toubleshooting read the maintenance manual of assembled vehicle and machine please For your life and property safes you must strictly read and impliment the safety part in this manual while using and opemting this turho—diesel engine Important safety items must be observed stricl. Ifyou do not observe han, may cause your life injured or engine damaged and even very dangerous In thismanual “waming’ means the danger thetmay damage human—body, “caution” means the danger thatmay damage the enging and “at tention” used ty mean the mportint information but without danger Following the requirment and changing of the market GW 2. 8TC tutbo—diesel en gine will also be mproved continuously, Pease notice that the mproved opemtion and ma intenance content will be added and corrected in republished manual Please understind thatwe would keep the changing right on aspects of diesel engine supply mnge equ iment and technology. Users cannot requ ire others accor! ing to the dat, illustatins and explanation in hismanual ‘The changing of diesel engine supply range RERMAM MASSA Aa) (Great el and interralConbstin Engine Compa LitesMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE equipment and technology is without notice In onder to mprove our products and perfect the operation and maintenance technolo gies we hope ourusers and readers could reflect your op inions about the quality perfsm ance and stmctuw of GW 2 8TC tibo—diesel engine as well as its operation maintenance and repair experience to us Our address ig GreatW all Baoding Intemal Canbustion En gine Mami&cturing Canpany Lintted, Development Zona D ingxing County Hebel Prov ince China Post coda 072650. Because thismanual deals with camp:ehensive content and he editing tine is lin ited therefor the oversight and even wrong contentmay exist Be kind enough to give us your opinion This is only a referenced manual during your works we are without ditect or indi rect responsbility for the loss caused by using thismanual G watW all Baod ng Intemal Combustion Engine Manufacturing Company Linited es tablishes special repair stations passin, U sers can handy consultwith and gain service afer sale fim the station for yourmaintenance twouble orwhen you need techn iealma intenanca tub kshoothg repair or replace parts W ithout pem issin of Great W all Baoding Intemal Canbustion Engine Manufcturhg Company Limited, anybody cannot copy and republish thismanual in any forn, GreatW all Baoding Intemal Canbustion Engine Manuficturing Campany Limited would msewe all right about copyright regulated in law, keeping changing right and explaining right Al right reserved, G reat W all Baod ng Intemal Cambustion \] Hingine!M ani fie uring Eom pany Lint ited ~ ~ Jane 16, 2006 ~ ~MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CONTENTS CHAPTER 1 TECHNICAL INFORMATION OF THE DIESEL ENG INE 11 The Canponent of the D ‘ese! Engine--- 111 > CylinderHead and Cylinder Block 112 Crank and Connecting—Rod Mechanism - 113. ValveMechanim and Intake Aixhaust System 114 Tuibo—Charging System 1 1.5 Fucl Supply Systm ssssssvsesssssessessssaseeeseesssenessssssseeseesveeesceesaneet 11 6 Lubrication System 117 Cooling Systan 118 Starting Equipment 119 EGR Systan 12 The View of the Diesel Engine 1 2.1 Front¥ iew of the D sel Engine 122 Rear View of the Diesel Engine- 1 23. Left View of the Diesel Engine 124 RightV iew of the Diesel Engine 1.2.5 Vertical iew of the D iese] Engine 1.3. Characteristic Curve of the Diese Engine 1/4. ‘Techn ich |'Panmeters and Specifications phe Bsa gine serrate teeny lay Ting Fase ott of the Engine 1 4 2 Tightening Tomue ofMain Tighten Pars of tre Engine 143 Main Adjusting Dat of the Engine ------ 144 The Range of Various Tanperature and Pressure of the Engine 14.5 Main Fittings Specifications of the Engine 14.6 Main Parts Specifications of Fuel Supply Systan of the Engine 147 Main Parts Fitting Cleamnce and W ear Limits of the Engine 15 Maintenance Sundari 1 6 TeehnicalM aintenance + 16 1 Technica! Maintenance Period 1 6 2. Technica! Maintenance Contents 1621 Daily TechnicalMaintenance--- 1622 The FirstG mde TechnicalM aintenance +++ +eresssresersteceese eee 1623 The Second G mde Technical Maintenance 1624 The Thiri Grade Techn ical Maintenance 162.5 Season Technical Maintenance 163. TechnicalMainienance of A IrF ilter . 1631 Maintenance of Oil Bat AirFillerW ith Inertia Steel W ire Villus Filter Elanent 1632 Maintenance of Air FilterW ith Bape: Pies Pent see 1 64 Technica! Maintenance of Fuel Supp y System « 164 1 TechnicalMaintenance of Fuel Filter +++ 164 2 Dminage of the Fuel Systan «+--+ 16.5 Technical Maintenance of Lubricating Systan 328 i] il is FS BR Zl Sp eaaans Marfan Comper Lined a) w a a a) a) (2) (2) (@) (2) (2) (3) (3) (4) (5) (6) (D (8) 09>, G9) ap ap a2) as a3) as) an a7 ag) ag) 1) ap ap 22) 22) 23) 23) (23) 23) (ay (25)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE VI Running—In of Diesel Engine « Aa Maintenance Treament 8 8 8 8 L 1 1 8 1 1 1 1 8, 1 L . 9, 9. 8 FastStarting Sysien Tightening Torue 6 5 1 Choose Lubricating Oil -- 6 52 OilLevelMeasure - . 6 5 3 Replace OM Oil and Use New Oil - 654 TechnicalMaintenance of O il Filter 6 Technica |Maintenance of Cooling Systen- 7 Technica! Maintenance During Storee 8 Attention Points for Technical Maintenance 1 Preparations Before Running— In -~ 2 Running—Ih 3 Attention Points During Running — In s++es+see+eeeeeeeee sortase 4 Technical Maintenance A flor Rumnn ing— In sree vesseseessneveeeeeseeneeane cee 5 Attention Points forNew Vehicle Operation 1 Model Symbol 2 AirFilter 3 Lubricating Systen 4 Fuel System, R41 Repkeing Process - & 4.2 Dminage Process of Fuel Filter 4.3 AirRemove Pmcess for Fuel Filter Cooling Systan 5.1 Cooknt Level 4,2), Check of Cooling 8 3 \ Check of RadfatorG ue & 4 Testing of Themostt Action - 6 Transm ission Belt & G1 A temator Transm ission Belt - & 2 AirConditioner Compressor and Power Steering Pump Transmission Belt: . 7 Diesel Engine Control & 7% 1 Check Ming Speed & 72 Adjusmentof Valve C karance & 73 Measurement of Compression Pressure StQTT, Byyseerea cee aie eeraely pe-gedeige Ope 1 Valve Bonnet Unit CylinderHead, and Rocker Shaft Stand «+++ 2 CylinderBlock Assembly ~ : 1.3 Crankshaft Main Bearing Housing Connecting Rod Cover Danping Pulley Assamb ly Fiwwhee] 0 il Sump « 4 Pulley Chamber Camshaft Tin ing Pulley Transition W hee! Unit Tensioner Unit Tining Pulley, Cansha{t0 il Sea ling Seat- Cooling Systam (Fan W aterPump Pulley W aterPump Pulley ChanberCoverA ssanb ly Themostat housing) 6 Lubricating Systm (il Filtey Oil Pump, Injection Pipe W ekimeat and Oil Simp) 7 Intake Manifok, ExhaustManifold, Exhaust Tube 8 Electric Systm (Generbs StarterAssambly and Preheating Plug) fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary Linked (25) @s) cs) 26) an (28) 28) (28) 28) 9) Cr) 29) 30) eb ep ep 32) 33) 33) 33) a) ay @ay BO), 3) 35) 36) an 7) 37) @7) 38) @a) ao) ap ay 2) 43) a) 45) 46) an 48)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.9.9 FuelSystem (igh Pressure Fuel Pump and H jgh—Low Presume Fuel Pipe Assambhy) +++ (49) 1.9.10 Exhaust Recycle Systen (50) 1.9.11 Sound Insulation Boart Assanbly and C teh Assembly (1) 1.9.12 Turbocharger Assenb ly (52) 1. 9.13 Diesel Engine Support Assambly (53) 1.10 Special Tools and Instument---+- (54) CHAPTER 2. TROUBLE D IAGNOSB AND TROUBLESHOOTNG 21 Troubleshooting: 1.1 Diesel Engine Cannot be Started ++++++eeessssrvssessesseeesssessenereenseenes 1.2 Diesel Engine Starts D ifficultly at Low Tamperature eres ssseseerese vores 1.3. DieselEngine W ith Insufficient Output Power 2.1.4 DieselEngine Mas Too Much Fuel Consumption 2.1.5 Diesel Engine Running W ith Unusual N cise 21.6 DieselEngine Has Abnoma!N oise - 21.7 DieselEngine Exhausts Gas with Unusual Cobr- 2.1.8 Diesel Engine Lubricating Systan Has 1 gher 0 ilConsumption and Low Pressure + 2.1.9 Diesel Engine Cooling System Has A bnomal Cooling Tanpem ture and Lack Liqgaidse+sessses ses sesesseecssesesceseeseeesssaneceneeeseeens snaceeeneanes (64) 1.10 Diesel Engine Turbo—Charging Systen Trouble (65) 1.11 Diesel Engine Fuel System Trouble (66) 1)12\; Diesel Engine W obbles at-Whlingy s+ys+r+s+ (68), 2.1. 13° Diese! Engine W rks atH ‘igh Idling * (69)| 2.1.14' StirierCan Not Run Starts Powerless and W ith Noise ~ (69) 2.1.15 StarterW orks ButD iesel Engine Cannot be Running (70) 2.1.16 Diesel Engine Can be Running ButCannot be Ignition to Start (71) 2.1.17 Fast Starting Systen Fault Causes D ifficult Starting «+++ +++ (71> 2.1.18 Diesel Engine Flameout But Can be Started Again- (72) 21.19 GenemtorRunsW ithout Output Insufficient Charge, and Too Large Cha wing Current (73) 2.1.20 Battery Capacity is Insufficient Starts Difficu thy Self—D ischarges Excessively - (73) 22 Trouble D iagnosis- 75) 2.2.1 Trouble Diagnosis Or Starting Sysiem « (75) 2 Trouble Diagnosis fr Turbo Charging Systam s++++++ssssseee ceeseeeereeeeeeeee (78) 2.2.3 Trouble Diagnosis for 0 il Leakage of Tuibocha ger (80) CHAPTER 3° MECHAN CAL SYSTEM (83) Al CylinderHead ++ (83) A2 Rocker Shaft Assen bly (89) 33 Vale Spring Valve Stem OilSeal Valve Guide (92) Q4 Camshait and Tappet ++ “ oe srsees (100) 35 Crankshal . 0s) 36 Piston and Connecting Rod Assan 24) 37 Oil Pump Assanbly ++ +++ a (132) A8 Cylinder Block « 36) @&MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CHAPTER 4 GW2, 8TC TURBO—DIESEL ENGINE 41 0 1 12 13 14 15 16 7 18 19 20 RAR A BRAR ABA a RA eae CHAPT y 1 B 5. 5, 5. CHAPTER 6 COOLING SYSTEM a. Summary + Engine Assembly « Engine Bracke! Intake Manifold + ExhaustM anifold « Valve ChamberCap Rocker Shaft Assan bly Va O il Sealing Ring and Valve Spring Cylinder Head Alnaemhl 8 and Gasket Timing Pulley Oil PllterAwedA hp ceeesantsvensnonrcornmnsees easntemttetatvecenniiaenseceavesness in 15! Shaft -~ Fkwheel and Front Bearing of Transm Oil Pump Assanbly +--+ OilSump Assambly +++ Canshail and Tappet +--+ Piston and Connecting Rod Assembly Front Oil Seal R ing of Cmnkshaft Rear Oil Seal R ng of Crankshaft + Crunkshaft and Main Bearing Cylinder Blick Assen oorccessesseessssnsee cxsssconsecntessennsonneesconsnontnens PER 5, FUBL SYSTEM Summary Y- 9° 1), Wigh SPyessure Pup Pump 2 Fuel Filter and Fuel—W aterSepamitor .3 Injector ae 4) High —Pressur Fuel Rail Sensor 5 1 Hull Effect Phase Sensor~ f 1 5&2 Heat—Fim Type Airflow Rate Sensor 5 3. Engine Speed Sensor 5&4 Cooknt Tenperture Sensor 5.5 PotentimeterType Foot Pedal Posilion Sensor. +++++++++++ .6 Electric Cont! Unit ECU) 1.7 Engine amess ++ Repair in the Vehicle «-+++-+++-- aed sessees eases teseenes 1 Fuel Filter Assembly 2.2 Filter Elment of Fuel Filter 2.3 Injector os 3 4 High—Pwessure Fuel Pump A ssembh 5 Fuel Tal G Fuel Liquid Level Indicators: s-++ereeese vesceneee 7 Electwn AccelertorPedal “ Summary +++ 43) 43) (45) (152) 54) (158) (162) (163) 166) a7b 79) (185) sz) ag1 95) agg) (207) (216) (222) (225) (236) (252) 1252)} (253) (254) (255) (256) (257) (257) (258) (259) (259) (260) (260) (262) (262) (263) (264) 268) (74) (76) @77) (279) (279)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 6.1.1 WaterPump = (280) 61,2 Themostat + (280) 61.3 Radiaor (280) G14 Antifreeze 81 6 2 Repair in the Vehicle (282) 6&3 Parts Repair (287) 6.3.1 WaterPunp « (287) 6.3.2 Themostat + (290) 6.3.3 Radiator 291) 64 Adjustment of Transm ission Bel (294) 6.4.1 Check and Repair s+ (2s4y 64,2 Belt Tension Adjusment s+: vsseessseessessensee c2s4y CHAPTER 7 LUBRICATION SYSTEM (295) TL Summary ve 7 (295) 72 Repair in the Vehicle (296) 721 OilFiler (296) 7 BQ Oil Pump svvervsrssevesessecsrsesesssenevste “ seeeteees (298) 7.23 Oil Sump Assenbly « (302) 7.3 Repair Single Part . (306) 7.3.1 Oil Filter +--+ (306) 7.3.2 OilPump + (306) CHAPTER 8, TURBOCHARG NG SYSI pp ymmge Yop eeromg sty (310), & 1 \ Sunman + 310)) & 2. Repair in the Vehicle 11) 8&3 Check and Repair 14) 83,1 Check the W oie § Status of Exhaust! (15) 832 Check the W osking Status of Turbocharger (15) 8.3.3 Measure the mpellerShaftA xial C learance G15) 8.3.4 Measure the Rotor Axial Cleamnce . (316) & 3.5 Measure the mpellerShaft and Bearing Clearance-- (316) 8.3.6 Measure the RotorRadialCleamnce + G16) CHAPTER 9 SYSTEM (17) 1 Summary - GI? 9,2 Repair in the Vehicle vs+tssrssessseesscetsescereeeteerestescosstenteenecenessensens (319) CHAPTER 10 ELECTRIC SYSTEM 2) 10.1 Battery - (22) 10.1.1 Battery - (322) 10.1, 2 Electolyte Canpound 22) 101.3 Battery Chawe + (324) 10,14 Detect the Capacity of Battery z (326) 10.2 Starting System ~ (327) 10.21 Summary : (27) 10.22 Repair in the Vehicle -+ serseees (828) 10.23 Repair Single Part - (330) IxMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 10.3 Changing Systan -- (338) 1031 Summary 38) 10.22 Diagnosis - : (38) 1033 Repair in the Vehicle G40) 10,34 RepairSingle Part ++ (aay (353) CHAPTER 11 EXHAUSTING SYSTEM «- V1 Suman oa 1. 2. Repair in the Vehicle 11. 3 Front Exhaust P ipe- cevevnoentememnariecravesson GETCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE CHAPTER 1 TECHNICAL INFORMATION OF THE DIESEL ENG INE 1 1 The Canponent of the D iese! Engine Diesel engine is a kind of canplicated machine tat can transform themal energy intomechani cal energy. Although there are various types of diesel engine that have different sttcture in detail they all include followingmechan isn and systan 4 1 1 1 CylinderHead and Cylinder B lock The function of cylinder is ® close the upper side of cylinder and foms the combustion chanber with the upper site of cylinder and the tp of piston There are intake valves exhaust valves am wekers and injectors mounted on the cylinder head. There are intake and exhaust ports and cooling Jacket on the cylinder head toa The cylinder block is one of the most important parts of diesel en gine, Ther area lotofmechanisn and systmsmounted on the cylinder block, 11 2) Crank and Connecting—Rod Mechanisn The cmnk and connecting rod mechan isn can transit the 1ecip wea ting motion of the piston in he cylinder into the wlational of the cmnkshaf ie ican Uansil he pushing fre on the piston by; bumed gas in; rotutioal pique of the crinkshaft it can also tnsit-the sowtinalmotion of the crankshaft inte ‘thé \18eiprecating motion of'the piston) i(e/ it tnsitthe wafional wigue of |thy ceninkstiaft into, the push ing force tol the piston’ so that it can make ‘he diesel engine achieving eyele of operation with output by crankshaft The ernk and connecting md mechanisn is mainly fomed by such camponents as pistons connecting mds crankshaft flywheel ete 11 3 Valve Mechanisn and Intake /Exhaust Systen The function of the valve mechanisn and intake /exhaust systm is to open and close intake valves and exhaust valves in tina guarantees more fresh and clean air could be absorbed into cylin der in time so that exhaust gas coud be pushed out of cylinder ih time asmore as possble The systm is mainly fomed by intake and exhaust valves tansm ission mechanisn (such as drive gears cam shafy tappets push mds rocker shafy am wckers), air cleaner and intake /exhaust ports In the air intake /exhaust systan, the EGR valve is equipped which being used to re—cycle the exhaust gas in this way the NOx can be contwlled efficiently 114 Turbo—Charging Systan The function of turbo—charging systan is to use the energy of exhaust gas to canpress he air com ing from air filter thmugh the trbochawes and then send the compressed air into the cylinder Although the volume of cylinder does not change the air density of the turbocharged has been in creased actually and the capacity of the air has been increased toa In this condition more fiel in Jected into the cylinder can be bumed completely; and then the ou‘put of the engine will be in creased. Usually turbocharger consists of air in take /exhaust system and exhaust— gas turb ine— char gig systan eta.MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 115 FuelSupply System The function of fuel supply system is to inject fuel ino chanber regularly at fixed tine fixed quantity and fixed pressure acconting to the working condition of the diesel engine so that providing fivorible condition for ensuring the diesel fuel could bum canpletely At the same tine the fuel supply will be adjusted autmatically by electric control unit (ECU) acconting to the load of diesel engine ensuring the speed of the diesel engine constantly. ‘The fuel supply system mainly consists of fiel unk ‘tel filter transfer pump. high—pressure fel pump, injectors high—pressu fuel mil high— low pressure fuel pipe various sensors ECU, various actuators connecting hamess ete 11 6 Lubrication Systen W hile diese] engine working the surface of crank and connecting md mechanism and other moving parts will occur friction and create wear So the function of lubrication systan is lubricating moving parts surface ducing friction resistance and weax and taking off the heat ofmoving parts cleaning friction surface and seal the surface The lubrication systn mainly inchdes oil stainer oil pump oil filter oil md iator ete, 117 Cooling Systen The function of cooling system is tp take off the heat frm the hot parts while the diese! engine working keeping the tmpem tue of diesel engine at nomal state Cooling system mahly consists of water tank (rdiaiod, water pump, themostat fan eta 11 8 Starting Equipment ‘The function of the starting equiament‘is to, tum the dieselengine by outside force, fran-st{e ning ing/state “The, starting’ spare eee inchidés $tarter battery and other elu ments: 1 19 BGR Systen BGR system (i e ExhaustGas Recirulation System) inducts suitable quantity exhaust gas into inwke manifold form ixing with fish air to duce exhaust emission contamination NOx The dilute fresh air decreases the cambustion peak temperature so that reducing the exhaustNOx Itmainly consists of EGR valve assamb i; EGR cooler vacuum regulator ete, Asmentioned above cylinder bock cylinder head crunk and connecting— md mechanism, valvomechanisn and fuel supply syste opemited together » direct complete the working cycle of diesel engine and tansit themal enewy into mechanical enewy. The technical condition of these components w ill directly affect the perfomance of diesel engine A Ithough the lubricating system and cooling system do not dict camplete working cycle of the diesel engine they are he necessary fac tor that could make diesel engine working for longer tine Moreoves the starting equimment px vides the initintive condition make the diesel engine sunning fim static stateCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 2. The View of the Diesel Engine 1 2 1 Front V iew of the D iesel Engine Figure 1—2—1 shows the fiont view of GW 2, 8TC tuibo—diesel engine 571 My 281 Flue 1-2-1 Front V iey of GW 2, 8TC Turbo—D ese! 1—Damped pulley) 2—Geneming 3—W ater pump pulley 4— Inspection caver 5—O il ump (Alum imm alloy)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 12 2 Rear V iew of the Diesel Engine Figure 1—2—2 shows the rar view of GW 2. 8TC tusbo—diesel engine 2 po hTIP [ 7 o of . A o LF 5 Figure 1-2-2 RearV lew of GW2 8TC Turbo—D level Engine | Cooling water conduit weliment 2—EGR cooler 3—Cylinder head 4—0 il filter 5—Oil cooks 6—Cluteh assamb ly 4 GS\RER MM Bil sls Ae ao ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 123 Left V iew of the Diesel Engine Figure 1—2—3 shows the left view of GW 2, 8TC tuibo—diesel engine = OF) ie Figure 1—2—3 Left View of GW 2 8TC Tuiho—D iesel E: 1—High presaime fiel pump, 2—High pressure fie! sail (common mib; 3—Intuke manifold; 4—High press oil pipe S—EGR valve assembly 6—Oil dipstick subassamb lyMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1 24 RightV iew of the Diesel Engine 2. 8TC tuibo—diesel engine Piguie 1—2—4 shows the right view of GW 552 Figue 1-2-4 RRhLV lew ofGW2, STC Turbo—D ese | 1—0il inlet pipe of urbochargee 2—Turbocharger assemble 3—Campressorhallee 4—W ater inlet pipe. 5—Oil etm pipe of vacuum pump 6—Oil etm pipe of urbochawer ngineCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 2.5 Vertical V iew of the Diesel Engine Figure 1—2—5 shows the vertical view of GW 2 8TC turbo—diesel engine Figure 1—2—5 Vertical View of GW 2. 8TC Turbo—Diese] Engine I —Generiog 2— Intake connecting hose 3— Turbocharger assembly 4 —Exhaust e how: 5—BGR cooke 6—EGR valveDIESEL ENGINE TURRO 80 MAIVTENANCE MANUAL OF GW 1 3 Characteristic Curve of the D iesel Engine Figurel —3—1 shows the overall power test curve of GW 2, 8TC turbo—diese! engine (are) 2H Cues) 28 ld mo 3300) 1500 1000 a (piminy OvemiIl Paver Test Curve ofGW 2. STC Tuibo—D ese! Engine Fieurel —3—1 Fuel consumption mate (g/kKW > i Effective power kW ): Pp in) Fuel consumption ((c Effective tomue (V+ m) G MeCHAPTER | TECHNICAL INFORMATION OF THE DIFSEL. ENGINE, 1 4 Technical Parameters and Specifications of the Diesel Engine 14 1 Technical Parameters of the Engine Main technical panmeters of GW 2, 8IC tuibo—diesel engine are shown as Table 1—4—L Table 1—4 Main Technical Parmeters of GW 2. 8TC Turbo—D iesel Bngine Tian Unit “Technical parm eis Model GW 2, SIC Inling 4—sttake water cooling eleetrie conto ed Type of engine high pressie fuel common rail direct injection, tur bocharging Type of con bustion chamber Quadrangle with shrinkage periphery and w type Cylinder number 7 Cylinder bore mm a8 Piston stoke mm 12 Compression ratio 7st Toil displacement cL TW Finng orler _—3— 1— Ralal power/speed Ythiny | |) 7) Asoo - ( Max Tonjue /spead Ne m/triniy | 225£5 /1600~<2600 — = = Min fuel consump tion rate gAW+ h < 218 Idle speed rnin 800 +30 Max no— load speed vinin 7200 Max explosive pressure MPa 120. 5 ee © | <0 an eran Lubrication way Pressure and splash compound lubrication Oil capacity (sump capaci L AG When wash or replace oil filed Oil pressure of main oll passage kPa = 100 al Mle > 441 at 2000 rm in Cooling | Fored eyele water cooling: Netweiht ke = 240 Dimension (L XW XHD mum 655X571 X78MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE The oil and coolant used by GW 2, 8TC tu1bo—diesel engine are shown as Tab k 1 —4—2, ‘able 1—4—2 Specifications and Technical Parameters of O il and Coolant Used by GW 2, 8TC Tuibo—Diesel Engine Tew Technical param elers O light dieseloil (choose —10" or —20°, —38" light diesel oil in winted eaieinietst id ing to GB 252—2000) Cac Guide of oll Choose class APICI—4 lubricant (oid acconling jo envimamental impem tire Coolant ‘Antiliceze und anti— mst coolant The main parts echnical pammeters of electrical systam of GW 2 8TC tibo—diesel engine are shown as Table 1—4—3. Main Parts Techn ical Panmeiers of E ectrical System of GW 2, 8TC Tuibo—Diesel Engine ‘Table 1 Ten Tne Technical paren Model 12V 9A. Gvith vacuum pump and inner regulatod Nom inal voltage 2 | Raed opment \— aA 0 | Paver [| Ww. 1, ogo fi : Rated speed vin 000 ~ ~ Genenlor Working speed rimin 900-11, 000 Routhg directa Clockwise (ee flan font wad Pole Nesative pole ervund ing Working sive Continucus mated sivle Roguliting vollage of 7 mea regulator W ork ing style Continucus med sivle Working speed niin 10, 000 Vacuum pump | Max vacuum degiee kPa 90,7 Aniving te r vacuum fies 5 Aniving tine of 66, 7TKPA<35 (1, 000 rf iv degive Model T2V ZEB RW Voruge v 12 Storr Power ouput Ww ZB Rowthe direction Clockwise (ee fam the direction of tie small gead Bate | Rated volige | v 12 4 Ii 7a a8 A) Gl tes FS BR Zi) 10 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 4 2. Tightening Tomue ofMain Tighten Parts of the Engine Tightening tomue ofmain tighten parts of GW 2 8TC turbo—diesel engine are shown as Table 1-4-4, Table 1—4—4 Tightening Torque of Main Tigh ten Parts of GW 2. 8TC Tusbo—Diesel Engine Name oF tghin par’ | TMARRREHMET Name orvahten pat | TeRBNTE Hrve Camshaft pulley flange transi “yoy " = ase2075 tional wheel tightener 100~120 Bolts of cranksha ft pu lley 195 ~225, Bolis of cam shafl tm ing pulley 1843 Bolts of flywheel 120~130 Bolissot tet piessite diel aay lots Bolts of injector eampressor sheet 2~30 timing pulley wasn bly Nuts connecting high pressure Bolts ofmain bearing housing 170 ~180 fue] pipe end and high pres ig22 aire fuel mil end Nuts of connecting md 80 ~90 Bolts of valve adjustment 15~21 Bolts of high pressure fuel punp 65—75 Bolts of EGR cookr air outlet 2045 pulley ibe mo up canneotings the “high, pres Z } ti 9 jolts of turbocharger, oi] ietum je Mele ne ee ai pe 22a ie we cht ; (oO figs Nuts connecting high pressure ~ ~ ~ ~ ~ ~ fuel pipe end and high pres 25~29 Bolts of themastiat lower housing | 20+5 sure pump end Bolts of cylinder head 100~105 Bo lis of themostat upper housing 20+ 143 Main Adjusting Data of the Engine 1431 Vale Timing Intake valve opens at24 BTDC (crankshaft tum ing angle) ; Intake valve chses at 55° ABDC. (crankshaft tuming angle) ; Exhaust valve opens at 54° BBDC (crankshaft tm ing angle); Exhaust vaWe closes at 26° ATDC (crankshaft timing angle). 1432 Valve Clearance Intake valve ckarance (cold state: 0. 35mm+0. 05mm: Exhaust valve clearance (cold state): 0, 4mm +0. 05mm, 1433 Max tiel supply pressure of high pressure fel mit 145 MPa, 1434 Fuel injection onler 1—3—4—2, 1435 Fuel supply advanced angle ¢ CA BIDC): automatically conuolled by ECU Ccamputed .MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 14 4. The Range of Various Tanperature and Pressure of the Engine The mange of various tempemture and pressure of GW 2 8TC tuibo—d ese! engine are shown as Table 1—4—5 Table 1—4—5 ‘The Range of Various Tenperature and Pressure of GW 2, 8TC Tusbo—Diesel Engine Tam Tanpewure mange Ta Pressure Tange Cookint outlet tempenanre off . soc +50 Idling oil pressure @. IMPa cooling systar! OT epee of bbseaths = Raied routing weed ofl pres | 35g gaara Note @ The coolant tmpemture of closed pressing water tink system can be up 105C. 145 Main Fittings Specifications of the Engine Mani fittings specifications of GW 2. 8TC tuibo— diese! engine are shown as Table 1—4—6, Table 1—4—6 Main Fittings Specifications of GW 2. 8IC Turbo—D iesel Engine Sysiem and con ponents Speciticalions Type of oll pump Gearhg iype Lubrication system ‘Type of oll filer |) | 7 Rotayy Hsia liation i y Type of fel file? ““—~ Rotary instalation with fiel—“waleescpan ioe BOSCIT CPIM ype axes nm— ype pumps magnet valve control with gear fuel punp BOSH IWR ype maximum hel supply pressie 145 MPa Hish pressure fuel pump Fuel supply system High pressuw fuel mil Type of injecor CRI2 0 ype Gorifice with six holes) GametGT22 orM itsubishi TFO3SHM type highest Inzike system Turbocharger : oe speed 180000 r/min maximum pressure ratio 2 Type ofwater pump Centrifugal Water pump ling head 000 efi ™ Cooling systen Type of hemosat Wax wpe hemostat Silicon off chsh and phate fn direct pintor ‘Tiel in unattached electric fin Picheating plug woluge -12V Specifications of sarer 12V, 2. SkW Electric system Specifications of altemator —12V, 1080 W Aliema ine wtsie direction — Clockwise (see fium the end of crankshaft pulley) fe Te ES It PA a A) ll is SB 12 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 4 6 Main Parts Specifications of Fuel Supp ly Systan of the Engine Mani parts specifications of fuel supply sysian of GW 2. 8TC turbo—diesel engine are shown as Table 1—4—7. Table 1—4—7 Main Parts Specifications of Fuel Supply Systm of GW 2, 8TC Tusbo—Diesel Engine Part name Medel Tastallation position ‘Speciication High pressure fiel — Rearend airice of BoscH CPL Axial3 nm — pump pulley chamber eae renee eae Top surfice of cylinder Nipple 6X0. 137, sonsitiviv’ of angeeiea Bes head magnet valve 0, 2ms Bo Left side of cylinder High pressuwe hel rail) Leser—wekled LVR) Oil supply pressure 145 MPa Elecitic contol unit | EDCI6Ca9 Inside helmet W orking voliage 12 V Upper partot fywheel Spood senior DG 6 housing W osting clearance 0, 2~1, 8 mm ‘Ouiside of pulley chan Cam shaft phuse sensor] PG & 8 therseap, W oncing cleamnce 0, 2~1, 8 om Rated voltage 5V 20. 15V, mated wsistance 2 5k2 £0. 0% for Water umpemtue Lower housing of themo TE Ww NTC type at 20C », mied arp eC) |) resistance d, oskO 2% fr | ~ ~ — NTU iypelatsooe? \ W orking volmige 7%. 5V~17. OV, Alr flow sensor HM 6 Air inlet of compressor floy measuring range 40 kg /h~ 64D ke /h High pressure fiel mill Front of high pressure Resistunce ype output. 5V~ pressure sensor fuel mil 45V wollage Pedal position sensor | FPM Inside cabin Voluge of power supply 5V surlhce of @linder Keeping consunt unpewure Pisheatiig phig OSK2 oo ‘of cy lind: ey 1 consiant tan pe w tu BGR vane 7 0006 OT Rearpant or nktphe | Vaciun bpe W ih manual diel pamp, oil—wa ler sepamior diesel heater (Now Fuel filter BOSCH Carrer nite 125 L/h), papery filter ele ment particle filtering mtio >15 um 100%, 3~Sum 94, 5% 14 7 Main Parts Fitting Clearance and W ear Limits of the Engine Mann parts filling clearance and wear limits ofGW 2, STC wiho—diesel engine are shown as Ta ble1—4—8,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Table 1—4—8 Main Parts Filting Clearance and W ear Linils of GW 2, 8TC Turbo—Diesel Engine No Fitting parts Fiting Clearance or supls mm) ) Wearing Im its (nm) y | eee foe une) Cleamnce 0,039 ~0, 071 0.20 inlet valve sien Vale gale nner hok 2 ubveypuide cnnerbo bead Clearance 0. 064 ~0. 096 0.25 exhaust valve slem Rockoram how and eke] = 3 | am shaftdimeter les sate 0.01 ~0. 05 Cylinder liner inner diame learanee ~0, 055 2 | eran econ fle Clearance: 0. 037 ~0, 0 at 5. | Tappethok and wppetout | Ca ance eso a erdimerr The 1% ring grave height i Cleannee 0. 078~0, 137 and ‘he 1°" ring height The 2"4 ring gmove height . ; 7 Clearance 0, 055~0, 095 015 and the 2"4 ring height Oil ig giowve hewht and ince 25~ 5 Bee bee Cleunne 4. 025~0, 07 at \ 1 1 20040 1. 50 W Ber be piste rhs ry\oo ee ot a (placed inside, 93am \ IL 060-0. 851 + 50: ring’ gduge) e it — = — sas th 0 35~0.65 1.50 Connecting md little en 1 | Commetiia— so e) Clearance 0. 008~0, 020 4.05 bushing hole end piston pin Wl Pion pi seat hoeiand Clearance 0. 002~0, 015 0.03 piston pin ‘Crank pin Jpamal and con i ~0. 291 1 35 2 | ee Axial clearance 0. 290 a3 1g | Cena bearmeand mt encase 0. 015~0, 085 112 shaft joumal 14 — and ofl sealing | 4 xigl clearance 0, 075~0, 145 0. 30 Connecting — wa bie end 15 | bore digmeterand ennk | Cleamnee 0. 029~0, 075 0.10 Pin joumal 15 | Main bears bore diet] Ces mnce 0. 033 ~0, 079 ou and main crankshaft jou mal 7 | Thnst ckamnce of emnk | eaance Lee 4.30 shaft 18 | Rotwrof tibochawer ‘Axial clearince =o 0 AN 14 fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 15 Maintenance Standard Diesel engine works nomallymeans that the consumption of fueland lubricantmeet original de sign requirement can output design power operating moot and stably without abnomal noise Eveuy exceptional cies concems with fitting status ofmovable fitting parts of the diesel engine Dur ing the assembling of each moveb le fitting parts the technical requirament is very strict parts geo metrical shape fitting clearance surfice ughness and cleanness should be up to standart W hen assembling countearts ensure fixed precision please the most inportant is the fitting clearance Too snaller clearance will cause operation retrlarea bigger friction, heating and even lock too wer clearance will cause noise impact difficult for fom ing lubricant oil fin and shorten parts life The utilization tine lin itof the diesel engine assembled through strict assembly and ninning in will be depending upon excellent maintenance The size and utiliation limit ofmain parts are as shown as Table 1-5 —1. Table 1- The Size and Utilization Lin it of Main Parts of GW 2 8TC Tuibo—Diesel Engine Part name Tian Standard Uiilwation Init] Ranark Phneness between cylinder heed plane and exhaustman if mm % 28 Cylinder | Cylinder head height 91, 95 ~92, 05 Cannot be head _ - regrinded Warp of cylinder head bom phne =08 0 20 Wap of lake moanifoll plae 020 f \ f Free heightmm wy T 47. Ha | installation Valve spring) Pempendiculriy am = LT height is 38, 9 mm Spring stain N 296 27. 9 Vahe sun dimenr | ke whe | 7 946~7, 961 7 880 oa Eshaust vike| 7, 921 ~7, 036 7, 850 Cleamnee of wie ana| Intake vake | 0. 039~0.071 a 200 mabe suite Exhaust wake 0 064~0, 096 250 Upper end helsht of valve guide ton bo _ ‘upper plane of eylinder head) mm. a Valve and valve gide | Surplus of valve gulemm = 6 Tnlake valve 79 150 Vane thickness mm Exhaust vale 783 750 Vahe seat notice ange (deem ® = Vane seat inierfice | Intake valve at am soitinae Exhaust vale 20 28 Push md Cambermm iMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Continue) Part mane Tan Sandan! Tilman Im] Renate ‘Axil eleamineemm 0 075—0, 145 025 Cam heghtmm 2 Tl, & Toamal dian ete ram F945 a0, OB B60 Cam daft Radial Ampiness mm =0e a1 Cam bearing inner dimetermm 50. 000~50, 030 50. 08 Cam daft play mm 0, 025~0, 085 0.120 Extemal diametermm 12, 97 ~12. 99 12.95 Tappet Pe ; yy (beween tappet and cylinder a block uppet hol) mm fosto Teo 50500 iiems 5000 im 12, 500 km | 100, 000 im 5 é 5 ne oF ho) RP RCE bel | Gow proveasienal aay mea Checking the enpearnce ef Wel somal be | mainknance st i every 80 000km)| tion for repairing Replice tights ner und ten sitin wheel Tightener and tun ae depending on prectical eon dition when rephicing belt W ater pump Check water leakage of overfill hole Check wite connecling genera Bleetrie equisment torand sturer Ventibtin systm of] Check and clean comnk shalt ease and clea Clean cooling Clean cooling system accord ing| \ Sysiom to technical requirement A 1 1 i fF f (Clean édibon "oil Girt water i 3 emstation oil pat -oll pipe) — se Clean diese engine Pi iston the ‘Check wom condition Cylinder ‘Check wom condition Connecting — od ” Check wom condition bearin 7 Acconling diesel Mam shaft bearing Check wom condition engine s working, __ cond ition oe Check wom condition Thmst phic Check wom condition Air intke and Check wom condition exhaust valve ‘ck wom cond iio 16 2. TechnicalM aintenance Contents In omer to ensure the diesel engine can work nomally, you should take technicalma intenance as flowing process during your utilization 1621 Daily Technical Maintenance () Check ng diesel oil (fued, coolant (see Figure 1—6—1) and oil (lubricating oi) levels (see Figure 1—6—13), refilling them accond ing to specification if necessary. Y Attention Only the engine stopped, you can comectly check every liquid level fe Es 1 YW a iG Fe Sl ‘reat Wal Bading Interval anbusto Engine Comperytintes = 1DMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue 1—6—1 Checking Cooknt Level of Refilling W ater Tank (Only for wference) Figure 1—6—2 Checking Elecunlyte Level of Battery Figure 1-6 Equipmens Checking Electric y Hames Joint Specificalion for diese] oil CiueD: The specifica tions prescribed by GB 252—2000 are 0° light diesel oil in summer —10° or —20" light diesel oil for south em ara in winter Gwam area and —30" or —35° for northem area in winter (cold area). \Y Attention Forbidden refilling fel into fuel tank during diese! opemtion Don t filly refilling fuel tank at fervent summer to avoid fue! overflow ing caused by heat expanding or expunge the overflowed fuel oil inmedkttely. (2 Clean the dirtor electiolyte overfiowed on the battery, keep breathe hol free In nomal condition battery needs not maintenance But if tampemtre is very high you should check electmlyte level for sane tine Electwlyte should be the level between and Mix marked at the side of battery (see Figure 1—6— 2. If the electmlyte is not insufficiency you shoud fill in distilled water YY Caution Don tadd dirty water and other liquid inlo the battery ofhenvise the chawging will not be nough-and~its using. will bevaffeeted_ If battery, liu | level falls Kown|quickiy | your shouldimake it repaired, at the maintenance station. — _ i VY Waming ‘The acid liquid of batter is conpsive Don t let it splash t your eyes skins and clothes Using waler forwashing if'acil liquid has splashed © your eyes, skins and clothes (3) After started diese Longing you must check if there is oll leakage water leakage gas (aid leakage or electricity leakage If there are “fur leakages", you must treat it in tme (A Checking the statis of every accessory device ekctric equipment ECU and every hamess joint (see Figure 1—6—3). (S) After started diesel engine check if diesel engine works as usual and check meter if the meter damaged, repair it or replace it in tme (6) Keep diesel engine clean ther should not be dirt or oil on electric equipment also there shou not be othermatter on the radiator (D Check and tighten the connector between tur bocharger and diesel engine Ranove the toubles of oil and gas leakages eta Keep the surface of tithocharger clean » QEBSEAIM ERM Za Malang eral Conbston age Naf Company LinedCHAPTER | TROHNIC Lt FORMATION OF THE DIESEL ENGINE Figue 1—6—4 Checking Transmission Belt Tighiness Degree Fieure 6—5 Grind Valve and Vale Seat cnr Lubricating 0- ‘T Anlifreeze and Battery fanirust liquid Flue 1-6-6 Used fr Diesel Engine in W inter YY Caution Assambie and clean te air filter every day if diesel engine working in the envirementwit heavy dusts Keep air filter in good working cond ition 1 6 2.2. The FirstG rade TechnicalM a intenance Canp ting daily technical maintenance A fter diesel engine have worked 100 hours or nun for 4, 000 5, 000km, adding maintenance listed below. () Checking clectmlyte gmvity or voltage of the baller. (2) Checking and adjusting drive belt deflection see Figure 1—6 —4, (3) Clean air cleaner () Checking the tighmess of every bolt and nut 1 6 2.3 The Second Grade Technical Maintenance Conp ting the first grade technical maintenance After diese] engine have worked fr250 hours or mun for 10, 000 t 12, 500km, add ing maintenance listed below (for new diesel or the dieselafier the third grade tech nicalmaintenance the first time carry out the sec ond gride technical maintenance shoul be ahead of schedule that after ithave worked for 100 bours or mun for 4/090 yt0 5, 900 km) ¢ C \ (D- Replace ‘the oil inside oil sunp. (Replace fel filer elament Thoma lly after mn fr25, 000 t 30, 000km), oil filter element and air fil ferclement (3) Checking valve clearance adjusting it ifnec essay: (@ Checking the overflow hole of water punp, if here is water leakage frm overflow hole please replace ‘he water puna, (5) Checking the connector of electric equ iment and every hamesg bumtwire should be replaced. See Figure 1-6-3, (® Chen the furring ih cooling pipe and mdiator (D Clean crank case ventilation system. 1624 The Thirl Grade Technical Maintenance Atnomal condition apart fion canpleting the sec ond guide technical maintenance after diesel engine have worked for 1, 000 hours or mn for50, 000 to 100, 000km (nomally for every 80, 000lm), replace ti ing tansnission belt checking transition wheel and tighie ner and clean whole cooling system please Adding fol jowing maintenance if necessary accom ng to practical slag fe TE EE A A) Bl is SB ‘Great al Baoding lterral onbuston Engine Mareecturing Company Limited == 21MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (D Disassemble diesel engine clean carbon, oil GB 252-2000 light diesel oi] (fuel) dirtand furring clean all oil pipe and oil hol, (35% light diesel ol (® Check forwom of connecting surfaces of valve, pushing od and socker repair or seplace than ifnecessa =20" light diesel oil me (3) Check forwom of piston ring cylinder liner or ight diesel ofl connector mall end bearing and big end bearing Re place than if necessary. () Check forwom of crank bearing and thst () Check forwom of cam driving geas finn Loil sealing and axial clearance of camshaft tansition wheel unit and tightener unit @ Check forwom of intake /exhaust valves and their seaty cany out the repair or mbbing (See Figure 1—G—5) and leakage testing Replace than if neces 25 “55 Boviconmental temperature for diesel engine Flaue 1—6—T Choose light Diesel Oil FueD Accor ne © Envinemenu! Tenperure Cle grade diesel cugine oil (lubricating oil) or sam higher grade produced by Exxon Mobile Corp, @ Checking oil pump, disassembling and chee ae | king easy damaged parts and adjust then, es (8) Checking cylinder head gasket and manifold SEEN gaskes replace them if necessane = es ee (M) Checking allemator and strley clean parts and oe EE bearings refill lubricating grease checking starter gear Ea TOS ee are | — OE Wom check tnnsit equiment frmoving snoob, PA a) 32 Sn yog 86 ton pe |) Environmental temperature for diesel erfine 1 62 5) ‘Season Tdohnica! M bintertantce (D7 It is suggested Mat before winter cam ing every Figure 1-6-8 Choose Lubricating Oil yeas you shoud! replace antiffeee and anti—must liquid Accorl ng ty Envimeamentt] Tenpem tre fiom cooling systam, (2) When enter into wintes you shoul choose suitable fuel (diesel oi) bmnd acconting © enviromental tempemtum see Figure 1-6 —7. (3) When enter into winters you shou choose suitable bricating oil forw inter see Figure 1 6-8. () Change consistence of electlyte accord ing to different season 16 3 Technical Maintenance of A ir Filter The function of air filter is to filter the dust and impurity etc in amosphere for avoiding abra sive wom happened to the eylinderhole piston ring and valve air valve and air valve seat There fore the air filtermust be provided high filter efficiency Absolutely forbidden GW 2, 8TC turbo—diese! engine witout air filler It could easy damage the airflow sensor and the diese! engine cannot opemte nomally with damaged airflow sensor Bob oil bath air filterw ith inertia steel wie villus filler element or air filler with paper filler el ment can be used forGW 2 8TC trbo—diesel engine accorting to p mactica] utilization requ iran ent Air filterwill not be installed on the engine if it is used forvehicl, itwill be selected and installed by vehicle manufacturer The flow of selected air filter should be larger than 450m’ /a It is vey inporiant 6 maintain the air filler regularly. If its not been maintained in tme itll be block up by dust The resistance of air intake will increase, this will cause heave smoke power filling and early wom of engine 29 (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1631 Maintenance of Oil Bath A ir FillerW ith Inertia Steel W ire V illus F iller Elen ent In general for every 4 000 ~5, 000km running of the vehicle equipped with diese! engine clean the oil bath air filterw ith inertia stel wire villus filter ement please The tines of cleaning may be ad usted accord ing to dust density of environment When cleaning fetch he steelwite villus and put it in the petwl for cleaned, then blow itdried by pressing air Clean oil pool of air filter meantine then fill propernew oil in it 16 3.2 Maintenance of A ir FilterW ith Paper ilter E lanent In general for every 4, 000 ~5, 0U0km running of the vehicle equipped with diese! engine dust on the shell of air filler should be cleared away and filler elanent should be cleaned (1) To clean the shell and cover of air filles when technicalmaintenance is laken or air filter elanent be changed, dust on inner of shell out cover and surface of sealing gasket should be cleared away cleanly (see Figure 1—6—9) . (2) To clear the filter elament when te filter elament is polluted by dust and is in dried con dition pressed aircan be used for clearing (see Figure 1—6—10). When clearing blow the dust fiom inner to outer of the filter elment by pressed aig rotating the filter element at the meantine ‘The pressure of pressed air should less than 490 kPa, Y Caution Don t clear the filter ekment fiom outer to inner by pressed air If so the dustwill go int inside of the filter ekment Rephice the filter elanent if Bikwing. situations happengs \ (the sihtet elanent is polluted by chateoa] and oil (2) The filterelement pollited heavily, dirty can not be easily cleared, () The filler elonent wamped and damaged. Pique 16-9 Mainimance of AirFiter ——-W/ Cautio () Air filterwith paper filter elament shoul not be cleared by oil or wates othemvise the dust will be stuck on it easily and filter elanent will be blocked. The engine s power output will be dropped down and heavy snoke exhausted due to the lack of air intake (2 The sealing of connector between air inbke pipe and air filter should be oflen checked, IPany leak age exit the trament shoul be adopted immediately such as replace sealing gasketand tighten the connector to avold abnomal wom of the diese! engine 164 Technical Maintenance of Fuel Supp ly Sysien. 1641 Technical Maintenance of Fuel Filler Fuel filler is installed at the loy—pressure fuel pas sage Diese] oil enter into filler then is pressed through fe Es 1 YW a iG Fe Sl ‘reat Wal Bading Interval anbusto Engine Conperytinites §=— 23. Figure 1—6—10 Clean A irFilier # lamentMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE flllerelanen} thus inpurilywill be cleared away Diesel oil afer filtered will enter into fel transfer pump on high—pressure fuel pump, GW 2, 8TC turbo—diese! engine adopts whirl—styk fuel filter Replace the fuel filterafter the engine has worked for 500 hours or the vehicle mns Or 25, 000 b 30, 000km, When low quality diesel oi] has been used by the diesel enging the replace period should be ahead of schedule please replace the fel filter after the vehicle run Hr 10, 000 t 12, 500km, ‘The rep lace method of fuel filter are as following (1) Clear the outside surfice of fuel filter assonbly thowughl: Grip the fuel intake pipa (2) Loose and disassemble the filter ekment by wrench or proper tools () Ensure that the screv connector is lightened on the filler seat and the inner of the filler seat is cleaning ( Lubricating new sealing ring with @ little clean fuel Screw the filter elment into the filter seat by hand until you feel the resistance. (S) Tighten the fillerelenent by wrench Open ftel passage and check the leakage (G) Remove the air inside the fuel filter 16 4 2 Drainage of the Fuel Systm Examplify a diesel engine for vehicle here W hen water level inside fue!—water separator rea a ches to the dangerous level the indicator mp of fuel —water sepa mtorwill bright (assanb led on the vehicle ‘ea panel see Figure 1611). é o> SY tater tion, During the opemtion-of the de’sel en, | “ging \the-and calor’ kmp ‘of! fuet— water “sepametor b nent ‘Drevermeans that the water inside fiel—watér sepam tor shou be drained out Figuet—6—11 IndicatorLanp of Fue]l—W ater SepamtorW ater Level W ater drainage method for fuel—water sepamior () Stop your vehicle on safety and flat place (® Open the diesel engine bonnet and puta con tuiner (content is about 0. 2 L) under the water drai ning plug p pe end of the fie]—water separator (3) Loosen the dmining pg in counter clock wise Opemte manual fuel— supply pump of fiel—wa ter separator up and down by hand to dmin off water (see Figure 1—6—12), until fuel fill h the fuel—wa. ter separator filly Loosen (4) Tighten the draining p hg clockwise afler wa 7 terdrained off then press manual fuel— supply pump ss vm) up and down fr seven! tines (see Figure 1—6—12). (5) Starting the diesel engine and confim ing no oil leakage atd mining plug and checking the indicator lamp of fuel—water sepamtor if it is un—bright at the sane tine Figure 1—6—12 Fuel Filler 1 Filter ement 2—Fuel inlet connectin. 3—Mamal iuel—supply pump 4—Fuel out let connection 5 — Electric connector 6—D minage p ue 24 GS\RERER a al il is ER ral Contin ie Naefctng Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE Y Attention Ifwaterneed dmined off frequentl, itmeans that the fuel used is not camply with requirenent or specificatin, W ater exited in fue! tank should be drained offat themaintenance sewice station 165 Technical Maintenance of Lubricating System 1651 Choose Lubricating 0 il The choice of lubricating oil for the ibrication system of the diesel engine should accord to the envirormental tempemture (see Figure 1—6—8), YY Caution Don tuse lubricating oil with different brand or different grade 1652 OilLevelMeasure Oil level inside oil sump of diesel engine ismeasured by oil dipstick mounted at the left side of diesel engine (see Figure 1—6—13), Sip he vehicle on level plane and then stop the diese! en ging afteroil getting still pull out the dipstick clean the oil on the dipstick by clean cotton — clot then re— insert the dipstick into oil sump and pull out dipstick again for checking oil level There are wo holes on the dipstick (see F gure 1—6—13). Oil level should be not bwer than Inwerhola because in this case oil level is lower than oil stminer so oil pump could not pump oil inb oil port Oil level also should be nothigher than upper hole because in this case crank may sirike oil when crankshaft mnning there will be lot of ofl brame or oil splashing hh crank case and cylinder liner more oilmay be bumt in chamber and there will be a lot of carbide on the top of piston and in the chamber piston ring may clogged, diese! engine willmect sme trouble such as exhausting black yoke”, causing oil -sea ling teakage-and increasing oil consumption-andsoron, ‘Therefore, apart fm natize the ol} presi you/are jlso needed t check oil vel’ before you want tb dtive vehicle go dut or your Soh has man for'eveiy 400 to 500kn.. PS V Attention Check the oil pressure when the diesel engine is ninning before mnning your ve hicle and check the oil level at any moment 1653. Replace OH Oil and Use New Oil After long tine operation there will be mpurities ordirt insite oil due to same fuel didn t bumt conpletely so thatmay cause oil get thin and also sme exhaust gas may cause oil deteriomted and cormpt parts at the same tine Therefore after operation hr sane tine (for exam pla vehicle sunning for 12, 500 km), you should drain ‘out all of the off fill new oil into oil sama Method for oil rep acing () Pkice the diesel engine or the vehicle on level position, Upper hole (2 Running the diese! engine until its oil tan pemure up wo 80C, then stop it (3) Place an oil sump under the diesel engine rmove the oildm inage plug and drain out the used oil (@ Use new gasket tighten the oil drainage plug accor ing requinment Fill new oil into engine and check oil level using the dipstick, Lower hole: Fur 16-12 Checking Oil Level ByD pstick fe TE EE A A) Bl is SB ‘Great al Baoding Iteral anbuston Engine Marfecunng ComperyLinted = 25MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE YY Waming Be careful to prevent fim scalded by heating oil appropriate dispose the used oil and pmtect envimnment If ther area lot of impurities in oil sump you should use 5 or 7 machine oil (light spindle oid 0 clean ibricating systm during engine s mnning in ibid using gasoline or coal oil for clean When you need ckan the inside of diesel enging fill5' or7 machine oil into oil sump to the evel betyeen upper hole and laver hole of oil dipstick, disassamb le all injectors and tum the crank shaft for2 © 3minutes then drain out allmachine oil quickly After oil rphce frevey tme you should mun diesel engine without bad for short time to en sure ‘hat the lubrication systan and other places needed lubrication will get enough oil When you fill oil frm oil inlet of the valve can You should clean the oil inlet filler and forbid ding impurity and dirt into oil samp. After oil filling tighten the cap filler VY Attention Check oil evel after oil filling forS minutes because the oil will flw to oil sump through the push rd hole of cylinder head and the side hole of the tappet of cylinder b lock, 1654 TechnicalMaintenance of 0 il Filter The whirl— styl filter elenent of oil filter should be rep laced when new vehicle have mun for manning in for4, 000 lm. Then rep lace whirl— style filter element and oil after driving for every ac cumulative 12, 500 km, See Figure 1—6—14. Method for filter elenent replacing and notice i tem ¢ (D_ Put a-conts iner under the oil. filter collect Foverfiow ing ofl | | (x Ky | (Q_Disassemble the filter ekmient of oil flier u sing special spanner by counter clockw ise (3) Check and clean the oil filler seat so that new oil filter elanent can be assemble ino it exae tly. (@ When assambling apply thin coat oil on the O—vype sealing ring at first (see Figure 1 —6—15), then sciew the element into the filter seat by hand until you feel resistance Finally screw the ekment clock Fiue 1—6—14 Disassenbling and wise with 3 4 cimles by special spannet Assen ling the O il Filter (5) Diesel engine can tbe started bef you con fim that there is enough oil fh the ofl sump. (@ Start engine after the assembling work has be done check if there is any oil leakage of the oil filter Check oi] level using oil dipstick and replenish oil if necessary, VW Caution () Whirl~style filter elanent is one— tine— sing part dont ruse it ( Whirl— style filter elementmust be weplaced regularly according to technical mainlenance require ment Figure l—G—15 Repke the Filter Element of Oil Filter fe Te ES It PA a A) ll is SB 26 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE The oil pressure limited by the pressure regulator of oil filler is 0. 55MPa +0. 02MPa This valve is properly adjusted befbre the diesel engine leaving factory please do not mad just it at com mon cond ition, When disassembling and assembling the oil filtes please do not damage the mbber—sealing ting othenvise itmay cause oil leakage, Replace the mbber— sealing ring of oil filter if it has been damaged. 166 TechnicalMaintenance of Cooling Systan 1661 While nmning the diesel enging there must have sufficient antifreeze and antinist (cooland in cooling system to tke away heat and ensure the diesel engine could work nomally. Therefore youmust check coolant level before running your veh icle fill clean antifieeze and antimst liquids and let ils level between the M in and Max inside the radiator refilling water tank (small tink), see Figure 1-6 —16. 1662 Usually the usage tine limited of long —effect antifreeze and antinust liquids is | to 2 years Replace itwhen its usage lim ited at tem, When rep kt cing the antifieeze and antinust liquids you should be accor! ing 6 the requitment and then start the diesel engine and keep rotting for S minutes so that the anti freeze and antinist liquids can fully fill into the cooling system, Then stop the diesel engine and check the lev el ofantifieeze and antinist liquids if not enough we plenish han again | AY Ayahetne! df () Forbidden using untreated Hard waier such as Figure 1—6—16 Checking Coolant Level tap water orm ineral water of Refilling W aterTank (Only fr referenced ©) Forbkden using lw quality antifeeze and antimst liquids doa tmix different type antifteeze and antimst liquids t avoid part cormpting (3) For over consumption of antifiveze and anti ust liquids al first you should check heir density If the density of antifreeze and antimst liquids hasn t in creased, this means that ther is leakage of the cooling systen, move this leakage and dont mix different type antifreeze and antimst liquids If the density of antifreeze and antiust liquiis increased, this means there is evaporation and distilled water should be add ed. When added distilled water or concentrated liquid, even mix than and check the density again until it meets the fivezing point If you are without the method mentioned above, you should go w the maintenance station for checking 1663 Checking the tightness degre of pump Hier 1—“@-17 nile: belt Press belt between pump and genematorwith foree Tenens EARS of 70~80N by hand, the suitable deflection of the belt is7 # 8mm (see Figure 1 —6—17 and F igure 1 —6— 18). fe Es 1 YW a iG Fe Sl ‘reat Wal Bading Interval anbusto Engine Comperylinites = 27MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1 6 7 Technical Maintenance During Stor age Diesel engine needs twehnical maintenance only ac conling its accumulative work ing hours or accumulative driving distances if the st mge time wer less than one month Special pmtecting steps shou not be needed Special techn ica Ima intenance must be carried out if the stomge tine were mor than one month The de tails of requinment see “Chapter 7 Sealing and Unsea ling of the D iese! Engine” of this Manual please Figue1—6—18 Checking and Adjusting she Tighiness Degree of the Tringn ission Belt 1 6 8 Attention Points for TechnicalM aintenance 16 81 Usershould maintain your diesel engine accom ing tw the technicalmaintenance mg ulations by gmda by item and by quality Especially during busy tma forbidden freaw ill duce themaintenance items or freawill delay thema tenance period. 1682 The thin grade wchnicalmaintenance should be carried on in—door for preventing dust into the inner of yourd iesel enghe 16 8 3 Same strict or very camp lex maintenance itas of your diesel engine should be car ried out by professional technician or take your diesel engine w the special maintenance station of Gat W ell Beoding IntemalConbustion Engine M anufacturing Company Lim ited formaintenanee, { | i l 1/7 Running~ In ar Diese! Engine. — - = aN New orheavy repaited diese] engine (include piston piston ring cylinder liney main bearing and connecting wd has been replaced) must be mn— in frum small load to we load gradually for sane time before nomal operation By this mnning— in pwcess you cou cany out earlier chec king adjusting and maintaining and the friction surface of diesel engine parts will fitwell quickly tp avoid abnomalwear and damage Experience shows that the working lifa rlisbility and econany of the diesel engine mainly depends on running — in at its initial stages 17 1 Preparations Bere Running— In 1711 Opemtors must read this manual! carefully and be familiar with he stucturs per fomance operation maintenance and service of the diesel engine 1712 Clean the outside surface of diese! engine 1713 Check the oil level in ofl sunp. Refill ofl t prescrbed level according to technical iequiranent if necessary. 1714 Adding Wbricating greases to every required phces 1 7 15 Check and fill fuel and coolant (antifreeze and antiust liquids). 1716 Check the electwlyte— level of batter: fillelectrolyte int battery to regulated level accord ng to echnical requirement 1717 Check the tension of belt 1718 Check electric equipment circuit ECU, sensors and every hamess connectors link than correctly and reliaby. 1 7 19 Set the handle of gearbox at “neutral” position fe Te ES It PA a A) ll is SB 28 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 17 2 Running—In New diese! engine must be mun — in for2, 500 lm on vehicle accom ing to running— in regulation (see Table 1—7—1) or 50 hours on engine test stand acconiing to nunning— in regulation Diesel engine afterheavy repaired such as the piston piston ring main shaft bearng connect ing— md bearing and so on have been rep laced must be run—in forS00km on the vehicle according to Table 1—7—2 or10 hours on engine test stand. During munning— in presses you could further check the assamb ling quality of every part of the diesel engine and cary out further adjusment ifnessary Table 1—7—1 Run— In Regulations For New D iesel Engine on Vehicle Mileage of vehicle (mn) Vehicle bad Rotting speed of diesel engine (r/min) 0~300 Load flee mated speed of relevant diesel engine >801~1000 6 rated load | 50% mated speed of we levant diesel engine >1001~1500 75% med bad | < 75% med speed of relevant diese! engine STBUT~2500 Full riled bad ) Lay on thin oil coat on O — sealing ring of new filter see Figure 1—8—7. (© Screw new oil filler inside by filer spanner until the O — searing ring of filter touch with sealing surfice, fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE Figiw 1-8-8 Fuel Filter | Inlet connection 2—Manual fue) sup ply pump 3—Outlet connection 4—Filter tank element 5—Dainage pig Figure |—8—9 Indicator Lamp of Fue]—W ater Sepa miprW ater Level ( Screw new oil filter inside 1 1/4 circles again by filter spanner Filter spannes 5 —8840 —0200 —0. 5—8840 —0202—0. 58840 —0209 —0. Add itive oil O7L Start diesel engine and check the oil filter leakage or not after assanb ie 184 Fuel System Fuel Filter V Caution @) Whirl— type fuel filter elanent is one tine u sing part forbidden reusing it (2) The filter elanent should be replaced tem ly accom ing to technical maintenance requimment 1.8.41 Replacing Process P_Open-the used filler counter ciockw ise by fil (er sparinge ( Pilter spannee 58840 02530" 22700). (® Clean the fitting surfice of filter upper cap and this will suit new filters installation. (3) Screw new filter inside until the filter touch with sealing surface () Screw new fuel filter inside 2 8 circles again by filter spanner Filter spanner 5—8840—0253—0 (JI—22700). (5) Operate manual fuel— supply pump fora few times and check the filler kakage or not Y Attention, Original fel filter of Great W all Auiomob ile Campany is recammended. 1.8.4.2 Diminage Process of Fue! F ilter GW 2, 8TC turbo—diesel engine assembled the fuel filwrwit fel—waler sepambr See Figure 1—8—8 When water kvel inside fel—waler separator ex ceeds the prescribed level the indicator lamp of oil— water separatorw ill bright’ See Figure 1—8—9. Dimi off the water and other inpurity from fuel— water separator accord ing to flowing steps () Stop your vehicle on safety and flat place RECN MSGR (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Figu 1—8—10 Fuel Filter 1—Filter tank ckment 2—Fuel connec tiny 3—Manuall fiel— supply pump, 4 — Ou tlet connec ton, 6=Dr Electric eonnecioe Figure 1-811 High—Pressure Fuel Pump High pressure fuel pump, 2— Fuel wetum pipe connecioe 3—Hoop 4—Fuel weum hose 5 ~ Thee way fel rem pipg 6—Inlet connector Figure 1-8 —12 Check ing Coolant Level of Refilling W ater Tank (Only fr wference, 34 (@) Open the diesel engine bonnet and puta con tainer (content is about 0. 2 L) under the water drai ning plug pipe end of the fuel—water separator (3) Loosen he dmining pig in counter cbek wise Opemt manual fxel—supp ly pump of fuel—wa ‘er sepamtrup and down by hand to dmin offwater for about 10 tines until fuel fill in the fuel—water separ tor fill, See Figure 1—8—10. (@) Tehten the draining pug clockwise immedi alely after water dained off then operate manual fuel —supply punp up and down by hand fr several tines (3) Starting the diesel engine and check is there have fliel leak fem drainage pig ( Check the indicator lamp of fue!—water sepa rator if is un—bright See Figure 1—8—9 1.8.4.8 AirRemove Process for Fuel Filter (D Loosen the hoop at the high — pressure fuel pump fuel retim pipe See Figure 1—8—11. ( Opemte the manual fiel—suppy pump of fi el filter until there is Gel.with fam flow ing out fom pipe \ ‘ \ @_ Reinstall the let mtam hipeof the nigh ~ pressuretie! puny = = @ Opemte manual fel— supply pump fora few tines and check there is fuel leakage or not 1.85 Cooling Systan 1.8.5 1 CookntLevel Cheek the coolant leve} filly fill the refilling tank of radiator if necessary See Figure 1 —8—12 If the coolant kevel is belov MIN sign carefiully check the kakage of cooling system, Then add coolant to MAX sign VY Attention, () Do not add overfill coolant into the refilling tank (2 Open the water inlet cap of the radiator only IPabsolutely necessary. VY Waming () The coolant level checking should be carried outwhen diesel engine at col sie @ Cooknt is poisonous please store it inside o riginal container to avoid people touch with it fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TECHNICAL INFORMATION OF THE DIFSEL. ENGINE, 0 sul TSN 2) 20 40 “So Freezing point ( 60 0 $10 15 2025 3035 40 45 $0 $560 Mixture ratio (%) Figure 13 CoolntM ixture Ratio Figure 1—8—14 Check Cooling Systm ne tnsmnyent Figue 1—8—15 Check the Water Inlet0 rifiee Cover € r ores sé Uy Delemine correct mixture ratio between cooling waler and antifeeze accom ing lo Figure 1—8 —13 please, 185 2 Check of Cooling Systm Insall he mdiator— testing insinment on mdiator Fowe pressure on the cooling system to check leakage See Fire 1-814, Testing pressure cannot exceed prescribed pres sure ‘Testing pressure 196 kPa Qkgf/an) 1.8.5 3 Check of RadiatorG want 7 \ The cover design of water in. ley orifice for rad igor “should keep’ the-pressure of 15-kRa—(Ip 05~kef/any') ‘Tnside the cooling system. Using the cover—Testing in stniment of water inlet orifice for mdiator to check the cover ofwaier inlet orifice for radiator see Figure 1 —8 —15. During testing process replace the cover if the cover of waler inlet orifice for radiator cannot keep the pressure Pressure of water inlet orifice cover of the radiator 88~118 kPa Pressure vali p sesso wane (0. 9~1. 2 kgt/am') Negati «. ah 1.0~3 9 kPa ceative Pressure VAN @, 01~0. 04 kef/ant) 1.8.54 Testing of ThemostatA ction GW2 STC turbo—diesel engine adopts wax ype themostat It is instilled at water outkt orifice of cyl inder head. See Figure | —8—16 Figure 1-816 Thermostat Configuration REA MMHSaRAS Great aang tera Conbstin Engin Mndactring Compa Lined 35MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (@) Place the wood block at he botlm of con biney fully immerge the themostat into water ‘Thermometer directheat he hemostat See Figure 1 —8 —17. (2) Heatwater gradually. Incessant chum the wa fer avoid direct heat the themostat 3) do not Watch tmpemture through the tremaneter inside water and check the initial unlocking temper tue of the themostt The initial unlocking tempemtue of the themostat sz aso) @ Check the fully unlocking tenperature of the themostat Figue 1-817 Check Themostat The filly unlocking temperature of the themostat 95C 203) Air conditioner compressor and power The valve lift mange at filly un lock ing steering pump transmission belt = 10 mm ( | i he) 6 trrbnit sion Bee 9 Check the wom or damaged status of the tansn is sion belt replace it if necessary See Figure | —8 — 18, ‘Altemator and fan pulley () Check the tension degree of the transn ission transmission belt belt adjust it in necessary. Fie 18-18 Check he Transmission Bel (2 Press belt with fore of 98N (10 kg) at its med ium part by hand and check its deflection at the same tine See Figure 1—8—19, Standart deflection Readjust its tension degree Altemator and fan pulley’ transmission belt Air conditioner campres 8~12 mm Figure 1—8—19 sor and power sleering pump transn ission belt Check the Tension Degree of Trans issin Belt 36 (FE EC ER Z ol ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER | TROHNIC AL INFORMATION OF THE DIFSEL. ENGINE, Locking bolts Figue 1—8—20 Check Altemator Transm ission Belt Figure 1—8—21 Check A irConditioner Canp ressar Transm ission Bell 1.8.61 A lemator Tmnan ission Belt () Install allemator tansn ission bell and adjust its tension degree See F gure 1—8 —20. (2 Install fixed bolts and tighten than © pie serbed pryue © Tighten tomue braltemator fixed bolts 40 Nem 2X Tighten torque or adjusting plate 19Nem 1.8.62 AirConditioner Canpiessor and Power Steering Pump Transnission Belt (D Move the air conditioner campressor to adjust the tension degree of air cond itioner comp rssor trans mission belt (2 Tighten the bolts & prescribed tomue, ®\) Tighten torque fr locking bolts of ad jusior | \ | (i 1&7 Diesel Engine Control 1.8.71 Check Mling Speed (1) Conti! vehicle parking break to break the ve hicle (2) Phce the uangn ission of vehicle at neutral position (3) Start the diese! engine and heat it (4) Install the speedameter at the diesel engine (5S) Check the idling speed of the diesel engine The idling speed of the diese! engine Figure 1—8—22 Check Hling Speed fieikcie 800 rim in+30 rin REKRAMMHsaRAG . (Great Wa Bang itera onbstin Engine Matalin Company LinitesMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.8.72 Adjusment of Valve C earance (1) Tum the cmnkshaft lo the top dead center on crankshaft damping pulley and align “I type bulge sign on the pully housing cover (see Figure 1 —8 —23). Now, the piston inside either cylinder 1* or cylinder 4 is at its the top dead center of campression stroke Figue 1—8—23 Tum the Crankshaft and Let Piston » be at Top Dead Center 1 Generator pulley 2—Path joeus of pul ley center 3 —Water pump and pulley housing cover assmbiy 4 — Inspection cover assembly 5— Bulge sign of pulley housing cover 6— Top dead conter reticle of pulley 7— Crankshaft damping pulley assembly 8—Cam shaft position sensor (2) Check ing rocker shaft rest nuts are loose or not /~) \ BofSp valve Cleamnce-adiusment “tighten any Hose “nut of woeker shat test See'Fignre\| —8 +24 : Tighten tomue Srnuts of meker shaft rest 55N- mt5 Nem (3) Check push md clearance of the 1"! cylinder intake /exhaust valvelf the push rod of the 1“ cylinder intake /exhaust valve have clearance. the piston of the 1st Figure 1—8—24 Check Rocker Shaft Resi Nuts cylinder will be at the top dead center of canpres sion stoke If the push rod of the 4" cylinder intake /exhaust valve is pressed, the piston of the 4" cylinder will be at the top dead center of campression stoke Adjust the valve clearince of he 1*' or4" cylinder and other clearnce of closed valves Valve clearance of intuke /exhaust valve (coH st ud Figure 1-8—25 Check Vae Clearance Intake valve 0.35 mm +0, 05 mm W ith FeelerGauge Exhaust valve 0.40 mm £0, 05 mm fe Te ES It PA a A) ll is SB 38 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER | TECHNICAL INFORMATION OF THE DIFSEL. ENGINE, Figure 1—8~—26 Adjust the Cleanince of the 14 2", 3, 6" Valve Figue | —§—27 Ad lust the Clearance of fre 4%, 54) 79.8" Valve 28 Meusure Canpression Presse Fiue 1-8 Fig 1—8—29 Mananeter (4) If the 1* cylinder is at top dead center of campression stoke loosen every adjusting serew for valve clearance See Figure 1—8—26, (S) Insert suitable thiekness of the feelr gauge between the rocker and valve stan. See Figure 1 —8— 25, (@ Tum the adjusting serew for valve clearance until you can fee! sligh lly resistance. (7) Tighten the lock ing nuts tightly. (8) Tun crankshaft Or360°. (9) Re—align the tining reticle of damp ing pul ey and the bulge sien of top dead center (10) Adjust the clearance of other4", 5", 7, 8" valve as F gure 1—8 —27. | ; ( y 1.8.73 Measurement df Canpression Pressure () Startengine and bt it mmning at idling speed until the coolnt tampemture reaching 70C ~ 80C 58 ~176«). (® Remove following parts — Allprheating plugs —— Allmagnet valve connectors of injectors () Instill the Joint and mananeter ino the pre heating plughole of the 1*' cylinder Canpression pressure mananetez W ith jont 5—8840—2008—0 (I Joint 5—8531 —7001 —-O, 29762). @) Using starter > tum the engine and recorl the data of the manameter Canpression pressure at 200 rémin Linit Standad 2,942 kPa (30 kef/am') 57 kPa (22 kgt/an')MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue 1-830 Mensie Preheating Pug Voltage Using Multineter (5 Re—opemte the step 3 and 4 forother cylin der If the measuring data is below preserbed lim it val ue maintain it consulting with “Trouble diagnosis and uoubkshoothng” of this manual 188 Fast Starting Systm Check ing Steps for Fast Starting System (2) Disconnect the connection of tamper tue sensor at the themostat waier outlet (2) Tum the starting switch to “closed’ position If fast starting system is working nomally, you will hear slightly static voice within 15 seconds when you switeh on the preheating re hy. (3) Usemultineter omeasure the preheating pig tem inal voltage immediately after you tum the starting switch to “closed” position Preheating plug tem inal voltage ‘Around 11 VCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 9 Tightening Tormue 1.41 Valve Bonnet Unit CylinderHead, and Rocker Shaft Stand 18 Nem 3.N'm Step 1 Step? Step 3 TSN-m5N-m |100N:m+5N-m__ Recheck Q[20N-m. 2 WNmt sNem) [220 N-m + 5 N-m Z ° ae 20N-mi5NemMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.92 Cylinder Block Assanbly 2) 20N-m + 5N-m \20N-m + 5N-m/4 S| 20N-m+5N-m BY Z & Step 1 40N-m + 5N-m Step 2 110 N-m + 20 N-m Step | Step? Step 3 9SN-m£5N-m_ 170N-m+10N-m RecheckCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.9 3 Crankshaft Main Bearng Housing Connecting Rod Cover Danping Pulley Assenbly, Flywheel Oil Sump DOIN Step | : Ye 80N-m = 5N-m u ‘Step 2 P 120N-m+10N-m h [| 170 N-m +10 N-m 210 N-m+15N-m Al 25 N-m + SN-m Ql 25N-m + $N-mMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.94 Pulley Chanbes Camshaft Timing Pulley Transition W heel Unit Ten sionerUnit Timing Pulley, Camshaft O il Sealing Seat [X20 N- m+ SN-m QU 110N-m + LON m [Q[20N-m+ 5 Nem Xl 20N-m+ 5N-m \ Q20N-m= SN-m on Seo Ql2N m+ SNem oaCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.95 Cooling Systm (fan W aterPump Pulley W aterPump Pulley Chanber CoverA ssanbly, ThemostatH ousing)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 20 N-m+ SN-m bs. 10N-m £2N-m QL 25N-mt SNem Lubricating System © i] Filter OilPump Injection Pipe W ekment and | 25 N-m 20N-mi5N-m La6 oilSump)CHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.97 Intake Manifok, ExhaustManifold Exhaust Tube 0 Nem 5 N-m I [R20N-m+ 3N-n Ql20N-m+ 5N-mMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.98 Electric Systan Genermtor StarterA ssanbly and Preheating Plug) [24] 20N-m + SN-mCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.99 Fuel System (H igh Pressure Fuel Pump and H igh —Low Pressure Fuel Pipe Assanb ly) 27N+m+2N-m] 2IN-m-t2Nom| \ x C= yj 20Nem £2Nem 6 - 7 20N-m + 5N-m B, if i EO a eS) 20N-m+ SN-m Q20N-m len 70N-m£ 5N-mMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.910 Exhaust Recycle Systan 220 N-m + SN-m 20N-m+ 5N-m 20 Nem S$ N-m 20 Nem 5 Nem = | co QEEREASMMERR ZaCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.11 Sound Insulation Boar Assenbly and C hutch Assanbly Ql1S N-m + 3.N-m 20N-m+ 3N-m [SA] 15 N-m + 3N-mMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.912 TurbochargerAssanbly eal sf 50N-m + 5N-m| 20N-m+ 5N-m] | QU10N-m+ 2N-m le 25N-m+ 5N-m]CHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.13 Diesel Engine Support A ssanbly [A] 40N-m+ SN-mMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.10 Special Tools and Instrument It is convenient and fast to use special tools instument and equipment for checking inspec ting maintaining disassembling and assembling the diesel engine and its parts and units as well as Sor uouble diagnosis Notonly the parts cannot be damaged butalso the maintaining quality can be ensured. Nane of the tol Code name of the tol Puller of cminkshall ming pulley ‘8840 —2035 —0 Erector of crankshaft tin ing pulley 5—8522—0024 —0 Conpressor of vale spring 98523-14230 29760) Knockout of valve oil sea ling 588410 —0373—0 Emetor of valve oil sealing 58810 —2033—0 Compressor of piston ring 5— 8840 —9018— Speedaneter 5884) —2093—0 Changer of valve guide 312120 Puller of can tin bg pulley 58) —0086—0 Measurer of mibber ngiiiy 5—se0—0199—0 Conpressivemangi ele 5— R840 —2p08—0 (J -(27 762) Manémeler connector = = ~~ 5-881 7002 = = Measuring device 5—8810—0145—0 Oil filter spanner 5-810 0020-0 ‘Anglemeasurer 5— ae) —0266—0 Injecormeasu er 5—as1) —9016—0 Knockout of injector body 5-880 —2031—0 Changer of bearing 5— 8840 —2038—0 Measurer of mid lator water filler cover 58s) 2035 —0 Fuel filler spanner 5— 8840 —0253 —0 G—22700) Knockout of fient ofl sealing 5 a840—2302—0 Erector of front ofl sealing 8840 —2361—0 Knockout of rar oil sealing 58840 —2360 Erector of rear oil sealing 58840 —25: Sliding harmer 5-884) —0019—0CHAPTER] TECHNICAL INFORMATION OF THE DIE: FL. ENGINE, (Continue) Name of the tol Code name of the tal lenockout of transmission 1°" shaft Front bear ‘8840 —2000—0 Fron bearing erecior of uansm Ission 1" shaft 58522 —0021 —0 Measuring bol of fuel injection syste Measurement of oil tum quantity KTS 650 0— S85 — 613 —100 0986 —612 —900 0-986 612 —901 The special tools mentioned above in thismanual are only able speck bols accom! ing lo yourmaintenance requ inm ent for reference You can purchase suitMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOT ING 2.1 Troubleshooting Because of the reasons such aswom, danaged and anamorphic parts aswell as incorrect utili zation and maintenance during the operation of the diesel enging sane parts of the diesel engine may be worse gradually. When same technical index exceeded proscribed lin ils itusually indicates the diesel engine Is in touble Therefor in this case you should twat the trouble cormctly and be gin toubleshooting in tine othewv ise the diesel engine would be not work stably notonly the out put and the econany will decrease but also the operation perfomance would become worse even more make sme parts wom in short time orwill cause accident damaged thorugh b. For diesel engine same touble such as there is gas in fel system, filler plugged and tans mission belt too loose and so on can be wken off through sane necessary techn icalma in tenance and adjisment But in sme cases because of the disfigurement in the mechanism such as cylindergas ket damaged piston rings wom heavily valve conic surface wom and bearing wom to much and so rth, you could not take off the trouble by sinple technical maintenance and adjisment The diese] engine needs disassemble for repairing or the partsmust be replaced for taking off these toa ble Princip |e, for Troub ke D iagnosis and, Troubleshooting (A) ‘The ‘fruits of the diese chs ing alvays caused by: inconect operation or lack maintenance. During troubleshooting chéck whether the mies of opémtion~ maintenance and service ave been strict carried out at first (2) When there is truble you should treat and tke off it in tme Carefully read the oper tion manual and technical specifications provided by the diesel engine manuficturer before trouble diagnosis You should check and analyze the reason carefully during toubleshooting at first then find what cause the twuble and forbidden blindfold and disonicred disassamb ling @) Only the technician after electric control system professional tmining can cany out the trouble diagnosis of the electric contol diesel engine For complex fault and trouble, you should use specia! tools instument and diagnostic lester Ifyou cannot cary oul the Loubleshooting for tub le diagnosis and diesel engine maintenance you can send your engine i the professional repair station of our company fr repair and maintenance (4) The diesel engine can work excellently only when it is in excellent technical cond itions Do not allow the diesel engine working with “il. Othenvise the [ll diesel engine will cause same parts wom in short tine shorten its working life and even cause malignant accident Attention Points for Trouble D iagnosis and Troab leshooting () Do not start the diesel engine before switch on the battery. (2) Do notdisassembie the battery firm the circuit inside vehicle when diesel engine is work ing (3) Forbiiden the reverse connection for the poles both battery and contol unit 4) Do notuse fast starting device to start the dieselengine only battery auxiliary starting can be used,CHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING (5) Ranove the battery to charge the vehicle battery. (6) Every connectoronly can be pull outafter sw itch off he electric switch, @) You should meet the specification provided bymanufietuer br wouble diagnosis of eeetric contr! diesel engine using suitble equipment Ground ing both the diagnosis device and the cylinder blocks of diesel engine please during trouble diagnosis (8) Do notuse traditional methods for the touble diagnosis for new type electric conte»! diesel engine, (Q) Use appropriate connection betveen the diagnosis device and the electric control unit of the diesel engine (10) Converse diagnosis method is used mostly for the trouble diagnosis of electric contol diesel engine systan, Find possible mason caused the trouble by diagnosis device at first then de tem ine the uoub-e position fhm periphem | equipment to contro! unit gradually fhally xmove the trouble contol circu it and ign ition 2.1.1 Diesel Engine Cannot be Started “Trouble characteristic and possible cause Ranedy () Incomect cireuit connection or link not | @) Check electric citwle linkage and reconnect if well necessary Electric | (2) Battery vollage is not enough (2) Charge the baitew accord ing to technical spec sysim itieation (2) Ingoneet touch beween-stirpr-eatbolic| @) Repwic or place carbolie brush, -eleun gam. mst /and Jcommutaty? ' || Muar siRec“hy sand paver” OD There is air in fie! sippy syste: |G) Cheekthe fietpipe link Yor-osing -Loose' fel reum pipe connector of high pressuze pump pump el by manual Riel transmissiin pump at fuel Miler until here is not alrbubble instie i el Then rassmble fie! retum pipe and reposi tion he menual fel trnmn ission pump Fuel @) Fuel supply system pipe p higzed 2) Check if the ite! pipe of fiel supp ly system appv Pipe is unblocked seem | ® Fuel fer pissed @) Clean fuel filter or replace ihe fuel fier ele ment @) Fuel pump cannot punp Wiel or thel | (4) Check the uel inlet pipe (br alr kakage or the supply not continuously stminer of fuel inlet pipe connector p ingzed clean the pigged and re— install it () Bletrie cont! fault of fie supply ) See Chapter 21, 11 in this section: tub le syst shooting for fel supp ly system D Pion thgwom bomuch @ Rephee pistn rhe rephce eylnder Iner if necessary Mechanical : eum. | 2 Vale leakage @) Check valve clewrince check the sealing per fomance of valve spring valve guide and valve seat repair or lipping the valve if necessiryMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 2.1.2 Diesel Engine Starts Difficultly at Low Tanperature "Trouble chameteristie and possible cause Ranady Fuel Inwintroratiwezng mein used diesel | Use lw soldiving pontdiesloil (ued weconing diesel | oil does not conply with specification so lo diesel engine s working enviromental temper oi that iis thick and concreting wwe In winter orat fieezing raion used lubrica | Use kaw viscid ity lubricathg oil according © diesel Lubries | {8 oll does not comply with specification | engine s working envionment] tmpemture and tng a | 90 DMLIS viseW ty becone bieand inerease| reduce sisting pover inner friction as well as increase stirting resistance tomyue of the diese] engine At fivezing egion the used baliery does nol] Use the baltery accotd ing to diesel engine s woke — comply with specification its capacity is | envimnmental tmpemtire itmust be low — lem smaller than 100 Ah Periture—used battery with the capacity more than 100 Ah Fuel supply] See Chapter2. 1. 11 in this section trouble See Chap ier? L 11 in this sec’ syst shooting for fuel supply sysien for fuel supply sysien 1m troubleshooting 2.1.3 Diesel Engine W ith Insufficient Output Power Diesel engine with insifficient power means that the output power of the diese! engine cannot meet the design quinment in this casa the diesel engine would trend to shu toffwhen vehicle with heavy load or vehicle clinb slope Diesel engine with, insufficient output power’ is aways going w ith sta rting pifeulise there iy closed relationship together /so~hat|you gan'refer to fHbw ing-artaly ses 7 Trouble chamcterisie and possible cause Remedy Fuel apply gsi fult | Soe Chapter 2 1. 11 in this we | Sco Chapwr2 1 11 im this section toubke power or speed does not} tio tub leshooting for fuel sup shooting for fuel supply system get higherwhen open | ply sysiom ‘he thotte kvely Inwke und exhaust sys | CD Air fem fiult exhaust tem iter is phigsed ( Ckar the dust on air filter elanent replace it ifnecessary pemure is higher than | (2) Exhaust pipe is plugged or 00, @ Clear the carbon inside exhaust pipo rin pomal condition and long radius is too snail or sul the exhaust joint pipe with enough ex exhaust gas is unusual ‘tbo many elbow haust section and the number of elbow do not exceed 3 Perfomance go to the | () Fuel supply system Bult @) See Chapter 21. 11 in this section trou bad at every gear bleshooting for diese! engine with insuii cient cuiput power within whole nnge in fel supply system (2) Valve clearance change 2 Check and adjust the valve clearanceCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING Continue) Tube chammrite and powbk cause Ranedy Diesel engine ovethea ting Cylinder bead un it fut in this casa not only the power is low also there ar air kak ago blick gas and abnamal noise but Chank/ afd ‘eénnepting vt ‘Vacuum sysiem @ Cookint tnpemure is bo high @) Oil tempemure is to igh (3) Exhaust gas temperature is too high @) Fuel supply system fault () Air leakage beween cylinder head and cylinder block, ey! inder head bolts lose or gus ket dunaged (2) Intake or exhaus age (@) Incomect valve clearance valve leale @) Injector hole leakage or cop perwasher damaged Copper beating 6f connecting wd ‘mall end febitched wit! pision | pin = om Ingorec| vacuum adjusiment () Check cooling sysian, nmove irring check and adjust the deflection of water pump bely measure themoviat @ Check the oil level refill oll if itis note ough If bearing linear or other moving part became heated, detem ine its position and the cause finally wemove it (B) Check injecting pressure and attm ization of the injector @) See Chapter 2 1, 11 in this section tou bleshooting for fel supply system (D Tighten cylinder head bolts wecord ing to specification at wice or replace the gasket () Ronove and check inuke/exhaust valve lap or repair sealing surfice of valve and seat (@) Re—adjust valve cleamnce t preseribed value 4 Disassemble check, repair or place the damaged parts DikessanbF oil simp check, Weonnecthe ma bis chd could move axiaihy if it is without mora. then disassimble piston connecting rod unit check and repair Check connecting pipeline und vacuum adius tos repairand space damaged paris Teh presse Wel pump injector Tridh presse Wel pump and injector fault Check or place High pressure Tel pump and injector Presume sensor of high pressure fel mil Prowure sensor of high pressie fel rail damaged Replace pressure sensor of hh pressure uel rail ‘Coolant tanpemiare sen sor Turbocharser Pedal position sensor Loy — pressure thelway Coolant tam peratire sensor broken or invalidated ‘Air outlet leakage or invalidated Income! position oF signal! prob lem of pedi | position sensor Oil supp of bw—prssue fel way blocked oF pressise is too iow Replace coolant tam pematrre sensor Tighten connecting part or replace it Replace new pedal Replice bw—prssure fuelway fielp pe or move b lockedMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 2.1.4 Diesel Engine Has Too Much Fue! Consumption Taube chancieristic and possible cause Ranedy uel systan Fuel leukuge Repke wlvant parts of hel systm AW filer Air filter element blocked Clear or rep hice wir filter elanent Tnjeclar and control eheuit Valve cleanince Compressicn 9 mssare Valve spring con to piston ring stickiness Tneonect fuel injection oF injection Tneoneet wilve clewnmee adjustment Cylinder head gasket damaged Valve spring too loose or bioken ‘Check injector and contol sysiam Adjust vale clearnea see Chapter 1.8 72 adjusmentof valve clearance Repkice wlevant parts Replice valve spring 2.1.5 Diesel Engine Ruming W ith Unusual Noise Distinguish the characteristic of unusual noise at first it is knock noise caused by unusual ex plosive or caused by incomectmoye of the parts inside diese! engine body. Then diagnose the sound source in acconlance with sound characteristic and suuewie principle V Attentio: Forbidden the diesel enghe continuous works when there are unusual sounds When unusually noise appears you shoukd urgent stop the diesel engine and check for toub leshoot ing Operate the diese! engine after tub leshooting Trouble thamcteriste and OER chase Ranedy 25 Fis ok t 2 “Hy See wlevant ran ovingm ches ~ see Chap wr a ‘ 2.1.11 in this sects tubleshooting for fuel supp ly system @ There Is sight but stent sound sometimes this @ Replace snall end Iner of connecting md wi sound could be heaxi easy at idling and get bigger in prescribed mnge when accelerating @ The ckamnce beween pision and cylinder Iner is. @) Replace piston ‘bo big. bit sound could be heani at oatside of cylin der and get biggerwhen accelemting G@) The fitting clearance is too big caused by afmain (1) Disissamble and check bearing liner replee it bearing liner wom of connecting ted you can hear iPnecessan; keep preserbed fitting clearance heavy and powerful paris knock when decelerating ) Vahe bumps pision when diesel engine mnning (5) Find the wason why valve bumps pision, check heavy and thyUm knock sound could be heart at valve tining and adjust the clearance of valve cylinder head @ Meal Metional sound fron pulley chamber () Check ekannce beween senal hon of cam shaft pulley and inner surfice of pu lley cham ber replace camshaft oll sealing acconting practical status @® The cleawnee beween hniake und exhaust valve is (7) Cheek and adiust vale clearances sce Chapter too bis bigger scund with thythm coukl be heard at “1, 8 7. 2% adjusment of valve clearance” in cylinder head ‘his Manual ZaCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING 216 Diese] Engine Has Abnomal Noise Checking for the diesel engine preheating is fully or not bere troubk diagnosis Trouble chaicteristlc Diesel engine pinging @ @) a Gas leakage noise wo @ @) @ ‘Continuoas noise aw 2 ® wo Rap noise wo 2) @ a Passi e cause Unsuitible fiel Injector fu Itor incorrect circuit connection Sealing gasket of eylinder head damaged or piston ring bmken Incorrect output sigal of cookint fenpemuue sensox pinging when accelerating tp heat diese | engine Exhaust be connection bose or broken hijector and /or preheating pg ose Exhaustman ifvké loose Cylinder head gasket damaged Waterpump tana sion belt bose Coo ling. fan lpose W ater pump beating wom orem’ aged " Altemator or vacium pun dan > aged heonect valve clearance udjusment heonect valve clearance adjusment Roker shaft or bearing wom Flywheel bolts loose Crankshaft and /or thrust bearing damaged orwom Crnkshaft and connecti bearing wom Connecting sed liner and piston pin wom or damaged Piston wom or damaged mod Ramedy @ Choose sitible fiel wo meet specifi cation accord ing to enviroment tmpemture @) Replace injector and tighten circuit connectin ) Cheek campressive pressum mplce relevant parts (A) Rep lice cooknt tmpertum senor @ Tighten exhaust lube connection Pkce exhaust tibe Tighten injector and /or preheating plug replace washer Tighten exhaust maniloid Replace cylinder head gasket Re—adjustwater pimp tnnsn ission belt tension degme Tighten-cooling fin Rei lece water pump bea riig Rep lee or wpairaltemaiorer vacu um pump Adjust valve cleanince @ @ @ a Adjust valve clearance Replace mweker shaft or bearing Tighten flywheel bolts Replace crankshaft and /or thrust, bearng Replace crankshaft and connecting rod bearing Replace connecting 1od liner and piston pin @ Replce piston 2.1.7 Diesel Engine Exhausts Gas with Unusual Color When the diesel engine is at excellent technical statis the waste gas exhausted frm exhaust tube atnomal load should be colorless and transparent he main canponents of the waste gas are CO., vapor and a little CO and lubrica after bumt incampletely (gas to little light b he and light my). at excellent techn ical status when it exhausts black, th orwith little light be and light gra At ig oil There the diesel engine is not bhe and white gas fram its exhaust tubeMAIVTENANCE MANUAL OF GW2.8TC TURRO DIESEL ENGINE Trubk chamcter ie and possible cause Tamed Exhaust gas with black smoke Exhaust gas with white moke c Y Diesel engine work with over bad (2) Fuel supply system full ©) Incorect valve clearance and valve sealing cause exhaust valve leukuge ® Air inlet quantiyy is insuffi ens or inlet blocked air flter ® Cylinder liner or piston ring wom heavily © Incorrect cumput signal of coolant tm per lure sensor @ ‘Turbochager damaged (8) Incorrect spmying quality and sp mying course @ Vacuum regulator or vacuum pipe damaged (Insufficient cooknt 2) There is water inside cylindes or water and gas inside diesel oil @) At the beginning of diesel engine starting fuel in individual cylinder do not combust \D\ Fue! supply system fauly—, } } ) Cobling fan cileuil is open etreuit — © Low pressure furelway blocked @ Too higher oil level in oil samp (®)_ Incorrect operation of preheating systom @) Cylinder head gasket damaged, piston ring stickiness (10) Va oil sealing damaged, wilve sian and vale guide wom (1) Decrease tre kad of diesel engine within prescribed range (2) See Chapter 2 1. 11 troubleshooting for fel supply system (3) Adjust valve clearanes check sealing eonie surfice Slearand rmove the dust and Rew lency inside air Giller mp lice filler ekment IPnecessary ® Replace piston ring (© Replace coolant tmper tire sensor in this section a @ Replace wrbocharger (8) Check the fuel injector and its control (9) Check connecting pipe and vacuum mgulatos repair or xplace than (@) Supply cookat Pind fiult cause and remove it (3) Appropriate increase the speed and load of the diesel engine mun it r longer tine (f)) See Chapter 2; 1-H. in’ this. section 1, treubleshooting Ayr fuel supp syst” “15 Check oF mp kee coating in (6) Clear kw pressure fuel way @ Drain same oil and correet oi quanti (8) Check preheating plug and preheating control system @ Replace relevant parts (10) Replace valve oil sealing valve stem and valve guide Exhaust gas with blue smoke @ Piston ring locked or wom to much with insufficient spring reverse install the cham fer of piston ring so that oil entering into combustion chamber Run with low bad for long te so that the clearance beween piston and cylinder tin er © be larger and oil entering into com bustin chamber (3) Oil in oil sump is toomuch @ Disassamble and check pision ring replace it if necessary and assan ble new one according to specification 2) Appwpriate inewase the bad or dis assanble and repair Sonect oi] quantity according to dip stick holeCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING 2.1.8 Diesel Engine Lubricating System Has H igher Oil Consunption and Low Pressure Every moving fitting athigh— speed operation of the diese! enginemust be supplied wit suifi cient mbricating oil to reduce friction and take away quantity ofheat for avoid ing parts lock and early wom In addition, lubricating oil can fillup the slightly clearance amongmoving fitting such as pis ton and cylinder liner so that reinfore the closed, avoid high pressure air leakage and ensure the diesel engine easily t start and keep original power Therefore lubricating oil shoul have fixed pressure @ 0,1 MPa at idling 0. 35~0, 55 MPa for other speed) and flow rate and it shoud be clean. Trouble chamicteristic and possible cause Ranody Too higher oil con | () Oilgmde cannotmeet the specifica tim (@ Replace oil and use prescribed sumption gnde oil ( Too much oil quantity Coneet oil kvel (@) Gasket and oil sealing fiir oil kakage |) Rep lice gasket and oil sea ling @) Piston ring or gmove wom @® Replice piston ring or piston (&) Piston ring boeked (© Rep ce piston ring or piston @ Valve auiée oil sealing guide or valve (@ Replace oil sealing guide or valve sim wom sien ® Cytinderwom @ Repair cylinder liner or rep ace piston ring piston Lower oil pressure | (1) Oil grade cannolmeel the specification, (Rep ice oil and use prescribed \ Jower oil visejdity insufficient oil quantity gnde-oil corectail quantity ©), ji filter elment/tlockey | (| OQ) Replace oil fifer'ekenent V @) Rekase vale blocked and /orbypiiss valve,’ (4). Ret bee Telease vile und bypass spring too soft ~ ~ To valve ~ > Oil pump stmainer is p buzzed (@) Wash or place oil punp strainer ) Oil pump driving and driven gearwom — | (5). Rep lace oil pump assembly ©) Oilpive splitor connector loose © Repair or wplace oil pipe @ Oilpump full ® Repair or replace oil pump assan bly (8) Crank bearing or connecting— md bearing) () Replace crank bearing or connect wom too much ing— td bearing @ Oilmancmeter danuged or oil pressure in | (9) Repair or wplace oil manmews dicalor damaged oil pressure indicator (1D) Rocker shaft bea ing wom (0) Repkiee weker shaft bearing (1D Cam shaft and its bearing wom (1D Replace camshaft and its hearing (12) Crankshatt and its bearing wom 12 Replace crankshaft and its bearing Oil cannot (@) Oilbole of eylinder block or eylinder head | (1) Clean or repair reach to blocked valve sysiem 2) Oilhole of weker shaft blocked Clean or repair @ Oilbole of meker shaft retainer blocked | @) Clean or repair @) Ollhole of weker blocked @ Clean or repair YY Caution Forbidden the diese! engine operation when ils hbrication systan without oil pres sure of oil pressure is very lov. In these cases you shoud stop the engine inmed iately to check and remove the troubleMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 2.1.9 Diesel Engine Cooling Systan Has Abnomal Cooling Tanperature and Lack Liquids Trouble chamclerisue and pawDbk cause Ranedy Diew] engine (D Goolant level is too low Clack (Supply coolant check leakage pair iP ovethea ting coolan D necessary @ Constant tm perature device (2 Rep lice constant temper re device damaged @ Fan drive belt is loosing orhinken (3) Adjust or rephee fin drive belt () Thermostat valve could nol open 4) Rep hice themosia assanbly () Waterpump fult () Check or rep lace water pump assenbly (6) Fuel supply systm fault () See Chapter 2, 1, 11 in this section trou bleshooting for fie! supply system ® Radwaior housing damaged or mda (7) Repke midialor housing or clean nidialor tor element blocked ® Coolant tanperature sensor (8) Rep kee cookint tenperiure sensor damaged () Damaged cylinder head gasket cau) Replace cylinder head gasket ses coolant leakage (10) Themostst damaged (10) Replace themostat CD Cooling systan blocked by (LD Clean cooling systen eyewinker (2) Cooling fan cireuit open. Bin 2) Replace cooling fan circu itor Gin damaged (18), Oil, leak fiom fan cath, (3) Replace fan clutch (4) ‘Exhaust systan blocked, \ (14 Ran exhaust system h (13), 07 tue iw oth Jena f)| )ftd spain ok sep nce pik_sonted on) apeh ty Diesel engine () Themosut valve cannot shut up) (1) Check or replace themostit super—cooling comp lee ly or damaged. ® Water tompemiue meter fiw (2) Measure coolant tenpemiurs mp hee wa ‘er tmpemture meter Water leakage (Radiator leakage @ Repair or rephce md ator frequently @® Radiatorhose joint lose orhose (2) Tighten the clip of md ior hose joint or damaged replace hose @) Water pump kakege (3) Check or rep lace water pump asson bly (Heater hose join! loose or hose @ Tighien the clip of heater hose joint or re danaged phice hose Preheating time i | (1) Themmosiat damaged @ Check or rephee hemostat too long (© Consiant temperature device dam @) Check or replace constant tem perature de aged vice VW Caution (2) When diesel engine is ovetheating fbrbidden siop it immed lately when it is munning or fil in coolant immed ately. You should reduce the speed and run it without load for sane tme then stop the engine when coolant imperatuze in cooling system is lawer for checking @) When diesel engine is still hea} it is mpossible © whe olf he filler cap br preventing fiom scalding Pay alientin © your safely when filling coolant (3) If the cause of overheating could not find by yourself you should contact withma intenance station or fae. Othemvise it could cause other parts b be danaged fe Te ES It PA a A) ll is SB 64 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING . 10 Diesel Engine Turbo—Charging Systan Trouble Trouble characteristic and possible cause Remedy Pover is insufficient (1) Inpuriiy inside oil piles up at the side—seal | () Repkee oil repair uibocharg ing of ushine er 2) Oil temperature fs too high oll supply is in (2) Check oil supply sysim. sulMicient and floating bearing danaged by repair turbocharger heating @) Oil leaked fam the wrbne and the shai of (3) Repair wephee oll reum pipe can pressor due to the damaged and wamaged oil retum pipe of turbocharger > Sealing ring of whocharger damaged and (4) Replace sealing ring of turbo fie charger (S) Lose the bakince of tuibine shaft lor () Check and wpair wplace the lor © Turbine bkde ond compressor blade friction (6) Check and pair and bioken ® Air filter blocked (too diry) @ Maintain air flier eplace filler element (8) Toomuch dirt insite intake and exhaust pipe | (@) Wash repair or replace line or air leaked in connecting part intake and exhaust pipe @ Turbocharwerdoes notwork wellor be bmken @) Check or ep hee wbocharer Fuel consumption is (1) Toomuch dirt inside intake and exhaust pipe) Check and repair them or higher jine or air leaked in connecting part replace damaged parts (2), Tunbochatger pe rim alice is hat very good 2) Clean adjustor-tep lace ur ( | ; bocharey h Oil consumption (D Sealing ring of turbocharger damaged. wom (1) Replace sealing ring (3) Connecting screws of oil inlet and oil rum (3) Check and repair oil inlet oil Pipe loosed, spacer danaged rum pipe repkce spacer Sounds are (D Olldirt in gas passage of the wrbine end is) () Clean replace unusaal toomuch and cause the passage section be coming nanower than usual © Olldirtut eampressor part is Bo much and @) Clean rephce the gas passige section becam ing narawer than usual (3) Floating bearing wom loo much thew aw (3) Replace Mating bearing friction among impeller and shell of tibine and compressor The fiictin anong (1) Unwonied object entered ini the tribine and) () Clean replace uusbing compressor ean pressor’ rior and housing = @_-Floaling bearing wom too much 2) Replace floating bearing cause vibration (3) Dynam ie balance of witb ine shaft fs bad (3) Check repair replace W Caution (2) Forbidden unwonted objects enter into air inwke and exhaust systen while cany out touble fe TE EE A A) Bl is SB ‘Great Wal Baoding lteral anbuston Engine Marfecunng Comperyinted = 5MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE shooting or assemble and disassemble diesel engine. Because the working speed of the turbocharger ro lor is very high, and the clearance between mlorand housing is very mall so that the operation of wm tor will be great affected by any softor hard, big or small unwonted objects when they enter into the inpeller even damage the inpeller If the blade of mpeller is damaged, itwill cause the abnomal vi ‘bration and noise, stop engine and check /repair turbocharger immed iately at this tme (2) If there is oil leakage fam turbocharger please don t replace ithastily Because the turbo chawger can be continues used after the touble elin inated if there is no friction between the impeller and housing and if the turbocharger is still rotating flexib 2.1.11 Diesel Engine Fuel Systan Trouble Most parts and units of electric contiol fuel supply systam are special parts and have litte tu bla don tdisassanble /assanb ke them hastily please If thew is possible trouble indeed, take than to profssionalmaintenance station for checking and repairing At that tme special instmments and diagnostic testers are needed The model of diagnostic tester is KST 650. You should campy with flow ing diagnostic principle and attention items during checking and repairing Trouble position and chameteristic Remedy Diesel engine can not be slaried Diesel engine stopped but can be stirted again ( Guad aginst helt sysim (2 Power supply sysian @) Main relay () Fuse /eonneetive cable /interface Sheed sensor of diesel ehsing /—) (6) ‘No, fuet or fa ineqrect @ Fuel systm has air (8) Low pressure fuel way blocked or leak age @) Preteating cireuit winted (10) High pressure fel pump or high pres sure fuel rall contm device (1D Injector magnet va lve (D Contwl unit 1) Fuse /conneetive cable /inte rfice con nection loose ® Incorwet fiel @) low pressure @ Fuel systam has air (special for kw pressure fie] way) Low pressure fuel way blocked or too (Check guard against theft system @) Check voltage of power supply sys ven () Check main rely (A) Check fuse feheck connective cable / whether interface is-flm_or nat 1B) \Chéek speed sengoirof diese eng ink (6) Supply fuel \accoiding ‘pwscrbed brine = = (@ Remove the air inside fel sys (8) Check and repair lov pressure fuel way (@ Check preheating circuit ov inted (1D) Checks high pressure fel pump or hich pressure fuel il contol device (1D) Check injectormagnet valve Input JRA cade ofnew ineewr into ECU i you replaced of injecwe the same input IQA code ofcurrent in Jector when you rep ce ECU: after input the NA code injector and ECU have parmersiip, sorb kiden inwrchange or replacing usage (12) Check eontrol unit ()_ Cheek fase /eheck connective cable / whether interfice is fim or not (2 Supply fuel accord ing prescribed brand (3) Check low pressure fel way @ Ranove the air inside fel system 66 fe Te ES It PA a A) ll is SB pg amp ied ret Wat mera Conbstin Eng MantaCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING Continue) Trouble position and chameteristic Renedy Diesel engine @ skipped but can be started again 6) Hh pressure flelway high pressure fuel pump pressure contiol device) High pressure fuel pump or injector control ¢ ire it @® Check hih presue tel pump and pressure contol device (6) Check high pressure fuel pump or injector cont! eieutt Diesel engine ( Baten voltage stunts difficulty = @) Starer (3) Reby and starting aviteh @) Fuel has problem ©) Fuel system has air (6) reheating systan @ Coolant temperaiure sensor (inteo (8) Low pressure filel way blocked or too low pressure (©) High pressure felway has loo low pres sure (10) H igh pressure fuel mil pressure adjus ting device Injectorwarks not very well or cantrol problem mh j ap. Diesel engine wos Pe athigh idling Pinging during wo processes to heat) Cookint temperature sensor Injector connection circuit () Check battery veliage (2 Check and repair stuter (3) Cheek and repair why and starting witch (Supply fuel accord ing prescribed brand (5) Remove air inside fhel sysim (@) Check and repair preheating system (Cheek coon | temperature sensor (winted (8) Check low pressure tel way (@ Check high pressuie fuel way, high pressure fuel pump and pressure contol device (20) Check high pressure fie! nil pres sure ad justing device (4D ‘Testor replace. infector () Cheek coolant temperaiure sensor 2) Check injector connection circuit engine and speed) Injector fault (3) Test or replace injector cce ler ting Diesel engine wob (1) Fuelpmoblan 1) Supply Wel acco ne prescrbed bles at idling brand (2 Fuel system has air (3) Loy pressure fuel way blocked or too low pressure (@)_ Injector works not very well ©) Injector cinuit (6) High pressure fuel mil pressure sensor high pressure fuel rail pressure adjus ting. systam @ High pressure ful pump Diesel engine with (1) insufficient power forall range © Air filter blocked (3) Fuel ph ln Vacuum systam (2) Romove air inside fuel sysim (3) Check bow pressure fuel way (4) Check or rp kace injector (5) Check injector circuit (@) Check and repair high pressure fuel rail pressure senson high pressure fuel nil pressure adjusting system () ‘Test and adiust high pressure fie! pump () Check whether BOR vacuum regula tor works nomal or not (2) Maintin or replace air filter elament (3) Supply fuel acconting prescribed brandMAIVTENANCE MANUAL OF GW2.8TC TURRO DIESEL ENGINE Continue) Trouble position and chameteristic Renedy Diesel engine with insufficient power forall range @ Low presur lelway blocked or bo dow pressure Turbocharger Rikure (G) Incorveet position or signal for pedal po sition sensor @ Waste gas bypass valve works incorrect @ (8) Leakage behind turbocharger compressor () Coolant tem perature sensor (10) High pressure fuel mil pressure sensor ap Injection high pressure fhel pump @ Cheek bw pressure fel way (5) Repair or replace turbocharger (@) Adjust the position of peda! position sensor (@ Check and repair waste as bypass valve (8) Check the sealing of turbocharger (9) Check and repair coolant tmpem tum sensor (10) Cheek and repair high pressure fuel rail pressure sensor (11) Check and test injector sure fhe! pump high pres Diesel engine exhausts wh ite orblue smoke (D Cookint tam perature sensor ) Fuel sysiem has air (3) Low pressure fuel way blocked @ Preheating system (Cheek cooknt tmperure sensor (2 Remove air inside fuel system (3) Check lov pressue fel way elec tric fuel supply pump and fue) 1 tum valve @) Check and repair preheating system () Too higher oil level in lubricating sys (3) Check of! evel in lubricating sys tem ‘am, din in off siperftuous oil. from | / j 1 oil simp conte Fatt aunty Diesel engine @) Ai filer ellment bheked —~ — OF Matsui and wep hee air Sher exhausts black smoke Cookin! lem pera lute sensor Turbocha wer Bult Injector and its cireuit (little) Vacuum punp ekment, (2) Check coolan | temperalure sensor Check wrbocha mer (4) Check injector and its circuit (@ Check whether the EGR vacuum systen nomal or nol Diesel engine over heating (Fuel prob len (2) Coolant tmpera ture sensor (3) Cooling fin @) Cooling fin cireuit ©) Cylinder gasket gus leakage (Supply Wel accontng preserbed brand (2 Check cookunt tmperatre sensor (3) Check and repair cooling fan (@) Check cooling fan cireut (5) Replace cylinder gasket 2.1.12 Diesel Engine W obbles at Idling ‘Cheeking position Possible crise Ranedy Fuel problan Fuel pmoblan Supply firel accowling prescribed brand Fuel system hus air water| Law pressure fuel way blocked Fuel system has air water Fuel systam has fel kakage or blocked Ranove ais water fam fuel stan Check repair or wphee wlevant parts system, of fuelCHA PYEH 2 TROUBLE DIAGNOSIS AND TRO )UBLESHOOTING Continue) Teck he poster Possinle cause Tanedy Tnjeewr works not very well Injecr beked Replace injecwr Atany the youmust input RA code of new injector into ECU if you replaced oft injector Injeewr works not very well Injector circuit Tum on prea of Ryetion & bo low Inco rect fuel injection con trol Injector cincuil broken Injector cineuil nose Check high pressure fiel mail pressure or replace injector Repair itaferdizgnosis e—write QA code for repaired injector and input it inv ECU Check hamess pair or repkace Reinforwe injector circuit High presw ie fuel rail high presse fuel mil pres sure adjusting system pressure sensor Tg pressure hel mail pressure sensor] damaged Replace high pressure Gel wil pressure sensor Teh pressare Wel rail pressure ads Check meterhe vane and Tel eum vale repkice if necessary Mechanical part of diesel engine Valve clearnce adjustnent inconect Cylinder head sasket damaged, ring stick iness or heavy wom piso Adjust valve ckamnce Check rephee cylinder head gasket piston ring 2 1, 13, \Diesel Engine W orks atH igh Idling Teck he pastor Pedal position sensor ‘ossTple_ause— — Pedal position sensar damaged Wis _ Replace pedal position sensor and input lo BCU 21.14 StarlerCan NotRun Starts Powerless and W ith Noise Tioube position and charac erste Tanedy Starter can not mn Slater star's powerless and cannot start diese] engine () Cont! cireuit such as siarting switch is open The connecting between brush and commutator ts not well ‘There is short link or break link in side the slater @ 8) Battery capacity is not enough @ @ Lead wire connecting not well The surface of camutator is bum ordiny Brush wom or brush spring insuffi cient so that the connecior between brush und conmuwior is not well Magnetic switch main con tict— point] bums link notwell ©) Bearing wom, amature wom @ o Check the cireulk connect it relia ble Adjust the bush spring and clear the commutator Check and repair the starter D @ @ G) Charging battery accom! ing to spec ification Tightening the connection of w ire Bumish the surfice of emmututor or move dirty Replace the brush oradjust its spring ® @ wo Bumish the main contact—pointby “q'* nometil sandpaper Check and 1ep lace bearing oO © REREAD a (Great aang teal onbstin Engin Mneactring Company Lites Mis ak2a 69MAIVPENANCE MANUAL OF GW2.8TG TURBE 0 DIESEL ENGINE Continue) Tioable position and chamewristic Ranedy ‘Suner mins continuous ly with strident noise aller diesel engine sured @D The copper contiet—disk inside srier relay could nol sepamte fren two contact—points Suter amauir shaft bioken orbent} @ 3) The surfice of gear getting mush o7| gear blocked @ Switch off the power supply mme diately check and tshten cireuit connection repair contact— point @) Switch off the power supply imme diately replace starter 8) Switch off the power supp iy mme dislely repair gear surkice 2.1.15 StarterW orks ButD iesel Engine Can not be Running ‘Cheek ing position Possible cause Raned) Batory © Battery minal bose il contact} (1 Clean and Jor w — tighten battery due to oxidation mist tom ina] 2) Battery without charge or 2) Charge or rep ace baitery accand hg insufficient charge technical specification Surer (Small gear damaged () Rep kee small gear (2) Magnetic sv iteh tim it 2 Repair or wplace magnetic sw iteh (8) Brush damaged, bnish spring dam | (@) Replace brush and /or bmish spring aged Diesel engine Piso cmankshafl bearing locked or | Repair or replace relevant paris \ ofter parts damaged) \ ( L) i : , Guan against theft Cdonot onic thisssim Check. and! repair guaid agains system system, Main why Main rehy damaged Replacemah hay Fuse cable interfice Fuse cable bose ill contact Clean tighten fuse cable Speed sensor Speed sensor damaged Replace speed sensor Fuel Tank without Gel incorrect fuel el system has air Air exhaust incompletely in fil system Low pressure fuelway blocked, Low pressure uel way leakage Cannot set up high pressure fuel rail pressure High pressure fel pump, high pressue del rail pressure contr) Supply fel or cioose preserbed thel Remove fitel systen air by air filter Repair low pressure fuel way: exhaust gas, Check high presi fuel pump, high Pressure fuel mail pressure sensor Injecibrmagnetic valve do not work or il con trol Injectormagnetic valve Check injectormagnetic valve working status Electric conti unit | ECU works incorrect (ECU) Replace ECU, IQA code of curment in Jecior should be input during ECU pheing Preheating systm Preheating plug works incorrect in win Replace preheating ping check control unit of preheating plug ter REA aR Za 70 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING 2116 Diesel Engine Can be Running ButCannot be Ignition to Start Checking position Posse nie Rancdy Fuelmanitbid system Fuelmanifod blocked ordamaged, fel manifbld connector loose Repairor mplace helmaniiols re tighten connector Too low pressure at low pressure fuel way Fuel system, @ Cannot cbse the overflow valve of fel) filter (2) Fuel manifold or fuel flier unit blocked Fuel system bas air @D Repair or ephice the overtkw valve of fuel filer 2) Check fel maniioK. filter ekment or unit wplice fuel Renove air by fuel filter Fuel supply pump Fuel Fuel sipply pump dan aged (D Used el cannotmeet specification (2 Fuel system has water Check and wep lce fuel supp ly pump () Use preserbed fuel according environmental tmpe mune 2) Remove water in fuel system or w place fuel Batiery with low voltage Too low pressure at high juessum fel way Inject works incoreet Coolant tempe miu re sensor (wintep 1 Battery connection bose tem inal mist] 2) Battery with insufficient charge 3) Genemtur belt loose or dan aged High pressure fuel pump, high pressure fuel mil pressure contwl incorrect { | negurmae darjaged maahe ite valve works incorrect Incorwet coolant teanpermture dai in win tes preheating plug do not work TD Chan and re— tighten battery ter minal ©) Chame battery @) Tighten or replace the genertor belt Check high presue fiel punp, high pressure fel mil pressure contol sys ni ( ‘Cheek’ or'repBée injecting ‘youmuist put QA code ofnew injector ints BCU ifyar rep heed oli injector Replace coobnt tmperature sensor 2117 FastStarting Systan Fault Causes D ifficult Starting Preparation for Troubleshooting (@) Disconnect tanperatuse switch connector (2) Make sure electrifying the preheating plug or not —— Confim that starting sy itch is at “of” position — Connect cylinderwall with freewill preheating pug by voltage meter —— Place the starting switch at “close” position If ekctifying the preheating pg the finger of the voltage meter will shows the voltage (2V); if the finger is notmova thismeans the preheating plug haven t been electrified (8) Check and repair fault Checking position Possible cause Preheating pg is electrified Tes! no light imp of preheating plug est lamp of preheating plug is damaged Remedy Replace the test lamp of preheating plugMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Continue) Checking position Possible cause Ranedy Fast starting tner Fast suiting ter is damaged Check or place fist suurting ther ‘Swith on He lest kip ofpie | Past slaitng lmer Ws damaged Check of place Gal siaring tier heating plug ford 3 seconds Switch on the testlanpof | (1) Tum suring swith fm “str” | () Replace fist starting tmer preheating plug for3. 5 sec position @ “close” position afer onds start the dieselengine if the close time of preheating plug lay less than 14 seconds the fast starting tiner is damaged Q) Tum stating sviteh fiom “off po Replace fist slarting ter sition to “close” position alter start the diesel enging if the clos: time of preheating plug why less than 14 seconds the fist susting tiner is damaged Tamperaiue vite Tenpemiure swiich damaged Replace tampemture switch Preheatng pig connection | Preheating plug cannot sith on No electricity with preheating pug ‘Test kmp-of preheating plug{Test-kmp-fise of preheating. p ug-bm no ah ¢ ken f | \ Fast starting timer: Fast lina tmer is damaged Replace preheating plug Replace iest limp fise of preheating pig C= h Cheek or repkice fist siarting tmer Switch on the est lamp of | (1) Prehealing phe lay damaged, af preheating pls Hrd 5 sec er tum the starting witch fom onds “off” position “close” position the preheating plug ky without swileh on yet Preeathng plug relay cirult wie damaged Fuse or ciruitw im dumaued, when tim the starting switeh frm “off” position to “close” position, the preheating plug lay switeh on @ @ a Replace pehealing plus Repair or rep ee preheating plug reky circuit wire (3) Replace fuse or circuit ire 2.1.18 Diesel Engine Flaneous ButCan be Started Again Checking postion Possibe cause Remedy Fuse /eonnective cable Cable connection inierfice loose Re—adjust cab le conneetion Fuel @iesel oid Fuel do notmeet specification Choose prescribed fel acconling 1 envimmmental tan pera tire (GB 252-2000)CHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING Continue) Checking position Possible cause Ranedy Low pressure fhelway (hel supply pump, fuel re wm valve) sum to low retum valve) Low pressir iielway blocked or pres (fuel supply pump, Repair or replace damaged parts of fie] Jaw pressure fuel way Fuel stm has air gain Or Low pressure fire] way) () Fuel system has air (2) Fuel sysiam has water High pressure fel way (high pressure fel pump pressure con ttl device) stable High pressure fuel rail pressure is un () Ranow airin bel ssi by fel filter (2) Drah off the fel included wa ler choose preseribed (ue! Check high pressure fuel pump, high pressure fuel rail cont! system High presse fel pump and injector con tml cireuit Inecbrwoiks incorrect Check injector contol gystem and high pressure fuel pump 1,19 Generator Runs W ithout Output Charging Current ‘Trouble position and characteristic Insufficient Charge and Too Large Remedy Genemior mins | (1) W ire connection fault connection break without output off contact notwell (2) Stor dol short circuit (@ Rectifier diode) dimseed, | @) Brish’con neting not well (@ Regulator damaged ‘Transm ission belt loose Brush con acting not well diry @) Regubstor damaged @ Battery electmlyte level tno kaw or pole ple sultimtion heavy or wo tinewom Genemior char | (1) ges not enough | (2) slip ring Cheek and repair cireuit @_Repairor iep bce zene raior assav bly, @ Repheelgine | GY Gieain. dirt or rep ee bres () Repairor ep hee wegulator (1) Adjust belt tension degree @ Adjustand clean () Replace the regulstor Refill with electrolye to prescribed ev el rphce the battery due w heavy sul firration pole plate ifnecessary 2.1. 20 Battery Capacity is Insufficient Starts D ifficultly Self—D ischarges Ex cessively Trouble positon and characteristic Ranedy Battery capacity | © Is insufficient Ekectob® level is very ow starts diesel Short eireuit among pole plates engine (3) Pole plate sulfimtion heavy difficulty D.C irouit tem ina | contacting not well there are @ lot of oxide an pole tem nals cha wing insufficiently (@ Refillwih distilled water or thin viol fc solution with density 1, 1 ( Clean depositand replace the electrolyte (3) Repeating charging and discharging bat ‘ery tp clean sulfimtin pole @) Tightening tem inal clean oxideMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Continue) Trouble positon ond charicteristic Ranedy Buiey si | () Them aw impurities h eecuwhye @ Fill i peserbed ekctwhye m kur dischaming is with pure sulphur and distilled water to much ©) Extemal wire of battery has stort cireuit) © Check and remove short circu it position ) Electmlyw overflow and cause short cir | (@) Clean the surlice of batery and temi cuit between pasitive und negative pole nalwith alkaline water orwam wate keep clear outside battery (do not put waler Into baitery @) Putting long metal tools or pole on the) (4) Forbidden putting long metal tools or batery pole teminals cause heavy shart! pole on battery surfice circuit ® Active matier fill off pole phia deposit) G) Repair or wp hee battery if necessary causes short eireuit anong pole plates retginer damaged causes short circuit a mong pole phites pole plates bent cau ses short circuit VY Waming (1) The gas emit frm batiey’ is easy & be fired by spark so he striking light firing and snoking should be avoided during batiory repairing and maintenance, Foibidden electrolyte splash your skin and clothes and doesn t forget wear glasses when you maintain it (2) Forbidden the short cireuit be ween wo tem inal posts of battery othenw ise the battery will heat pid’ ormay ‘be explosive ; : : ; 13) ‘To/prevent short ¢imuit pe the. battdry, the Houch\— ‘iron wiky should bbe disassanb led Gist’ Bul wlied you change’ bul You can omy av ite off wlevanl avitehes =~ @) When disassanble batier, you should tuke down the touch— ion wise firstly, and hen is the positive pole wire The second to tke down the battery fender and then take out battery fam frame. The assamble sequence of the battery is Just the reverse process to disassemble itCHAPTER 2 2.2 Trouble D iagnosis 221 Trouble Diagnosis for Starting System Check whether the battery Starter do not run I Cheeks battery nomal ornot at first then begin for following dit UBLE DIAGNOSIS AND TROUBLESHOOTING Charge failure or useful lite finished Check battery Baltery is normal Check terminal Terminal connection break off ‘Clean batery terminal and reconnect Switeh on headlamp and starting switeh Tetminal connection is normal heck sturter or starting switch ¥ Have touble Repair or replace v eadlamp not light or very dark (1) Baticry charging insufficient (2) Shor circuit of starter coil ) Starter parts failuce Headlamp is brightMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE ‘Meshing fault between small gear and ring gear I whether the magne or not ‘Turn start switch to “start (STY" position, then check switch terminal “Shas voltage Yes Or | ‘Sonal gear and ring ‘gear worn heavy ‘Starter sfding resistance too big I I Not ¥ In this case, check the magnetie switch connector 3 BW of ro-stariing relay has normal voltage or not Repair or replace starter, replhce ring gear Repair or replace starter Normal Abnormal | i l + = ‘Check whether the connector of'starting relay starting ‘Show circuit between staring sswiteh and magnetic switeh ‘or conection fault switch has vollage or not Repair ‘Short cireuit between Starting switch connection fault] | starting switch and battery or eomneetion fault v Repair Replace starting switchCHAPTER 2 UBLE DIAGNOSIS AND TROUBLESHOOTING Continue) ‘Although tum the start switeh to “start ST" position, the magnetic switch without operate ¥ Turn start switeh to “start (ST) posit \whether the magnetic switch terminal or not | s No ¥ ‘Check whether the test lamp of instrument display normally or not | ‘Normal Abnormal i | Check the ennneetion normal Shc ey nen check has volige arnotheseeenstaning swish | | Ser cet ooon OF snd magnate rch canneton fa terminal" SlporaPsvallacar| | Shor cveitor bum of 1 | cannot mone magieswichoresl| = (4 Toa ‘eh onestion al CW OE ( ~ [tec cus, | — [Replacestring site] — Repair or replace starter me me starting switch ond meshing between sinall year and ring wean, but diesel engine cannot run ¥ ‘Ceck grounding cable ‘ 4 Goud Bad 1 Repair or replace grounding cable ¥ Brush and rectifier ction fault | Repair or repMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Although tum the start switel return from “star” position to “close” position, starter sill operate Disconmect the connection wire of start switeh to check its operation No. of connector B-67 No. ofterminal | 1 [Key position 0 No. of terminal starting switch acc] B | on] st |B, | P| Bm] Ww lw Disconnection Closedown a Assesory OFo Oo lose Close ofo-o oO Start ° ° ‘Ensure thal there is open eizcuit apart from the connection mentioned above ‘Conlaei-poinl af magnctie switeh Replacowarerswitol ‘melting and cannot move, or return spring broken or damaged Replace magnetie switeh 2.22 Trouble Diagnosis for Turbo Charging Systan Trouble dugnosig @ The purpose of touble diagnosis is to find the uoub le position and reason so that ty suit the rmedy to the case @ Do not replace old turbochargerwith new one before solve the poblan, @ The digenosis method and procedure of tubo— diesel engine is the sane as ofher diesel engine @ Trouble diagnosis cannot be carried out Or disassanb led tusbocha merCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING Fault phenanena " ie 3 2 a|2 2 2 2|e\¢ £ 24/f alala]/eg Tile at We heat 2 22) 2/2) 4/5\3 rub le diagnosis fr bibo—diesel engine Pa aie aloe 2 e/2 2/8) e]/ 8) s 2 8/2|3) 2) 2/8) 3 2 £) 2/8/38) 2] 3 g 3) e)2| 3/2) 2 3 4/8/2/2)2\2 2 2) 2/8|8lals PREbE Ge Haaaly Air filter dirty Repke filter ekement of air filter Compressor air net Clean mpurly acconling © pracikcal condr blocked tion or place damaged parts Campressor air autiet lube blocked Clean mpuriy accomling to practical condi tion or mp lace damaged paris Diew! engine intake blocked Clean inpuriy nse lake whe Pipe air kakage fiom air Replace seal part accom! ing practical con filter ta com pressor dition or tighten sten ing part accard ing priscribéd (pique L —t ame: pe air leakage frm” \ Replace seal part accos! ing w pricticsl edn can pressor t) dies®] diton or tighten fasten ig part atoning b engine prescribed tome Joint surfice air leakage ( Rephice gasket acconling ty pmctical condi between diesel engine “on or tichten fastening part accoing air inlet pipe and prescribed one cylinder head Diesel engine exhaust Clean inpuriy inside exhaust pipe pipe blocked Muffler or ils rear air outlet tube blocked Clean inputily inside exhaus! acconting o Paactical cond ition or rep lace damaged parts, Joint surfice air leakage Replice gasket acconling practical condi between diesel engine tion or tighten fastening part acconling to exhaust pipe and cy: prescribed wawe derhead Jomntalr leakage heween Replice gasket acconths © practical cond lusbine inlet be and on or tighten fasiening part accorling to dicselengine airutlet prseribed wmue Air kekage of uibine air Ranove kokuge of trib ine gir qutlet pipe outlet pipe Turbocharger oil etm | Clean impurity acconling i practical condi Pipe blocked lion or mepkice air outlet pipeMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Continue) Fault phenamena 5 b a : E/ a] 2 2 3 2 2/2 g £ 5 al5 a alg 2|2 = z é Q 3 Troube diagnosis tor t1bo—diesel engine 2 8\/2 2| 2/2) 2 2) 2/2|2le/s|2|€ eel el el al al ele 2 2) 2/2) 2] 2] 8) 2 & alélalé|2las Possible cause Ranody Bregher ofdwvel engine Clean impuriy nee biewher diesel engine crankcase blocked crankcase Turbochamgerm Wi —case Replice oil and oll Tiker accoling @ practt fom ditor ar cal condition or heavy repairor replace tar hocharger Ticonect a uSMeNT of Repos oF WERT Wen pewue eT par high pressure fiel punp and relevant parts acconling ty practical or injector cond ition Tneonvet diesel engine _ Rephce damaged paris_adjust img of lining diese! éngine ‘ h 7 f J} ott | y Diewlengine pistun ting \Repair diesel’ engine and “Teplice parts, 4c, oreylindsrwom caases Ginling wPmctieal condition —— gas scumy Inner pioblan oT'diesel Repair diesel engine acconiing w practical engine (valve piston) | condition Compressor mpeleror Clean find and renove Ihe reason Torun difliser bide fm dit filwraty wpkee oll or oll Mer Turbocharger damaged | Pind and amove the reason caused damaged heavy repairor rep kee turbocha wer accor ing t practical cond ition YY Attention The abochamerwith excellentappeamnce flexible opemiting mtor and without bkde attrition means that this tuibocharger is at excellent status 2.23 Trouble Diagnosis for O il Leakage of Turbocharger The sealing of turbocharger depends on the air pressure within two end — cases of turbocharger higher than the air pressure within m id —body oil retum chamber (equal to the pressure inside crank case) Before dhgnosis move both the oil inside front inket pipeline of canp wssor housing and the soiled oil on the exhaust pipe before tuib ine housing inlet and so on co QEBREAIMERm Za Walang neal Conbstion Ege MarfanCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING Trouble diagnosis fr oil leakage al the end of cam pressoz @® Check compressor impeller is Yes Clean and repair air inlet system, se damaged or not by other object place wibochaiger LNo ® Check turbochaner shaft aril —ygg_ | Remove factors cause clearance in cleanince inewase or not (compres creasing of turbochawer rephee tur sor bade wearw ih housing ar nob bocharmer LNo ) Diesel engine illing time is boo Yes Clean bibricating oil avoid idling for) long or not (more than 20 m inue> long tine LNo Yes [ec eases eens Clean or repkce filter ekment of air filter LNo ® Check turbocharger inlet is Huot Ranove ficlors cause inet throttle off Ue or not tusbocharger [No @® Check all exhaust pipes bose or Yes | Tighten pipeline or replace broken byoken Pipe VAV¥ LNo: Z } | i to ( : a ’ =| Clean and tereve throitld> wp bee ~ + @ Check wibochamer hibricating oil Yes sate the 3 >| lubricating oil oil dmining tube if retum pipe blocked or not Lectin pps biosked ornet __l necessity [No I GLB OT] Check and repair using maintenance ® Check diesel ensine crankcase Ye | emai gvned by demi mie breather blocked or not ee y e manuficuer @ Check diesel engine fault or not Yes | Check and repair using maintenance (piston heavy gas scurny pressure of erankease) higher manual provided by diesel engine manufacturer @® Cheek iubricuting oil of erinkeas Is toomuch or not Adjust lubricating oil level ‘crankcase to correct height insite’ Suggested testing air inlet negative pressure ior eference <6. 5 kPa)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Trouble diagnosis for oil leakage at the end of tubine @ Cheek turbocharger shah axl Yes | Ronove ficiors cause clearance in clearance hnewase or not Ccanpres creasing of uurbochager place tur sor blade wearwith housing or nob bocharger {No @ Diesel engine idling tine is too YS __| Clean iubricating oil avoid iting tor long or not (more then 20 m ina) long tne [No ® Too much hbricating oil added in Yes) Unwanted lubricating oil will be advance bum, do not adopt treatment No @ Check diese! enzine crankcase] Yes __| Check and rpair using maintenance She titel eee manual provided by diesel engine manufietirer No mtacsceoel esol r lean and mmove throttle mp ce 5) Check turbocharger tibricating oil] Yes Clean an (eau pipe Venkat a nat lubricating oi! oil draining tube if necessary LNo )) Check m id—housing has silt or Yes | Maintin ubricating syst of diesel not_or lubricating oil coking or not engin replace tibocha reer \ aNo \ i ! { » Check iubrivsting oil of chankcase Adjust oil ‘level’ inside vmnkease 1) is tho much or not correct height No ® Check diesel engine fault or not Check and repair using maintenance (piston heavy gas scurps higher manual provided by diesel engine pressure of ernkease) manuftewrer Oil leakage is a usual phenanenon for turbo — diesel engine if you can find and rmove the Phencmena in tine you can avoid turbocharger failure Following instance will cause wibocharger for leaking oit (1) Blocked air filter or oil inlet pipe of the diesel engine result in larger air inlet negative pressure, (@) Curving or damaged oil retim pipe of tubochager result in retam oil thmttle () Accumulated carbon inside oil chamber ofm id—body result in retum oi] blocked. (4) Air leakage of the connecting pipe fium canpressor housing outlet to diese! engine intake ube (5) Air leakage of the connector frm volute air inlet 1 exhaust outlet () Too longer idling tme. (@) Too higher pressure or oil level inside crankcase crankcase s ventilating flue blocked. (8) Toomuch lower gas scuny of the diesel engine Incoriect leakage diagnosis Start the diesel engine after disassen bling the connecting pipe fm camp ressor housing outlet engine intake ube then observe whether ther is oil kakage following the injecting air flow or not fim compressor housing outlet fe Te ES It PA a A) ll is SB 82 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 3) WECHANICAL SYSTEM CHAPTER 3 > MECHANICAL SYSTEM 3.1 Cylinder Head Disassembling sequence A Thermostat system ___ assembly. ® Injector assembly (3) Preheating plug and _ its connecting piece D Rocker shaft and rocker 5) Push rod Cyl Reassembling sequence Reassembling sequence is reverse to disassembling sequenice Fue S=T=1 Disissenbling and A ssanb ling Sequence torCylnder ead fe TE EE A A) Bl is SB Great Wal Banding internal ambestin Engine Manfactving CompayLintee = 2SMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE —2 Disassemble the Hold — down Bolts of Injector TORONTO Figure 3-1-3 _Disassamble the Inieg\or Body Pia 3—1—4 Disasyanble the Preheating Plug Disassan ble the Cylinder V Attention (D) During disassenbling the parts belong to valve unitmust be collected together at ane place and marked with symbol so that to ensure that these parts could be eassemb ed to restore their original position (® During disassembling injector position must be marked with symbol and restored to original position when reassembling fibidden lo wrong position () Please cany out the compressive testing and weeoxl testing result for one tine before disassembling cylinderhead frm the diesel engine and disassembling valve unit ‘+. D isassanbling Disassemble the themostat system assamb MD) Disassamble the injector assan bh®) () Disassanble the hold — down bolts of injec tor See Figure 3-1-2. (2) Disassemble the injector and hold — down plate logether using injector body knockout and sliding hammer See Figure 3-12 | i Injector body krockouk 58840 20340. Sliting hanmez 5—8840—0019—0. Disassanble the preheating plug and its connect ing piecé3) Disassemble the rocker shaft and rocke@) Disassemble the push md3) Disassemble the cylinder head®) Leosen the cylinder head bolts ata few tines grad ually according to the sequence Na as shown as in Figure 3—1—5, loosen a little at each tine VY caution Ifyou do not loosen the cylinder head bolts at a few times gmdually accowlng to the sequence as well as just bosen a little at each tma there will have bad impact on lower surface of cylinder head. Figure 3— Head Bolts a4 fe Te ES It PA a A) ll is SB ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 3 WEGHANIC AL SYSTEM 6 Check Cylinder Head inder Head Boll Figure 3-1 Figure 3—1—8 Cheek CylinderH ead Figure 3—1—9 Check CylinderHead Clean Up (D Cylinder head bolts (2) Cylinder head Carefully clean up alloildirt carbon— smoke and accumulated carbon until it showsmetal color Forbid den electric metal brush for any gasket and sealing sur fice | Check and Repair If you find heavy wom or danaged paris during checking it is necessary to adjust wpair and rep kee the parts ) Check leakage mst and gas scurty at gasket surface of cylinder head. You should find the reason if the cylinderhead gasket file Incorrect assan bly. —— Cylinder head loose or wam. Insufficient tighten torque for cylinder head bolis —— Cylinder head block surface warp. (2) Check screw thread of cylinder head bolts: damaged or elongated or not or incorrect tools damage the cylinder head. Yi Chutiog Doub tir Feylinder héad wolts shod be mephiced: na ot be (3) Cheek there is erick ornot for cylinder head especial at the places of cylinder head valve seat and the outlet (A Check there is mst or not at botlm phne of cylinder head, arenaceous and loose hok or not inside cylinder head. YY Caution Forbidden well the cylinder head replace damaged cylinder head immediately () Check cylinder head plane and pkine degree ofmateh ing surfice between intake and exhaust mani folds See Figure 3—1—8 and Figure 3—1—9 ‘These surfaces can be cut and grinded. If the plane degree of the surfices is notwithin the prescribed lin ib cutand grind fhese surfaces tomeet technical speci fication Replace than if plane degree exceeded limit too much Standard Linit Plane warp of cylinder| head bottm plane Cylinder head height <0.05mm) 0. 20mm 92 mm 9. 55mm fe TE EE A A) Bl is SB ‘Great Wal Baoding lteral Canbuston Engin Marfecunng ComperyLinted = 2MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Fie 3-110 Measure the Wamp Beween ExhaustM anit and Matching Surtice —— Piaiey 3-1 AT) | Asigpibl/ the Valve Seat Figue 3—1—12 Measae the Upper Height of Valve Figue3—1—13. Agsamble the Valve Ol Sealing (@ Measure the wap of the matching surface be ween exhaustmanifold and eylinder head by ruler and inspection gage See Figure 3—1—10, If he measuring value is between piescribed lin it and standart, r—grind the matching surface between exhaustman ifold and cylinder head please Rephce exhaust manifold if measuring value ex ceeded prescribed lin it W aup of the matching surface between exhaustmani fold and cylinder head Standard <0. 05 mm 0. 20mm ** Reassambling Reassamble the cylinder head@) () Assamble the valve seat Carefully assan ble the accessory @) (its extemal diameter is slightly smaller than the valve seab at valve sea), See Figure 3—1—LL. \Y Attention: ‘The surfice contact with vale seat { shloy ld be lacdessory s slippeiy suttide _ Fore the accessory into valve-seat gridua lly for Its position using bench pres@) YY Attention: Forbidden ovemuch fre of bench press othenvise itwill damage the valve seat Valve guide installation heightmeasured fun the side at top p kine of cylinder head is shown as F igure 3 1-1. Height (lor reference) 13 mm Y Attention If valve guide has been disassom bled, ‘the valve and valve guile should be replaced in coup les. (2 Assemble the valve Lay oil on extemal dianeter of valve stm befre valve installation, (3) Assemble the spring washer ( Assemble the valve oil sealing —— Instill new oil sealing al valve stm. See Fig ure 3-113, —— Use special too! for leading Valve oil sealing erector 5 —8840—2033—0. fe Te ES It PA a A) ll is SB 86 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTE 3) WECHANICAL SYSTEM ® Assemble the valve spring —— Install valve spring at spring washer —— Install valve spring seatat valve spring Y Attention —— The end with paint of the valve spring shou kl be downwark See Figure 3—1—14 Input comp wssive air fam preheating p lug of cylinder head into cylinder to fowe valve for its posi tion (@) Assemble he valve amester 1 Figure 3-1—14 Assmble the Valve § Figuw 3115, Assemble the Valve A reste Figue3—1—16 Tighten Fixed Bolts of Rocker Saf Press valve spring 0 its position by spring compressor See Figure 3—1—15, —— Install valve arrester into spring seat — Slightly knock amund the arrester head foree it for its position by mbberhanmer 3 —1423—0 Valve spring compressor 9—85 29760). Reassamble the push wd5) (D Clean the contact surface of meker shaft seat and cylinder head by white cloth (2) Insert the convexity of eight push mds with a litte of oll into relevant holes at the top surfice of cyl Hider head ane pace them“ their gosition Reassamble the wekér shaft and weket (1) Place the rocker assanbly on cylinder head ac corling » comect direction let valve adjusting screws a lign upper end concave of push rod (2 Tighten the studs and bolls of tocker to pre scribed tomue See Figure 3—1—16. eu Tighten lormue br studs and bolls 55Ne mt5 Nem YY Attention Studs and bolts should have plane washers Reassanble the preheating pug and its connecting piecé3) Screw preheating plug into relevant hole of eylin der head, tighten it to prescribed torque using 1k spanner See Figure 3—1—17, 2X Tighten tomue br preheating plug Figue 3—1—17 Assemble the Preheating Pug 20N+ mii Nem TE ES Dd 2 A) ll is BR Company Lined Wall Bang neal Combustion Engine Waneacting 87 @éMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 118 Install Injector Gasket and O —Sea ling R ing Figure 3-119 Assamble the Injector 0 Assamble the Themastal Systm Assembly Figure 3— Reassamble the injector assembly (1) Phe injector O — sealing ring into the 1st grove of injectos then insert following injectors into relevant hoks of cylinder L 2, 3 and 4 accoming the serial number 1, 2 3 and 4 on the injectors (2) Use the open end of inzector hold —down plate ‘v clip the injector another end pressed at the cylinder head bolts Place the injector hold —down p late washer into the concave of the cylinder head bolts at first then Jet the convexity on the injector ho —down plate bot tm surface align the concave of injector hod — down plate washer the washer cannot be tum now fix the injector hold — down plate using injector tightening bolts During assembling the concave sie of the in -ector hold —down p hte washer should be upward the line connect the V symbol at the injector hold —down plate washer and the concave center is vertical with crankshaft axis or let the sive of the washer extemal round with the shortest distance fem round concave center Wo face the rear end of the engine Lay a little of grease on the injector hol —down plate bottm surface is helpfir! for orientation, 24° Tigh tem torgue ‘hr injector hold down be lty a 27 Ne m£3 Ne h- (3) Forbidden removing the dust cap of injector oil inlet YY Attentios The nozzie pinhole of injector can not be polluted or damaged when nmove the dust cap of injector oil inlet Reassamble the themostat system assanb hi Tighten the fixed bolts of themostat systan assen bly prescribed toryue See Figue 3—1—20, ®X Tighten torque for fixed bolts of themostat system assambly 20N- m+5 N-mCHAPTER 3) WECHANICAL SYSTEM 3.2 Rocker Shaft A ssenb ly Disassembling sequence @ Rocker shait assembly @ Rocker shatt cicelip 3) Rock: socker shaft spring, Zocker shaft Reassembling sequence Reassembling sequence is reverse to disassembling sequence. Figue $=2=1 Disassamb Ing and Assan bling Sequence for Racker Shall Aswan bW fe TE EE A A) Bl is SB ‘Great al Baoding lteral onbuston Engine Manfectuang ComperyLinted = 3MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue 3—2—2 Measure the Bowe of Rocker Figue 3—2—3 Measure the Exemal Dimeter of Rocker Shaft ) Disassembling Disassamble the wocker shaft assembl¥1) Disassemble the wocker shaft cire]ix®) Disassemble the swckei®) Disassemble the socker shaft seat) Disassanble the wckeiS) Disassemble the weker shaft spring) Disassemble the rocker shaft?) 8) Check and Repair If you find heavy wom or damaged parts during checking it is necessary to adjust repair and rep hace the parts Cheek 0 il—Bound Fim Clearance @ Measue he bow of weber using vemier cali perormicmmeter caliper See Figure 3—2—2, Rephce the mweker if temeasured value exceeded the prescribed Limit Rocker bore Slandard Linit 1s 03d~i91 060 mim. 18, 1.00 mm (2 Apart fram swing at weker shaft measure the extemal dimeter of mcker shaft using sew m iemme ter See Figure 3—2—3 Replace the weker shaft if the measured vale exceeded the prescribed limit Extemal diameter of mcker shaft Standard 18, 98~19, 00 mm Linit 18, 90 mm Fie 3-2-4 Check the Oil Hole of Racker Clearance between wcker and rocker shaft Standard 0. 06~0. 08 mm Linit @. 10mm (3) Check the oil hole of eker as shown as Fig ure 3—2—4, it should not be bbcked. Bbw the oil hole of mcker to be clean using can pressive air if necessary. lis SRR Bol 30 S fei is Bia Manafacturing Corp LinedCHAPTER 3 WEGHANIC AL SYSTEM 5 Corteet Rocker Fige 3 Figuy 352-6 .Mcasyre the Radia! Jupiness of Rocker Shaft Sequence for tighten bolts of roeker shat Figure 3—2—7 Assemble the Rocker Shai Figie 3-2-8 Check the Rest Bolls of Rocker Sha @é RockerCorrection Check the step —style wont ofupper valve stm contacting surface of rocker See Figure 3— 2-5 Finish upper valve stm contacting surfice with slight wom and nick using whetstone please VV Caution Replace the wcker immediately if its upper valve stom contacting surface with serious wom and nick Check the Rad ial Jumpiness of Rocker Shaft () Place weker shaft at V —bbek (2 Measure the mdial jmpiness at the middle position of rocker shaft using m fermeter See Figure 3 —2-6 If the 1adial jump iness is slight correct the rad ial jump iness of rocker shaft using bench piss. V Caution Replace the weker shaft if the meas ured value exceeded the preserbed limit Linit-for mdial jump iness of rocker shaft ‘ } 10, Bmm— \ | ot) Reassamb ling Reassamble the weker sha ff7) (D) Daub a litte of oil on weker shaft (2) Assemble the rocker shaft and weker rocker shaft spring and rocker shaft rest together at the cylin derhead See Figure 3—2—7. Reassemb le Reassamb le Reassemb le Reassanb le Reassemb le Reassamb le wo derhead, (2) Tighten the mcker shaft seat bolts to pre scribed tomue accor ng to the sequence shown as Fi ure 3-2-8 Tighten torque Hr rocker shaft seat bolts the the the the weker shaft spring6) rocket) rocker shaft seagl) rocket) the weker shaft cirelig® the weker shaft assamb KD) Install the rocker shaft assanb ly at the cylin a 55N- mis Nem TE £0 Pd A) il is BR Wel Badg eral Combustion Engine Mofactving Compr Limited = 911MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 3.3 > Valve Spring Valve Stem Oil Seal Valve Guide Push Rod Disassembling sequence @) Rocker mechanism assembly falve arrester alve spring @ Valve ®© Valve stem oil seal Reassembling sequence © Valve guide Reassembling sequence is reverse to disassembling sequence. FRU S=3=1 DV RaSSGTh IAG Tad ASSEN DINE SAUCE FV URE SPFRE Valve Stam Ol Seal Valve Guide and Push Rod fe Te ES It PA a A) ll is SB 92 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 3 WEGHANIC AL SYSTEM Figure 3—3~2 Disassamble the Valve A rrester ti Pigye3—3—3 Meuse Valve Spring Free H visht, ; a Figure 3-3-4 Meusure Valve Spring Pe end ieu larity “Disassembling Disassamble the ockermechanisn assemb ly1) Disassemble the valve arrestef) Use special ols to press valve spring and disas sembling valve arrester See Figure 3—3—2 Valve spring campressoe 9—8523—1423—0 (I —29760). Disassemble the valve spring3) Disassemble the valve) Disassemble the valve stan oil seals Disassanble the valve guid®) Valve guide changee 9—8523—1212—0. 1) Check and Repair If you find heavy wom or damaged parts during checking il is necessary to adjusi repair and rep bee the parts Check Valve Spring VY Attention Cheek valve spring by eyeballng 1 place it if it is damaged or has abnomal wom obviously (D) Measure the fiee height of valve spring _->\ Meaailte the fite heigh bof valve spring Sel Fig Lure 83-313, Replace it Ifthe height is-lower than pie scribed thrit Free height of valve spring Stinda Linit 48. 0mm @) Check valve spring perpendicukiiy —— Measure valve spring pemend icularity using steel square See Figure 3-3-4 Replace valve spring if the measured value exceeded the prescribed limit Linit of valve spring perpend ieu brity 47 1mm Figue 3-3-5 Meise Vale Spring Tension 1.7mm 8) Check valve sprhg ensin SS Press the valve spring to installing height u sing sprngmeasurec Measure cam pressive spring ten sion See Figure 3—3—5, —— Replace vabe spring if the measured tension is lower than prescribed limit Valve spring tension Installation height — Standard Linit 38, 9mm 296, ZN 257. IN GS\RERRR DHsaRaa .. Gat Wal Badger Constn Engine arty Company LinedMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Exhaust valve Intake valve 6 Check Vale igie 3—3 Figur.3—3=7 Measuw Vale Guide Exte ma D fan efor! Figue3—3—8 Replace Valve Guide Wb Fie 3-3-9 Meumre Valve Guide Height 94 fate te i A al ie ae Aol ret Wong ner Combustion Ege Mnetecting Cn U8) Check Valve Guide VY Attention: () Do not damage vale seat contacting surfice when remove the accumulated carbon on valve head, (2) Carefully check the scmpe and abnomal wom ‘on valve guide See Figure 3-3-6, (3) Replace valve guide and valve in couples if it, is scraped or has abnomal wom obviously. Check Valve Gu kde Clearance (1) Measure extemal diameter of valve guide u sing micumeter See Figure 3—3—7. Rephce valve and valve guide in couples it if ex temal diameter of valve guide is mailer than prescribed linit Extemal diameter of valve guide Standart Linit TIntuke valve 7. 946~7. S61 mm Exhaust valve ~ 7-921 ~7.-936 mn 850-mm ‘el I ' [ (2)_Mensuie valve guide bore using micrmieten (3) Subtwctmeasured valve guide bor fiom meas ured extemal! diameter of valve guile Replace valve and valve guide in couples if the value after sub tracted excee ded the preserbed lint Valve guide cleamnce Standard Intake valve 0, 0839~0. 069 mm 0 0640, “Exhaust valve Linit 0. 200 mm a6 mm | Oo. 30 mm Rep hee Valve Guide () Knock out the valve guide frum one side of cambustion chanberusing special tool See Figure 3— 3-8 Valve guide changee 98523-1212 (2 Daub oil on oulside surfice of valve guide, Install new valve guide fiem one side of cylinder head upper surfice using special tool and check the heightof the valve guide See Figure 3-3-9 Valve guide changer 9—8523—1212—0. LinedCHAPTER 3 WEGHANIC AL SYSTEM Figure 3-3—10 Measure Valve Thickness Measure Valve Figure 3-311 Shrinkage —12) Measure Valve Contacting W idth Figs Heightof valve guile G): 13 mm Y Attention Replace valve guide and valve in couples if valve guide has been disassanb led. We) Check Valve Check Valve Thickness Measure valve lhickness See Figure 3—3—10, YV Attention Replace valve guide and valve in couples ifmeasured valve thickness is smaller than pre scribed lin it Valve thickness Linit Standard Intake vale Timm | a ey ee] 50 mm Exhaust valve Check Valve Shrinkage () Install valve) on eylinder head®. See Fig ure 3>3—11. (| \(@) Measure'valve | shitinkage fjani"botum’ plane of ‘cylinder Head ‘using ‘depth 'gag@ “aller oF swel’ ruler See Figure 3—3—11. Rephce valve seat ifmeasured valve shrinkage value exceeds prescribed lin it Valve shrinkage Standard Linit Intake vale 73mm 1 28mm Exhaust valve 70mm [1 20mm Check Valve Contacting W ith (1) Check the roughness and planeness of valve contacting surfice The valve s contacting surfice should be snooth, (2) Measure valve contacthng width See Figure 3 3-12, Repke valve seat if measured valve contacting width vale exceeds prescribed linit Valve contacting width Intake valve 1.7 mm Exhaust valve fe TE EE A A) Bl is SB (Great aang teal onbstin Engin Mneactring Company Lites 20 mm 95MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE U8) Check Valve Seat Check the Contacting Con ic Angle of Valve Seat at Vawe (D Measure the contacting conic angle of valve seat See Figure 3—3—13, (2 Replace valve vale guide and valve seat at the sane tine ifmeasured value exceeds prescribed linit as Standard for the contacting conic angle of valve seat at valve Piguie 3-313 Measure the Conueting Conic Angle of Valve Seat 45° Disassanble the Valve Seat (1) Ar welling inside around] of valve seat ®. See Figure 33-14, (2 Cooling valve seat Ora fw minutes tisw ill cause valve seat to shrink and make it is easy to disas san ble () Prize the valve seat and let it cames off using screw openefS). Carefully operating and do not damage cylinder head@). @ Carefillly-elean accumulated caibon and ether, (impuriyy fym/ the Installing hole of falve seat of cylin, Figure 9/814 Dibassemble nf dérhead: Vane Seat = = = = Assambk the Valve Seat @ () Carefilly install accesson{) Cits extemal di ameter slightly snaller than valve sea at the valve sea@), See Figue 3—3—15, Y Attention Smooth surface of accessory shou contact with valve seat (2 Use bench pres@) gradually fores the acees sory and forces the valve seat to its position See Figure 3-83-15, —3—15 Assemble the Vake Seut VY Attention Forbidden using lawge force of the bench press or damage ‘he valve seatCHAPTER 3 WEGHANIC AL SYSTEM Figue 3-316 Figue 3—3—17 Machining Valve Seat Using M ling Cutter Figue 3—3—18 Grind Valve Seat Coneel Valve Seat () Clean accumulated carbon fiom the surface of valve seat (2) machining valve seat using milling cutter (5, 45° and 75° blade), minimize the scarand oth er roughness area so that get back the standard value of valve seat contacting width. Valve seat angle a5° VY Attention — The move part is only the sear and rough ness forbidden cut too much to avoid cutting the area of valve seatw ithou td isfigu rem en t — Use adjustable valve milling cutter guid Foibidden swaying the valves milling cutter guide in side valve guide VCO MCS_t < (3—Daub~ab misive en surface of va lve seat (4) Insert the valve inlo valve guide (5) Slightly knock valve guide up and down, tum valve w let it fitwith valve guide well at the same tme See F igure 3-318 (6) Check valve s contacting width is suitable or not (7) Check valve seat surface contacting all around of whole valve or not 18) Check Push Rod Canber Figure 33-19 Measure Push Rod Cuber () Place push md on table (2 Roll the push wd along the table and measure its camber using inspection gage See Figure 3 —3 — 19, Replace push md ifmeasured value exceeds pre scribed limit Limit of push rd camber <=0.4mm (3) Check the tvo ends of push wd have heavy wom and damaged or not by eyeballing Rep lace push wd if have heavy wom and damaged, REKRAMMHsaRAG . (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANUAL 21;-Assantile;the Valve Figure 3 Story Oi} Seal ! I 22. Assemble the Valve Spring Figur 3-38-23 Assmble the Valve Spring fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary Linked 98 OF GW2.8TG TURBO DIESEL ENGINE “| Reassamb ling Reassamble the valve guidd@) (2) Daub oil on outside surfice of valve guide (2) Install new valve guide fram one side of upper surface of cylinder head using special tool See Figure 3-320. Valve guide changer 9—8523—1212—0. Reassanble the valve stan oil sea) Install new valve stem oil seal using special tool See Figure 33-21. Valve stem oil seal erector 5—8840 —2033 —0, Reassamb ling valv Daub oil on outside surface of valve stm, brdastenk ih the va lve. sp ring3) \ InsGill valvesp ring al spring wather See Figure 3 3-22, The end valve spring with paint should be down wank See Figure 33-23CHAPTER 3 WEGHANIC AL SYSTEM Figue 3—3—24 Assemble the Valve A rester Pigue 33°25) ‘Assenble! the oe Mechanism A/ssimbly Reassanble the valve arreste@) () Fore the valve spring to its position using spring canpressor (2) lnstall spring seat and valve arester See Fig ur 3—3—24, (3) Slightly knock around the arrester head to free it tbr its position by mbber hanmer Valve spring conpressoe 9—85 —29760). 3—1423—0 (I Reassanble the wekermechanisn assenb 1) ‘Tighten fixed bolts of mcker shaft to prescribed torque See F gure 3-3 —25. 4) Tighten torque fr fixed bolts of mcker 55N*mt5 NemMAIVTENANCE MANUS OF GW2.8TG TURBO DIESEL ENGINE 3.4 Camshaft and Tappet Rear connecting plete of cylinder block assembly ‘amshatt front gasket seat “amshaft © Tappet Reassembling sequence Reassembling sequenee is reverse to disassembling sequence. nit a Figie 3-1-1 Disessenib ling and Assenb ling Sequence torCanshait and Tappet fe Te ES It PA a A) ll is SB 100 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 3 WEGHANIC AL SYSTEM Figure 3—4—2 Disassamble the Camshaft Timing Pulley Figure 3-4-3 Disassanble the ThrustPlre Fige3—4—4 Measure Can shaft Axial Clearance Figure 3—4—3 Measure Joumal Diameter of Cam shaft ©) Disassembling Disassemble cylinder head assanb ly) Disassanble the fywhee®) Disassemble the sar connecting plate of cylinder block) Disassemble the oil sump assanb bid) Disassemble the oil pump assanb. Disassanble the cam shaft tin ing pulley assanb h©) () Remove fixed bolts of camshaft tin ing pulley fiom cam shaft the the he VY Attention Fix camshaft © avoid it is mnning (2 Pullout camshaft tin ing pullex2) using gen eral puller camshaft tin ing pulley procedure bolt. See F gure 3—4 — (3) Remove cam shaft front gasket sea@). Disassemble the Canshaft front gasket seal) Disassamble the camshaft) Disassemble the uppe®) TB) Check and Repair Ifyou find heavy wom or danaged parts during chee “Tha jit fs pecossany 0 ad jast-repai and wep lage the paps, " Cheek Cunshaft a (1) Measure can shaft thst camnce — Measure camshaft axial clearance using m ierme ter See Figure 3—4—4, \Y Attention Measunment should be cared out after camsha ft— tim ing pulley has been disassembled. Rephce wom part (camshaft front gasket seat or cam shaft pully flange) if cam shaft axial clearance ex coeds the prescribed limit Cam shaft axial clearance Standant 015~0. 140 mm Linit 0 25 mm (2) Measure Joumal diameter of camshaft measure the joumal d imeter of camshaft at direc tior{D) and directiot2). See Figure 3—4—5. Rephce canshaft ifmeasued vale is smaller than prescribed linit Joumal diameter of camshaft Standard 49, 945 975 mim 49, 600 mm fe TE EE A A) Bl is SB (Great aang eral onbiston Eg MneectvingCompayLimtes 1 1MAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Figur 3-4-7 Measure Radial dump inegs, of Camshaft Figuie 3—4—8 Bearing Bore of Canshaf Figure 3-4-9 Disassemble the Bearing of Can shaft (3) Measure cam height Measure cam heightH usingmicnmeter See Fig uw 3—4—6 Rephee canshaft ifmeasued vale is smaller than prescribed limit Can height Standard Linit 42 02mm 41. 65 mm () Measure rad ial jump iness of camshaft —— Place camshaft at V —b lock —— Measuw mia! jampiness of cam shaft using micnmeter See Figue 3—4—7, Replace camshalt if measured valie exceeds prescribed lin it Radial jumpiness of camshaft Senda SSC <0, 02 mm 6. 10 mm () Measure beating clearance of ean shalt Meash ie bearing bore of camstlafrusing m i¢mme Yer See-Figue 3—1—-8.— A Bearing bor of can shaft Standard 50. 050, 03 mim Linit 50. 08 mm Bearing clearance of canshaft Standard 3 mm Rep bce bearing of camshaft ifmeasured value ex ceeds prescribed linit Rep hce Bearing of Can shaft Disassemble the Bearing of Can shaft (1) Renove the bow | plug of cylinder block See Figure 3—4—9, (2) Remove the bearing of cam shaft using bearing changer Bearing changer 5—8840 —2038 —0. ico QRERMAMM SAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM nee Figure 3—4—10 Assanble the Bearing of Can shaft e ® Figne3-4—H-Cheek and Measure the Tappet Gan shaft 2 Measure Exemal of Tappet Figure 3 Diane: Feue3—4—13 Measure the Bore of tole for Insta ling Tappet in Cylinder B bck Assanbk the Camshaft Bearing () Letoil hole of bearing align the oil hole of cylinder b lock (2 Instill camshaft bearing using bearing chang er Bearing changer 5—8840 —2038 —0, Check Tappet Eyeballing check if there are pitting cmck and other abnomal condition al fhe conlacting surface of appet and canshatt Replce tappet if you find any pitting erick or ofher abnomal condition See Figure 3—4—11, ) Nomal contact @ Crack ® Pittng @ Abnomal contact 3) Abnomal contact VY Attention: ‘The surfice of tappet is mund. do not try to use whetstone or similar tool for cuttng or stinding itdusing repair process Replace tie tappet if THIS damaged) ( Measure Extemal D fameter of Tappet (1) Measure extemal diameter of tappet using screw micrmeter See Figure 3—4 —12, Rephee it ifmeasured value is smaller than pre seribed limit Extemal diameter of tappet Sanda) SSC~C—~C TE 12, 97=12 99 mm 5 mm (2) Measure the bore of hole for installing tappet in cylinder block and calculate the clearnce as shown as Figure 3—4—13, Rep hce tappet and /or cylinder block if the clear ance between tappet and tuppet installing hole exceeds prescribed limit Clearance bebveen tappet and tppet installing hole nd ardMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Re “4 Figure 3—4—14 Assemble the Tuppet Figue 3—4—16 Instill Canshatt Front Gasket Seat Figue 34-17 Assanble the Camshait Tim ing Pulley “| Reassamb ling Reassanble the Tappe@) () Daub oil on tappeti) and tppet hstalling hol@) at cylinderbbck See Figure 3—4—14. (2) Detem ine the position of tappet acconting © the symbol marked during reassanbling (if the tappet is used again. VY Attention Install tappet bere the assenb ling of can shaft Reassanble the cam shaft® () Daub ofl on camshaft and camshaft bearing (2) Install the canshafl © cylinder block See Figure 34-15, YY Attentioe Do not damage can shaft bearing Reassanble the camshaft font gasket sea| Install cam shaft front gasket seat to pulley housing and lighten the fixed bolts of cam shaft font gasket seat lo prescribed ue See Figure 3—4—16, ®) Tighien torque Sr fixed bolts of camshaft font gasket seal Et Tf tt ef tt tay “20N+ im t5 Nan VY Attention At first install camshaft front gas ket inside and O — sealing ring outside of the camshaft front gasket seat daub a little oil on O — sealing for a voiding damaged it during press — installing period when press— Il the camshaft front gasket seat Reassamble the camshaft tm ing pulley assmb 4 () Install camshaft tin ing pulley assembly on cam shaft VY Attentio: Daub Letii 587 silica gel on ‘wo sides of phine washer when tighten fixed bolt of tin ing pulks. Othervise oil leakage fian here will danage tin ing pulley (2) Tighten fixed bolt of timing pulley to pre scribed torque See Figure 3—4—17. Al Tighten tonue for fixed bolt of cam shaft tin ng pulley 110N+ mt10N+m toa (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 18 Assamb ling Oil Panp 3 WECHANICAL SYSTEM Reassamble the oil pump assembly) () Daub oil on oil pipe O —sealing ring and in stall it into 0 — sealing ring groove of cylinder b lock (2 Install oil pump assanbly and oil pipe tw cyl inder block Tighten fixed bolt to prescribed tore See Figure 3—4—-18 EX Tighten torque fr fixed bolt of oil pump as sanbly 20N+ m+5 Nem Figue 34-19 Daub SeakntW ithin Vaulted, Area Figure 3—4—20 Assemble the Aluminum Alloy 0 il Sump and Front/Rear Cushion (3) Tighten sleeve nut to prescribed iomue EX. Tighten tonque fr sleeve nut 20N+ m£5 Nem Reassanble the oil sump assembly) () Daub mcanmended liquid sealant or equiva kntonNa 5 main bearing housing vaulted area groove and tin ing pulley housing vaulted ata in accorlant with positions shown as Figure 3—4 —19, (2)_ Insert the wear yer part of gasket ino. Na. (mbin bearing ‘hdus|ng gmave { (@)_Ensure_the layer part cling ing’ into groove () Instlloil sump tomachine hull (5) Tighten fixed bolt of oil sump © prescribed torque See Figure 3—4 5 ®Q) Tighten torque fr fixed bolt of oil sump 20N* mt5 Nem Reassanble the rear connecting plate of cylinder 12 (D Let the dowel hole of war connecting plate of cylinder block align the dowel of cylinder bbck See Figure 3—4 —21. (2 Téhien fixed bolt of rar connecting phie of cylinder block to prescribed torque @&) Tighten torque fr fixed bolt of rear connect ing plate of cylinder block Figuwe 3—4—21 Assanble the Rear Connecting Plate of Cylinder Block 85 N+ mt10Nem GSRERRA Mas AR Zo ‘Great Wa Banding itera ambustn Engine Marfactving Company Linitee = 1 OSMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Figure 34-22 Assmble the Flywheel Figure 3—4—23 Assanble the Cylinder Head Gasket Figure 3—4—24 Measure the Bulge Fron Piston Top tw Upper Surface of Cylinder B lock Figure 3—4—25 Measure the Bulge of Piston Too Reassamble the fywheet®) () Daub oil on flywheel bolt @ Tighten fywhee! bolt to prescribed toxue di viding into wo steps See F gure 3—4—22, &\) Tighten torque br fiywheel bolt ader will up ward (pressed top dead center position) when install fywheel “I” symbol at flywheel align up central posi tion then tighten fywheel bolt Othenwise valve tin ing me cannot be ensured Reassanble the cylinder head assanb hf) (D CylinderHead Gasket ‘The choice of cylinder head gasket depends on the bulge of piston top to upper surface of cylinder block ‘There are three kinds gaskets with different thickness inpiove engine perfomance Choose one gasket fiom thiee gtoups accord ing to follow ing sequence please Clean the accumulated carbon on piston top and upper surface of cylinder bick before measurun ent clean the used ausket suifice toa ‘) \/@) Medsure'the Bulge of Piston Top ——Measie_ the bu'ge (of piston’ top -usiig mi enmeter —— Measuring position of the buke of piston top, See Figure 3—4—24 A Ilmeasuring positions should be as close to cyl inder hole as possible — Measure the pont DOO difference values for each cylinder G ). See Pigure 3—4—25, —— Obtin themaximum value fim fourcylnders — Obtain the maxinun bulge of piston mp ac conling above and choose required gasket gimup ac coming © following table Gasket thickness of cylinder head and obiain bo 2 and — CmnNe OF ule oun ww | Suet A 0. 7430 ~0. 8400 mm 1. 50mm B 0. 8401 ~0. 9400 mm 1.55 mm CG 0. 9401 ~1. 0550 mm 1. 60 mm YW Attention The measured difference beween maxim and m ininum bu lke of piston top cannot exceed 10mm ico QRERMMAMA SARA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM (3) Reassemble the Cylinder Head Install the dowel of cylinder head to cylinder block. —— hbsull cylinder head gasket upwarl, —— Clean lower surfuce of c: per surface of cylinder block. — Daub oil on the screw thread of cylinder head its top smmbol is jinder head and up Figure 3—4—26 Tighten the Cylinder Head Bolt D ivid ing Into Three Steps A ccond ing Sequence Sequence for tighten bolts of rocker shaft Figure’ 41/27 \) A’ssattbyel the Rockey Shait Pigue 3—4—28 Tighten Rocker Shaft Bolt Acconling t Sequence bolt and matching surface —— Tighten cylinder head bolt to pieseribed lomue dividing into three sleps according to the sequence of Fig uw 3—4—26, aN Tighten torque br cylinder head bolt 100.N 75N+m m ) Reassenble the Push Rod Daub oil on push md and insert it into cylinder head, ® Reassemble he RockerA ssanb ly —— Loosen all adjusting screws i install wekes’ Fis: big ofl hole ¢ “shou ld fice 10. the ‘font of engine 7 = Tighteh weker shaft seat bolt to Dreserbed torque according tw the sequence of Figure 3—4 —28 4mm), S) Tighten torque fr rocker shaft seat bolt 55Ne mt5 Nem —— Adjust valve cleamnee, Read Chapter 1 “L. 8, 7. 2 valve clearance adjust ment’ in this Manual pleaseMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 3.5 Crankshaft Disassembling sequence ® © Cylinder head assembly © Crankshaft, camshaft and high pressure fuel pump pulley. transition wheel, tensioner and camshaft front oil seal seat © High pressure fuel pump © Timing pulley housing @ Oil sump assembly Gil pump assembly Piston and connecting rod assembly @® Flywheel @ Rear connecting plate of _ cylinder block ® Rear scal of crankshaft © Main bearing housing, @ Crankshaft Reassembling sequence Reassembling sequence is reverse to disassembling sequence. Figure 3=5—1 Disassenbling and Assembling Sequence br Cmanksialt fe Te ES It PA a A) ll is SB 108 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 3 WEGHANIC AL SYSTEM 2 Disassanble the Tin ing Pulley Figure 3—5 3} Disissambie the Rear Seal of C rankshitt ; Figue3—5—4 Messure Crankshaft Thnust Clearance q lal} | fo d lo G TReoBe eR G Figure 3-5-5 Sequence for D isassemb ling Main Bearing Bolt ‘| Disassenbling Disassanble the cylinder head assanb ly) Disassemble the crankshaf camshaft and high pres sue fiel pump pulley tansition whee} tensioner and cam shaft fiont oil seal sea@) Disassanble the high pressure fire! pump) Disassemble the tin ing pulley housings) Disassemble the oil sump assenb ly) Disassemble the oil pump assanb lx Disassemble the piston and connecting wd assem vO D fsassemble Disassemble block Disassemble the flywhee@) the rar connecting plate of cylinder the sear seal of crankshafi). ‘Thmust the crankshaft deeply so that disassamb le the gasket using special tool shown as Figure 3—5—3. Rear gasket knockout 5—8840—2360 — \Y Attention Do not damage the sealing surfaces of rear connecting plale and crankshaft when disassem bling sear seal of crankshaft Disassemble the main bearing housing Disassemble the crinksha Mi | 1 Check and Repair Ifyou find heavy wom or damaged parts during chee king it is necessary to adjust pair and replace the parts Measure Crinkshaft Thmst Clearance Installm icmeter as shown as Figuie 3 — and measure crankshaft thrust clearance Replace grup thnust bearing if crankshaft thst ibed limit —4 clearmce exceeds the pie Crunkshaft thst clearance Standard 0. 040~0. 201 mm Linit 0.35 mm Measure Crankshaf\Main Bearing Clearance (1) Disassemble the main bearhg housing ac coming tm the sequence of Figure 3—5 —5. Place disassamb kd main bearing housing accom ng t the sequence of cylinderMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (2) Disassemble the cmnkshaft disassembling main bearing (3) Clean upper and lovermain bearings and main Jpumal surfice of crankshaft (@) Check main bearing for damaged and transi tion wom YY Attention Replace main bearing in— group if you find damaged or transition wom. (5) Install upper bearing and thst ring their origina | positions Carefii lly assembling crankshaft (6) Instill bwerbearing to thema in housing ofo riginal positions (D Place plastic string clearance gage on the main 7. 27 O joumal of crankshaft as shown as Figure 3—5—6. (8) Installmain bearing housing Daub oil on the screw thiead ofmain bearing housing bolt and matching surface tighten main bearing housing bolt to preserbed tore Figure 3-5-6 Insiall Plastic String Clearance Gage ®\ Tighten toque Hrmain bearing housing bolt | ‘Shane haleon aa rol ETON Rese \Y Attention Forbidden tmning the crankshaft (®) Disassembling main bearing housing (10) Measure the width of plastic string clearance gage and detem ine oil fim clearance See Figure 3—5 —7. Replace main bearing and/or crankshaft in — group if oil fin clearance exceeds prescribed lin it 11) Ranove plastic string cleamnce gage fim main bearing and crankshaft (12) Disassembling crankshaft and main bearing Oil fim clearance Fire 3—5—7 Measure the W dh of Phstic String Clea nnee Gage Standard mit 7 035~0, 080 mm 0 110mm Measure Crankshaft Rad ial Jump iness () Carfirlly put crankshaftat V—block, Slowly tum the crankshaft and measure its mal mdial jampi ness See Figure 3—5—8& 3-5-8 Measure Crankshatl Red ia] Jum pinesCHAP’ PER 3 WECHANICAL SYSTEM 44 fi if W Figue3—5—9 Measure the Diameter ofC rankshaftM ain Joumal and C rank Pin and Uneven W om Rephce crankshaft if its mdial Jumpiness exceeds prescribed limit Radial jumpiness of crankshaft Standard Linit 6. 08 mm. <0. 05mm \ (2 Measure the diameter of cmnkshaftmain jour na] and cmnk pin and uneven wom, Repke crankshaft if the uneven wom exceeds prescribed lin it Stnda dl Linit Diameter of main jumal 9% 91? ~68. 982 mm 69, 910 mm Dimewrof 59 915~52 930 mm | 52 900 mm crank pin Uneven wom 6, 05 mm 0, 08 mm Cheek Crankshaft (D Check excessive wom Biase surfages-of emanksha fhm ain Joumal and crankk (2 Check excessive wom or etn mdged gusket mate ‘hg surfaces ~ (3) Check oil hole blocked or not 10 Check Crankshaft Testing part should keep level so that testing liquid cannot flow ‘Do not daub testing Siding surface of \. Tiquid around ofl hote crank pin or eer ‘main journal About 10 mm, Crankshaft Soft N itrifica tion Checking () Use a kind of oganicmater tp clean the crank shaft campktel: Surface of checked crankshalt should be no oil vestige (2) Prepare anmonim chloride copper liquor is solve in distilled wate with the concentation of 34 10%. (3) Daub the liquoron the surfice of checked erm shaftusing injector ‘The surface of checked crankshaft should keep level Figue 3-511 Crinkshafl Soft N itrification Checking completely to ayoid the liquor flow ingMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Y Attention Porbidden the Liquor flow to reach oil hole and. its surround ing area (@ Testing —— Waiting for 30~40 seconds Crankshaft is usefil if the testing surface color hasn t changed after 30 ~40 seconds Rephce the cankshaft if the testing surface color changed to copper—colord after30 ~40 seconds —— Clean the surface of checked crankshaft u sing stean when finished the testing immediately: \Y Attention Ammonium chloride copper liquor isa kind of very caustic liquor Therefor it is abso litely necessary to clean the surfice of checked cmnk shaftwhen finished the testing immediate lx Choice of Crankshaft Bearing W hen install new crankshaft bearing or rep ace oH crankshaft bearing please consult with Tab le 3— to choose crankshaft bearing W hen choose and install new crankshaft bearhg you should note the diameter size symbols both-of joumal hole) of cylinder Heock {ahd ofmajn puma) of giankshatt manne = = = = —— Figue 35-12 Choose and Instill Crankshat Bearing Table 3—5—1 Choice of Crankshaft Bearing 5 Mah jumalaimncwrot Main bearing d meter (mm) Bearing size oman crankshaft (nm) ‘sibel at Oil fib cnkshan. | clearance énm) Size symbol Bore Size gmbol | Extemal diameter Tor— 68, 927 ~69, 942 Black 0. 035~0. 061 I 7a 987~74, 000 | 2 or— 69, 922~69, 927 0.082 ~0. 058 Blue 3or— 65, 917 ~69, 922 0. 063 0. 087 Tor— | 69 927~09. 942 0.031 ~0 036 Gwen 2 73, 975~73, 987 | 2 or— 69, 922 ~69, 927 0 0350, 048 Sor— | 6a g17~69, 922 Black 0.033~0, 058CHAPTER 3 Piewe 3-§ +14; Assanble the Cmnkshatt Figure 3—9—15 Instill Main Bearing Figue 3—5—16 Install ThustW asher WEGHANIC AL SYSTEM YY Attention A Ithough all upper bearings ofmain Joumal (at the side of cylinder block) have oil groove and hole and all lower bearings ofmain joumal (at the side ofmain bearing housing) have no oil groove and hole you are still needed t identify them. See Figure 5-13, “| Reassambling Reassamble the cranksha fi C1) _ Install main beating at thel cylinder bbek and main bearing housing “~— alt NS Ensure their coneet position (2) Daub new ofl on the surficos of upper and lavermain bearing () Carefiilly install cranksha tt (4 Daub oil on thrust washer (S) See Figure 3—5—1@ pce the thrust washer into the washer gmove ofNa 3 main joumal The oil groove should face to crankshaftMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE + lol Tel Fie 3—5—17 Assemble the Main Bearing Figure 3—5—18 Daub Scaknton Na 5 Main Bearing Housing 19. Assemble the Main Housing om, fone cil a Po taowace Fy Figue 3—5—20 Tighten Crankshaft Beating Housing Bolls Divided into A Few ‘Times Acai ing to Sequence 114 fg Se ES I Os i 1S BR 2 ret Wong ner Combustion Ege Mnetecting Cn Reassanble the main bearhg housngif () Daub recanmended liquid sealant or equiva kentonNa 5 main bearing housing) of the crankshaft accor! ing b Figure 3-5 —17. (2) Use finger sending the vaulted sealing washer intoNa 5 main bearing housing grove). (3) Daub recommended liquid sealant or equiva fntonNo 5main bearing housing3) of the crankshaft accor ing t Figure 3—5 —18, V Attention Ensure the matching surface of bearing housing have no oil dirtbefore daub liquid seal ant Forbidden liquid sealant block screw hole of cylin der block and bearing y-hssenble, he min beating housing’ the jar Tow on the top ofmain bering housing should point » the front of engine See Figure 3—5—19, (5) Daub new oil on main bearing housing bolt and screw thread match ing surface (6) Tighten main bearing housing bolts divited into@ faw tines to prescribed tonjue accom ing to the sequence of F gure 3—5 EQ Tighten torque Srmain bearing housing bolt 170 Ne mt10N+ m \Y Attention Tum the crankshaft by hand © check its operating flexible or not LinedCHAPTER 3 WEGHANIC AL SYSTEM }— 12,5 mm+0,3mm i | © Li] Figue3—5—21 Assanble the Rear Seal of Crankshaft Figure 3—5—22 Assanble the Rear Connecting Plate of Cylinder Blo Figute 3—5—23 Assamble the Flywheel Tighten Flywheel Bolt Gmdus lly bloek@) Reassanble the rar seal of cranksha Ni (1) Install war seal crankshaft at the cylinder block using seal erector Rear seal eecbe 5—8840—2359—0, VY Attention Clean the mst and chipping on the surfice before free into the seal Note the foreing di reetion of the rear seal (2) Use tvo bolts t instill tre connector of spe cial tool to the rearend of crankshaft (2) Install the seal to the outside round of con necior (4) Insert skeve into the connector and tighten the bolt (4121. 75 L=70) until the end surface of connector contacting with sleeve () Disassemble the connector and sleeve (6) Check seal instilling size when finished in stallation Stundand of seal installing size 12,5~12 8mm Reassamble the rear connecting plate of cylinder 1) Let mar connedtng piate|align the dave!\ of -eylinder lick > — - a (2) Tighten fixed bolt of rear connecting phte of oylinder block 16 prescribed torque See Figure 3—5—22, A Tighten tomue fr fixed bolt of rear connect ng plate of cylinder block 85 N+ mt10Nem Reassanble the flywheef®) () Chan oildirton the cmnkshafl screw thread cemplete ly (2) Flywheel ains at the dowel of crankshaft (3) Install flywheel to crankshaft then install washer (Daub oil on screw thread of fiywhee! bolt () Tighten fywhee! bolt to prescribed tomue di viding into to steps Tighten sequence shown as Fig ure 34 —23, Ql Tighten torque Sr flywheel bolt Step 1 (clingy lomued Step 2 (final torud) B0N+ miSNe m 120N- mE10N- m Fad S28 fl il i FSB REE a Great Wal Banding internal ambustin Engine Marfactving CompanyLinteg 11SMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Reassanble the piston and connecting md assen bhD () Install the connecting md bearing to connect ing tod body and connecting rd cap. (2) Daub new oil on cylinder hola connecting wd bearing and crank pin Figime 3—5—24 Assemble the Connecting Rad Body and lis Hous (3) Check piston ring opening position is correct or not ( Fowe the piston /connecting md assembly in 'o cylinder using piston ring compressor See Figure 3 —5—25, The front symbol of piston and connecting tod should face to the front of diesel engine Assemble the Piston] Ring \ ‘ ) ‘ ( Reassamble the oil injection pipe weldmentunit (@) Install oil injection pipe we ment unit to cyl inder block See Figure 3—5 —26. (2) Tighten pipe bolt and pressure regulator © prescribed torque aN Tighten torque Hrweldmentunit fixed bolt Figue3—5—20 Assenble the Injection Pipe W eldment Unit aN hten torque fr oil pressure regulator 46N+ mis Nem VY Attention Slowly tm the crankshaft lo check if there is obstmctive between piston and oil injection pipeCHAPTER 3) WECHANICAL SYSTEM Figure 3-5 Figure 27 Assanble the Oil Pump Assanbly 5-28 Assamble the Tin ing Pulley Housing Reassamble the oil pump assembly@) (1) Prepare the solution consisting of 80% oil and 20% molybdenum disulphide (2) Daub thick above solution on the teeth of oil pump small gear (3) Install oil pump and tighten fastening bolt prescribed tomue See Figure 3—5—2 @& Tighten tomue broil pump fastening bolt 20N+ m+5 Nem VY Attention: Do not damage the O—sealing ring when tighten fasien ing bolt @) Tighten sleeve nut to prescribed omque Q) Tighten tomue Br sleeve nut 20 N+ mi5 Nem Reassanbe the oil sump assemby) Read relevant content in. “Chapter4. 14 oi] Sunip, \agsambly"] in! this Manual’, | Reassamble the tin ing pulley housing’) () Assanble the tin ing pulley the cylinder block VY Attention: Do not wist front gasket (® Tighten be fixed bolt of timing pulley and sealing ring to preserbed tome ®) Tighten toque fr fixed bolt of tim ing pulley and sealing ring 20N* m£5 Nem (3) Cul the bulge of sealing ring on contacting surface,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Reassamble the high pressure fuel pumps) (1) Daub a small quantity of fuel on the inner ring of pad of high pressuze fiiel pump and sealing ring of hh pressure fel pump free the pad of high pressure fie] pump into high pressure fie! pump the hole of high pressure fue] pump should align the hole of pad of high pressure fie] puna Assanbke the the high — pressure fuel pump and the pad of high — pressure fuel punp on the pulley housing use thive bolls with location rod (with sping washed 0 fix it Finally install a woodmit key inside the keyway of the high —pressure firel pump, Figure 3—5—29 Assemble the High Psauie Fuel Rupa ley EX Tighten torque br bolts with location wd (2) Tighten and fixed hgh—pressue fuel pump tm ing pulley using hexagon nul Gvith spring washed . The keyway of can shaft pulley flange should align woo dnuff key of high— pressure fuel pump during assonb ling (7) (BY yrighten ‘tonjue pir fixed Holts of High — pies, ‘su fuel pump tin tig pulley-assanbly 70N*mt5 Nem (3) Install one end of el eum hose with fuel outlet pipe of high pressure fuel pump another end with fuel retum three —way jointes and clanp than lightly using two snall sieel bell ype spring hoops ( 11, 7). Hol the enclosure of the fuel outlet pipe of high—pressuw fuelpump to ensure the cleanness of fi el pipeline Reassanble the crinkshaft camshaft and high pres sure fie! pump pulley transition whee] tnsioner and cam shaft fiont oil sea] sea@) Reassanble the Crankshaft Tin ing Pulley Assanbke the crankshaft timing pulley @ using crankshaft pulley erectofl). See Figure 3—5—30, The smbol (“gap”) of crankshaft tin ing pulley should be outside Figure 3—5—30 Assanble the Crinkshaft Crankshaft pulley erectos 98522-0020 —0, Tim ing Pulley ne QRERERAM AES ER ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3) WECHANICAL SYSTEM Reassamble the camshaft tim ing pulley (1) Install the tin ing pulley of camshaft on cam shaft after installed the camshaft front gasket seat on pulley housing (2) Tighten the fixed bolts of camshaft tin ing pully to prescribed torque VV Attention Daub sealant587 evenly on two planes of plane washer when tighten the fixed bolts of cam shaft timing pulley Figure 3—5—31 Assanble the Camshat ot un Tin ing Pulley X) Tighten torque £r cam shaft tin ng pu ley 110 Ne m+10 N+ m Reassenble the high pressuze fuel pump pulley Reassamble the tin ing belt transition wheel unit Fix the tin ing belt tansition wheel unit on pulley housing using one fixed boltw ith hexagon flange See Figure 3—5—32, Qi_Tigien~tormae for fixed bolt of titing) belt \ transition wheel unit : ( TON mt10N-m Figure 32 Assemble the Tin ing Beli Transition W heel Uni Reassamble the tensioner unit Fix the tensioner unitusing one fixed boltwith hex flinge and one fixed bolt with fixed skirt (See Figuie 3 —5—33). Do not tightly tighten the fixed bolt with hexagon flange timporary t ensure tensioner unit can move freely EA] Tighten tomue fr fixed bolt of tensionerunit 20N- mi5 Nem Figure 3—5—33 Assemble the Tensioner UnitMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue 3—5—34 Assanble the Tooth Belt ‘Tension Rod Reassamble the looh belt tension rod Fix one fixed boltw ith location id on pulley hous ing fie the tooth belt tension md on the fixed bolt with Jocation od using the mutwith hexagon flange (see Fig ure 85-34). Do not tightly tighten the mut tmpor y to ensure the tooth belt tension wd can move fieele &Q Tighten tome fr nut of woth belt tension rd 20N + mi5Nem Reassamble the tin ing belt Durhg the assanbling of tin ing belt the piston of Ist cylindermust be at the compressive top dead cen tee the gap of outer edge of emnkshaft tin ing pulley should ali the “I” ype mised symbol of pulley hous hg cover At the sane tme fix the assembling lech nique hole of camshaft tin ing pulley an the locating shaft hole using technique fixed bolt Sinilarly fix the assembling technique hol of high pressure fuel punp on the beating screw hole of the pulley housing using assambling. fixed bolt Then install the belt ~the se Fayence of the! belt to’ ring -is-as folkpring CQ) crankshaft tin ing pulley \@) can shatt' tining pulley \@)tmhsition whee} @ high pressure tie! pump pulley and®) tensio ner Forbidden the phenamena such as unwanted teeth and inconect teeth among these tmveling wheels oil dirton belt and bend ete After ring the belt hang a heavy of 8 S0kg+0, IDkg/I4. 20ke +0. 10kg at the end of tension wd or forve 139. 2N ad at the vertical direction t tension the belt and then tighten the fixed dolt of tensioner Then nmove the technique bolt of camshaft and high pressure fuel punp pulley, tim crankshaft Or about720 degree in reverse to its working direction remove heavy loosen fixed bolt of tensionee hang the heavy again lighten the fixed bolt of tensioner lo prescribed tonue See Figure 3—5—85, Disassenb ling heavy and rtm fix the tension rod. Vv Alten tion: (1) Belt has moving direction symbol forbidden reverse assembling (2) If you have change a new tining bell the poise r the timing belt tension should be 14. 20 kg+ O10 kgCHAPTER 3) WECHANICAL SYSTEM Reassanble the camshaft and high— pressure fuel pump pulley hold —down plate (1) Fix the camshaft and high — pressure fuel pump pulley hold —down pute on he camshaft tin ing pully unit and high—pressure fie! pump tin ing pulley unit respectively using bolt with hexagon flange See Figure 3—5—36 (2) Fix and tehten the tooth belt tension wd u sing one bolt unit tightly tighten the nut of the tooth bell tension rod al the sane tine Fixed boltwith hexagon flange temporary to ensure Fie 2—5—36 Assenble heCamshal tensioner unit can move freely and Py lley Hol —Down Plate of High Passinis' Fuel Paiip &) Tighten tomue for fixing bolt of canshafl and tooth belt tension md ON+m45 Nem Reassmble the water pump, pulley housing cover () Strike to stds into right side of crankshaft hole of pulley housing and the top hole ofwater pump. See F gure 3-5 —37, (2) Cleanwater pump, pulley—housing cover as sambly and pulley — housing cover matching surface Place water pump, sealing.ring horizontally in “sealing groove \ddub \sea lan t587 bn water pump-see ling tingie well. ~~ ~ ~ ~ ~ (3) Conectly match wo stids rwater pump pul key—housing cover assanbhy, slightly strike to their posi Figue3—5—37 Assanble the Water tion Tighten and fix than using bolt unit M8 X70, M8 Pump, Pulley housing Cover X55), nutwith hexagon flange and hexagon socket head screw, A Tighten torque for fixed bolt of water pump, pulley—housing cover 20N- mt5 Nem Reassamble the inspection cover Fix inspection cover assamb ly on pulley housing u sing bolt unit See Figure 3—5—38, Assanbke the canshaft position senso fix cam shaft position sensor on water pump, pulley — housing cover using one bolt unit Aflerassanb}y slowly tum camshaft to find if there is impact between induct— ion and cm shaft positin sensor ©) Tighlen tomue fr fixed bolt of camshall po sition sensor Figure 3—5—38 Assmble the Inspection Cover WW aor QI RNNEReZ ,., Great al ard tral ands xine Mnf Conga intelMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE no Figure 3—5~39 Assanble the Cmnkshaft Dumping Pulley Figure 3—5—41 Assemble the Cylinder Head A sseamb ly Figure 3-53-42 Assanble the A ema tor Reassanble the crankshafi damp ing pulley Tighten the bolt of crankshaft damp ing pulky © prescribed tomue See Figure 3—5—39. VY Attention When tightens the boltofemnkshalt damping pulley. flywheel ring gear should be fixed for avoid ing crankshafts running ®&) Tighten torque for fixed bolt of crankshaft damping pulley 210N+ mt15Nem Reassanb le the cooling fan assembly Oiinal install fn pulley silicon—oil clutch and cooling fan assembly on water pump shaft Strike wo suds into righ t side of crankshaft hole of pulley housing and the wp hol ofwater pump. Tighten be nut pie scribed toque See Figure 3—5 —40, ©) Tighten torque fir fixed nut of fan j Tg Nem | / Reassamble the cylinder head assan bhyt) Read relevant content in this chapter “3. 1 cylin der head”. Reassanble the altemator (@) Install altematoy transmission belt of power steering pump and adjust the tension of the belt See Figue 3—5—42, io QQRERMMEM EAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM Transmission belt of| powser steering pump. Figue 35-43 Checking ‘Transm ission Belt Tension of A liemator and Power Steering Pump (2 Press miidle part of the belt with 98.N force (10 kg/0 and check its tension degre See Figure 3 —5—43, Deflection of transmission belt 8~12 mm (3) Tighten locking nut of idler t prescribed torque Q) Téghten torque fr locking nut 2 NemMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 3.6 Piston and Connecting Rod A ssanb ly Disassembling sequence @) Cylinder head assembly Oil sump assembly @) Oil pump assembly @ Connecting rod cap ) Piston and connecting rod assembly © Piston ring @ Piston pin locking clip © Piston pin @ Piston ® Connecting rod (Aluminum alley oil sump) Reassembling sequence Reassembling sequence is reverse to disassembling sequence. Fee S01 Dissssanbing and Assen bing Sequence lor Pision and Connecting Ral Assan bly fe Te ES It PA a A) ll is SB 124 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 3 WEGHANIC AL SYSTEM Figue 3—6—3 Disassmbke the Piston Pin Locking C lip Figue3—6—4 Disassemble he Pision and Connecting Rod ©) Disassembling Disassemble the cylinder head assamb ly) Disassanble the oil sump assanb ly) Disassemble the oil pump assanb ki) Disassemble the connecting rd cap) Disassambling piston and connecting 1d assanb i) Scrape the accumulated caibon on upper past of cylnderwall using scraper before disassembling p iston and connecting wd assanbly Disassemble the piston ring6) Disassemble the piston ring using pision rhg ex pansion diktor See Figure 3—6 —2. Pace disassembled piston ring accowt ing to cylin der omer number Disassemble the piston pin locking clip) Disassemble the piston.p in locking. clip using nee die nose piliews See Figure’ 3—6 Tt Disassemble the piston pits) VY Attention Place disassembled parts fam every cylinder acco ing © onlermumber Ensure that resbre all parts to their original position when reassamb ling, forbidden to wrong position Disassemble the pistor®) Disassamble the connecting mdi) 1) Check and Repair Piston () Carefully clean the accumulated carbon on Piston top and piston ring groove VY Attentio: Forbidden using metal bmsh t clean piston or the piston would be danaged or hurt Ifyou find any crack sear and other heavy wom during eyeballing checking the piston must be rep heed.MAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Figuie3—6—5 Measure the Bxiemal Diameter of Piston Figure 3—G—6 Measure the Bore of CylinderHole fot 1 Figue 3-6-7 Check Opening Ceamnce of Piston R ing (2) Measure the extemal diameter of piston for different group using sera micrmeter See Figure 3— 6-5 Piston group position 74 mm (fim pp) Extemal diameter of piston Size symbol Standart A 92. 975 ~92. 984 mm B 92, 985 ~93, 994 mm 93. 94. 004 mm 93. 005 ~83, 014 mm (3) Measure the bor of cylinderhole, See Figure 3-6-6, Bore of cylinder hole Size symbol Standart 93. 021 ~93. 030 mm B 93; 031,~93, 040 mm e 93. 041 93.050 min D 93. 051 ~93. 060 mm The cleammnce between the piston skirt and the cyl inder hol bor should be 0. 037 ~0. 055 mm. Piston Ring () Opening clearance of piston ring Install the piston ring into cylinder and measure its opening cleannce by inspection gage See Figure 3— 6-7 Opening clearance of piston ring Standard Linit Cean Iring | 0,20~0. 40 mm pws. ring I ring | 0.20~0.40 mm | 0, 150 mm Oil ring 0, 10~0, 30mm (2) Axial clearance between piston ring and pis ton groove ino QRERMMBMA EAR ZA Bang eral Conbston age Naf Company LinedCHAPTER 3 WEGHANIC AL SYSTEM Figure 3—6—8 Measure Cleamnce Beween Piston Ring und Piston G move Using Inspection Gage Figie's 6-9 /Medsum tye Bxiemal Diameter of Pion Pin Figure 3-610 Measure the Bore of Connecting Rod Small End Hole Figue 3-6—11 Assembling Piston Pin Measure axial clamnce between piston ring and pis ton gmove using inspection gage See Figue 3-6-8 Rephce the piston ifmeasured cleamnce exceeds prescribed limit Axial cleanmee between piston ring and piston groove Standart Linit 0, 078~0. 137 mm Iring 0. 055 ~0. 095 mm} 9 150 mm IL ring Piston Pin Ifyou find any cmck, scarand other damaged during eyeballing checking replace piston pin if necessary. (1) Measure extemal diameter of piston pin at thiee different positions and two directions using screw micrmeter See Figue 3—6—9, Rephce the piston pin ifmeasured valie exceeds prescribed lin it Extemal diameter of piston pin Tiana 30, 995-31, 000 mm ease hole See Figure 3—6 —10. Replhice the connecting rd or hushing and piston pin if the clearance bebveen the connecting td snall end hole and piston pin exceeds prescribed limit Clearance between the connecting md small end hole and piston pin Standard Linit 0. 008~0. 020 mm 6. 05 mm (3) Insert piston pin into its seathole and tum it See Figure 3—6—11. The clearance isnomal if piston pin tum flexible, Measure the clearance if there is clearance or rough ness Rephce the piston or piston pin if the clearance exceeds prescribed lin it Clearance between piston pin and ils seat hole Standard Linit 0. 002~0. 015 mm 0. 030 mm fie te Great el Band interal CombsMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Figure 3—6—12 Replace Piman Shaft Bushing Figuie 3-6 <13) Megsure Center EmorBetween the Big End and Small End of the Connecting Rod Figure 3—6—14 Measure Axis! Clearance of the Connecting Rod Bushing Disassembling: use suitible stick and bench p ess or hanmer Assambling use suitable stick and bench press VY Attention —— Bushing should align the connecting md small end hole After installed new pitman shaft bushing youmust use muller formulling the bushing Conneeting Rod (1) Center line enor between the big end and snall end of the connecting 1nd Check the center line err beween the big end and small end of the connecting md using connecting wd rguhior See Figure 3—6—13 Rephce the connecting md if the canber or twist exceeds prescribed lm it Camber or twist of’ connecting tod "7 Sundaes PS. Lint Canber Svea | 0 20mm ‘Twist <= 0, 05 mm 0.15 mm (2) Axial clearance of the connecting md Measure connecting md thmst clearnce at con necting md big end using inspection gage See Figure 3 6-14, Replace the connecting md ifmeasured value ex ceeds prescribed linit Axial clearance of the connecting md Standard Lint 0. 175~0. 230 mm 0. 350 mmCHAPTER 3 WEGHANIC AL SYSTEM Figue 3-6—15 Measure Oil Fin Clearance Betveen Connecting Rod and Crankshaft Figue 3—6—16 Measure Pisstic Line Clearance Gage W id th and Deter ine Oil Fim Cleanmee Assenble the Piston Figue 3—6—17 Connecting Rod (3) Oil fim clearance between connecting md bearing and cmnk pin —— Ramove connecting md cap nutand connect ing wd cap —— Put away disassembled connecting md cap acconl ing t cylinder orier number Clean the surfice of connecting md bearing and crank pin Carefillly check if there is damaged connect ing wd bearing All bearings must be replaced even if you find on ¥y one damaged or heavy wom bearing — Reinstall connecting wd bearhg t their o riginal position Place plastic line clearance gage on crink pin — Reinstall connecting wd cap to their original position —— Tighten connecting md cap nut ® prescribed tomue divided into wo steps a Sep 1 (clingy wiqued ‘Tighten torque fr connecting wd cap nut Step 2 (final worque 85.N° m5 Ne mj, a5 Nemes5Nem VY Attention Forbidden tm crankshaftwhen tight en connecting sod cap nut — Ramove connecting md cap. —— Measure plastic line clearance gage with and detemine oil fin ckarance See Figure 3-6 —16 —— Ramove phstic line cleamnee gage fm crink ph Oil fim clearance between piman shaft and crank pin Standard Limit @ 029~0. 075 mm 0.100 mm “4 Reassambling Reassanb le the connecting rdid) Reassamble the piso) Install piston on connecting md the fmnt symbol at piston top should be at the same side ofGW symbol at connecting 10d See Figuwe 3—6—17. YY Attention Do not change the piston /p iston p in unitwhen change piston /connecting rd unit fe TE EE A A) Bl is SB Company ‘Great al Baoding Iteral anbustoa Engine Marfecutng ComperyLinted = 1 29.MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE TOP symbol ~ (compression ring) Figue 2 —6—18 Assemble the Pision Ring Surface with mil Figue 3-619 Assanble the Sequence For Piston Ring Figue3—6—20 Assanble the Positions forPistn R ing Opening 130 Reassamble the piston p in) (1) Daub oil on pisin pin and piston pin seat hole, Push piston pin into piston pin seathok using fingers (2 Weigh each piston and connecting md assem bie ‘The choice of piston and connecting we unit should ensure that the change of the assambly mass difference r different evlinder is within prescribed range Prescribed vahe for the mass difference of piston and connecting rd matching unit <38 Reassamble the pisin pin locking clip Reassanble the piston ring®) (D Assanble he piston ring using piston ring di tor TOP symbol should be upwari when install piston ring Figwe 3—6—18 shows the position of piston sing identifying symbol (Installing sequence of piston ring is as follow ing See Figue 36-19. \@ /O4l ring “Ww ith’ cap-ring) i (Q) “LT com pression, ring (printed shin bol “TOP” || is Upward > - ~ ® Leampression ring (printed symbol “CYPR” or “CCC” is upward) VY Attention ‘Two compression rings cannot be interchanged. —— Piston rings cannot be warped. —— Forbidden disfigurement or mpurity inside ring gmove (3 Daub oilon all piston rings surface and check if they mnning flexible after finished installation Reassanble the piston and connecting md assan bho) (1) Daub oil on cylinder hol connecting rd bear ing crank pin and every piston ring and piston surface Check the open ing position of piston ring is correct ornot F gure 3—6—20, fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3) WECHANICAL SYSTEM (2) Assanble the piston /eonnec ting 10d assanbly into every cylinder using piston ring compressor See Figure 3—6 —21. Fiat ymbol at piston top should face to engine front Reassmble the connecting md cap) () Let the printed syn bol at connecting rod align the printed symbol at connecting md cap (2) Daub oil on the screw thread of connecting od cap boll and matching surface —6—21 Assmbke he Piston/ () Tighten connecting md cap nut preserbed Connecting Rod Assembly tonjue divided into wo steps %) Tighten tome Sreonnecting md cap nut Fieure Siep 1 (clingy bmque) Step 2 (final torqud J Cheek if the crnkshatt running flexible or not after tighten the connecting md cap nut Reassamble the oil injection pipe weldment unit (1) Install oil injection pipe we Hment unit to cyl inder block See Figuw 3—6 —23, 2 -A-ssanble the Connecting (2 Tehten_pipe bolt and pressure, regulator 0 Rod Bearing, Cap Pipserited) torque J h Gie® i ( V | 2A Tighten’ tomuie- for jail injection ‘pipe’ well ment unit fixed bolt W M8 X 1, 25 20 (@) M6 XL 00 10N+ m+ *miSNem Nem EX Tighten torque Qroil pressure regu lator 46N* mi5 Nem Figure 3—6—23 Assanb le the O il Injection VY Attention Slowly tum the crankshaft check Pipe W eldnent Unit if here is obstuctive beween piston and oil injection pipe Reassanble the oil pump assembly) Read relevant content in this Chapter “3, 4 cam shaft and tappet. Reassanble the oil sump assembl¥2) Read relevant content in this Chapter “3, 4 cam shaft and tappet’, Reassamble the cylinder head assan bly) Read relevant content in this Chapter “3. 4 cam 6—24 Assanble the Oi) shaft and tappef’. Pump Assembly GSRERRA Mas AR Zo ‘reat al Baoding lteral Canbuston Engine Mareficunng Company Limited = 1 31 FigureMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 3.7 Oil Pump Assembly Disassembling sequence @ Oil sump assembly © Oil pump assembly & Oil pipe @ Strainer © Pump cover © Driven gear and bushing © Driving gear ‘Output shatt Reassembling sequence Reassembling sequence is reverse to @ Oil pump body disassembling, sequence. Figue S=7=1 _Disissanb Ing and Assembling Sequence oro Pump Asanbly 132 (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM Figue 3-7-2 Disisenble he Oil Sump Assembly Pigumt 3-478 | Digissonbie the Oil Pump Assanbly Figure 3—7—4 Disassamble the Pinion Pin Figue 3-7-5 Between Upper Teeth of Gear and Inner Wall of ousing Measure the Cleannce ‘| Disassenbling Disassemble the oil sump assenb hi) Disassemble the oil pump assanb k2) Disassemble the oil pip) Disassemble the stminefa) Disassanble the pump cove) Disassanble the driven gear and bush ing®) Disassemble the driving geat?) Disassemble the output sha) Disassemble the pinion pit®) (D File pinion stop pin rivet 2) Strike out pinion stop pin using hanmeer and stick (3) Disassembling pinion Disassemble the piniortid Disassemble the driving shaft Disassanble the oil pump bodstiF 2) Check and Repair Ifyou find heavy wom or damaged parts during chee king it is necessary to adjust repair and replace the parts { | i : ( Housing and Gear. — SPN Rephce oil punp assembly if you find ®liwing one case () Bushing of driven gear shaft has heavy wom or damaged (2 Gear teeth has heavy wom or danaged. Clearance Between Upper Teeth ofG ear and Inner W all of Housing () Measure the clearance between upper teeth of gear and inner wall of housing using inspection gage See Figure 3-7-5, (2) Replace gear or housing if measured clear ance between upper leh of gear and innerwa ll of hous ing exceeds the prescribed linit Clearance beween upper teeth of gear and inner wall of housing Standard Linit 0.14 mm 0. 20 mmMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Clearance Between Pump Cover and Gear (1) Measure the clearance between pump cover and gear using inspection gage See F gure 3—7—6 (2) Repke housing if measured clearance be tween pimp cover and gearexceeds the preserbed init Clearince between upper teeth of gear and inner wall of housing Lint Standard Fisue 3—7—6 Measure the Clearance Bebveen Gear and Pump Cover P jure 3 ~7 -7, Measure Extemal DimeerotDiiving Shaft Clearance Between Driving Shaft and Oil Pump Body () Measure extemal diameter of driving shaft u sing screw micumeter See Figue 3—7—7, (2) Measure the bore of pump body using mi crmeter (3) Replace oil pump assembly ifmeasured clear ance between driving shaft and oil punp body exceeds the prescribed limit Clearance between driving shaft and oil pump body Standard Linit 00d mm. 0.20 mam @ g, C léafance Between.D riveri Shaftand Bushing (D Measure extemal diameter of driven shaft w sing screw micameter (2 Measure the bor of bushing using bor mi ermeter (3) Repkce bushing ifmeasured clearance bebveen driven shaft and bushing exceeds the prescribed limit Crarance between driven shaft and bushing @ ip Standanl Linit Fie 3-7-8 Measure the Cleance S:dosreny O13 mm Between Driven Shaft and Bushing ** Reassanbling Reassamble the oil pump bods Reassanble the driving shaft Reassanble the piniortid Reassanble the pinion pix) (1) Install new transmission shaft on oi] punp body, (2) Install pinion on driving shah (3) Bore one 5mm hole using drill through pinion and tungnission shaft fim thishole See Figure Figure 3—7—9 Assimble the Pinon 3-7-9. fe Te ES It PA a A) ll is SB 134 ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3) WECHANICAL SYSTEM @) Insert pinion pin into the hole and rivet it Reassanb le the output shai) Reassanbke the driving geat?) Reassanble the driven gear and bush ingé) Reassanble the pump covetS) Reass¢mble the straines Assanbk the strainer assembly and tighten fixed bolt of strainer assembly to prescribed tomue See Fig ure 3—7—10, EX Tighten toque for fixed bolt of stainer as sembly 16Nem Reassanble the oil pipe) Read relevant content in this Chapter “3, 4 cam shaft and tappet’. Reassamble the oil pump assenbh2) Read relevant content in this Chapter “3. 4 cam shaft and tappet’. Figure 3—7—11 Assanble the 01) Pump Assembly Sump Asamb ly Reassanble the oil sump assanb xi) Read relevant content in this Chapter “3. 4 cam shaft and tappet Figue 3—7—12 Assable the OilMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 3.8 Cylinder Block Beh KG Cz A, Disassembling sequence We @ Cylinder head assembly @ Oil sump assembly © Crankshaft timing pulley @ Tigh pressure fuel pump assembly © Timing pulley housing assembly Flywheel © Rear connecting plate of cylinder block ® Rear gasket of crankshaft G) Main bearing housing @ Crankshaft G Camshait @ Tappet Reassembling sequence © Cylinder block Reassembling sequence is reverse to disassembling sequence. Figure 3—8—1 Diswenbling and Assanb lng Sequence ior Cylinder B bok 136 (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM Figure 3—8—2 Disassemble the Every PartofCylinder Block Figue3—8—3 Measure Upper Surfice of Cylinder Block Meusure the Bore of Cylinder ©) Disassembling Disassemble the cylinder head assamb ly) Disassemble the oil sump assenb ly) Disassemble the crankshaft tin ing pulley) Disassemble the high pressure fuel pump assamb ly) Disassemble the tin ing pulley housing3) Disassanble the oil pump assanb lx Disassemble the piston and connecting md assen bho Disassemble the flywhee(®) Disassemble the rar connecting plate of cylinder blo Disassemble the rear gasket of crankshaft) Disassemble the main bearing housing Disassemble the cranksha hi Disassanble the cam shafthif Disassemble the mppekig Disassanble the cylinder b lock ® Check and Repair If you find heavy wom or damaged parts during checking it is necessary to adjust pair and rep hee the parts, (C2 Disassemble the-any other inserted parts) on sealing washeé ‘gasket andicylinder block, 7 VY Attention — Forbidden any other substance fall into cyl inder block accidentally. —— Do not semape upper surface of cylinder b ck. (2) Disassemble the the gaskets on match ing sur face of oi] sump assemb hs spacer of war gasket and oil sump. (3) Clean the surface of cylinder b lock Fatess (D Disassemble the cylinder block pin (2) Measure the four edges and two diagonals of upper surfice of cylinder block See Figure 3—8 —3. Replace the cylinder block if measured value exceeds the preseribed lim it Measure the bore of cylinder Measure the bow of cylinder at the point]) along mst fore dictions?) —@) and cunkshaft axial direc tio) 3) using bore micmmeter See Figure 3—8—4. Height atmessuring point) 20 mm fe TE EE A A) Bl is SB Great Wa Banding itera ambustn Engine Marfactving CompanyLinteg = 1 37MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figure 3-8—5 Assemble the Tappet Figure 3—8—6 Assanble the Canshaft Figue3—8—7 Assanble the Pision Pin Locking C lip Check and repair the cylinder to specialmaintenance slalion ifmeasured value exceeds the prescribed lin it Bore of cylinder hole Standard Linit 93 021 mm 93. 100 mm Resanb ling Resanble the cylinder b loci Resanble the uppeb% Resanble the cam shafif (CD Daub oil on uppet surfice and tappet instil ling hole of cylinder block (2) Install the tappetatd isassembled position Cif use the tuppet again). (3) Daub oil on camshaft and camshaft bearing (4 Install the camshaft on the cylinder block VY Attention: Forbidden damage the canshaft bear ng Resamb/e the cranksha ff# Read relevant content in this Chapter “3 5 cmnk shaft’, Resanbe the main’ bearhg housings : Read] relevant content iit this Chapter “& 5 cmnk shaft’. -~ it — es Resamb/e the war gasket of cranksha fli) Read relevant content in this Chapter “3 5 crank shaff . Resmble the rar connecting plate of cylinder block®) Resanbie the fywhee(@) Read relevant content in this Chapter “3. 4 cam shaft and tppet’. Resanble the piston and connecting rod assanb Ni (1) Daub oil on pision pin and piston pin seat hole Push piston pin inw piston pin seal hok using fingers (2) Weigh each pision and connecting md assanb ly. The choice of pision and connecting md unit should ensure that the change of the assanbly mass difference Sr diferent cylinder is within prescribed range Prescribed vahe for the mass difference of piston and connecting td mateh ing unit <3¢ (3) Climp the connecting wd using pliers and do not damage it () Install fe piston pin— locking clip into its gioove using needle nose pliers See Figure 3—8—7, ic QRERMMBMA SAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 WEGHANIC AL SYSTEM Figue 3-8-8 Assemble the Piston, Connecting Rod a Fiaule 8-855) Alssanhie/ the Piston Rin Figue 3—8—10 Assambie the Pisin Pin Lock ing Clip 1 compression rin Surface with symbol = ¥ is upward @ Nag {Ucompression suclace cyanea Oil ring. ee Pige 3-8—11 Assenble the Piston Compression B ing Y Attentioe Do not change the pision /p iston pin unitwhen change piston ‘connecting md unit (5) Install piston on connecting md. See F gure 3 8-8 The front smmboll) at piston top should be with the sme direction of “GW” simbol2) at connecting tod, (6) Daub oil on piston pin and piswn pin seat hole Push piston pin in piston pin seat hok using fingers until it to piston pin— locking clin See Figure 3-8-9, ch-bress Piston p in locking ub78 ite dmsoyd ‘Sing fingers SeeF gure 3—8—10. Check the opening of connecting tod on piston pin is flexible or not (8) Daub oil on piston ring surface Assanbke the tive pision rings using piston ring dilator Piston ring dilalog 5 —8840 —9018 —O, Assanbke the sequence for piston rings is shown as Figuie 3—8—11 @® Oil rng (oil cup spring and oil ring). I canpression ring (printed symbol “TOP” is upward. ® J compression ring (printed symbol “CYPR” or “CCC” is upward). RETA MM HisaRAG |. (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE TOP symbol ~ (Ll compression ring) Ficur 3-812 Identify Piston Ring Symbol Serew spring- support opening ¢ 1 Compression ring s 4 i ring Figue 3—8-—13-Cheek ste Opening Position of Pistpn, Ring Pigue 3—8—14 Clean the Dirton RearBack and Asumble the Surfice of Connecting Rod Bearing Figure 3 140 8-15 Asamble the Pisin Ring V Attention —— The surface with symbol should be upwari when install compression ring See Figure 3—8—12, Insert se1ew cup ring into oil cup givove and ensure that there is no cleamnce at both side of screw cup ring bere assamb ling oil cup, lwo compression rings cannot be interchanged. —— The upward symbol of eampression ring should fice to piston top. — Piston sings cannot be waiped. —— Forbidden disfigurement or inpurity inside pision ring gmove (® Install the opening position of piston ring as shown as in Figure 3—8—13 Check if piston ring is tuming flexible in piston ring groove 9) | carekaly lente att and! Josity oh fhe “urfice Of connecting md Bearing and clean itusing silk fabric See Figuw 3—8—14, (1D Daub oil on the surface of lower and upper bearings of connecting mc install than into connecting od bearing seat (12) Daub ofl on cylinder wa ll The top front symbol of piston ring should face to the front of engine during assembling Fore pisin rig using pision ring compressor Pure 38-15 Piston ring campressor 5—8840—9018—0 (J— 8037). (13) Push piston into cylinderusing harmer handle until upper bearing of connecting md conucting with crank ‘Tum crankshaft until crank pin to bottan dead center at the sane tine See fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 3 “i Front symbol 16 Assemble the Connecting Rod Figures Pine 8717 /Agsenble theComfotng Rod Cap Figure 3—8—18 Assamble the 0 il Injection Pipe W element Unit WEGHANIC AL SYSTEM (14) Place connecting md cap and let its font symbol face to the font of engine See Figure 3—8— 16. Align the cylinder onier mamber symbol at con necting md cap with the onler number symbol of cylin dev (15) Daub oil on the screw thread and matching surface of every bolt of connecting md cap, (16) Tighten connecting sod cap nul to prescribed torque divided into wo steps 4) Tighten tomue fr connecting md cap nut Step 2 (fnal torqued ‘ep 1 (cling; y brque) {| Wi alitention; Tum the crankshaft hy hand to eheck he crankshaft aunting~flexble orhok ~~ — Reassanble the oil injection pipe weldment unit () Install oil injection pipe we Hment unit © cyl inder block See Figue 3—8—18 (2) Tighten pipe bolt and pressure regulator prescribed tomue EX Tighten torque for oil injection pipe weld ment unit fixed bolt () M8 X1, 25 20N+m+i5Nem 10N+mi2N-m @) M6 XI. 00 a ‘Tighten torque Hroil pressure wgu lator 46N- mt5.Nem YY Attention Slowly tum the crankshaft io check if here is obstmetive beween piston and oil injection pipeMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Resanbie the oil pump assenbl¥@ Read relevant content in this Chapter “3, 4 cam shaft and tappet’. Resamble the tin ing pulley housings) Resanble the high pressure fuel pump assembly) Resamble the cmnkshaft tm ing pu lley3) Read relevant content in this Chapter “3 5 crank shaft’, Figue3—8—19 Assanble the 0 il Pump Assanbly Resamble the oil sump assamb 820, Assendiethe oft Simp Assemb Resemble the cylinder head assen bi) Read relevant content in this Chapter “3, 4 cam shaft and tapeCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, CHAPTER 4 GW 2. 8TC TURBO —DIESEL ENG INE 4.1 Summary GW 2, 8TC tutbo—diesel engine adopts electric diesel i direct injection technology and is instilled with BOSCH i high— pressure fel rail system so that ik atured with lov — idle speed large tomue excellent accelerated perfomance and enemy saving and envionment friend ye GW2 BTC usbo—diesel engine adopts» — type can bustin chamber and electric control high pressure fi el mail fuel supply systan. This design provides excel lent fuel econany performance within wider operation jange and meets the Eum III standari Its canbustion efficiency is increased more than 8% with traditional Fie4—1—1 LeftView ofGw28Te Wtbo—diesel engine and its fuel consump tion per hun Tubo—Diesel Engine dred kilometers is decwased more than 10% with tadi tional wibo—diesel engine and its noise reduced more than 16% \ ©) Gasket of eylinder head is piled tip w ith tin steel i pias. i Wenn, ol ‘There are three sizes of gasket of cylinder head ac ce cor ing tomeasured vale with piston bp relative tm the bulge of eylinder block so that duce the divewence t range of campression ratio Te Use torquemethod to tighten the fixed bolts of cyl inder head, connecting md and flywheel] | Cylinder hole Ralused witout lines the distortion . 3 of cylinder hole is mall good mediation, and idealma terial and metallogmphy has been used so that has high erwear ‘© reduce heat dilation and noise during cooling the engine stee| bracket has been founded at the pis bon skirtwith finetion of self—canpensaty for heat Soft nitrification crankshaft has very long working life ‘The crankshaft cannot be grinded also due to taf er nitrification teament Crankshaftma hh bearings and connecting red bear ngs are potmetal bearings with stonger lading ab ili e Therefors it is very important to keep the oil hole for bearing clearmca the cleanness for ofher relevant surfaces and to rmove the in purity Figure 4— Right View of GW2 8TC ‘Tutbo—Diesel EngineMAIVTENANCE MANUAL O OF GW2.8TC TLNBO “DIESEL ENGINE Figure 4—1—3. Vertical View of GW2, STC Turbo—Diese| Engine The sof nitrification weament (nitrification teat men) fr crunkshafl increases its intensity and elimi nates the operation to grind crank pin and main jour nal and so on Oil injection device has been set for cooling p iston at oil passage The function of the device is © inject oil to piston by one—way valve through mach ine hull oil passage Do not danage the oil injector during the disassenb g and assenb ling of piston and connecting 1d assan by. GW 2 8IC turbo—diesel engine adopts electric con tol high — presume fiel mil pressure fr fel supply can be up to 145 MPa and the injector is 6 —hok elec tric control type so that it is possible obtain the opti mal mixture ratio between air inlet and fuel injection GW2 8TC turbo—diese] engine adopts GSK pre heating plug controlled by electric control unit It fea tured with mpid preheating and heating after starting as wellas start quickly and less ham fill gas en issionCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4.2 Engine Assenbly Disassembling sequence @ Transmission assembly and clutch assembly Radiator assembly ‘Air inlet tube and flow rate sensor Heater hose @Hlamess Preheating plug Fuel hose Wire of oil pressure switch 5) AIC compressor assembly W Power steering pump assembly 1} Vacuum pump hose @BFront exhaust tube Engine bracket (Engine assembly Reassembling sequence Reassembling sequence is reverse to disassembling sequence. FEU I =2=1Disissenb Ing and Assanb Ing Sequence for Ene he Asem REKN AMSAT, . anafecturing Company Lites (Grea aang eral Combs EgMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Figue4—2—2 Disassemble the Gwunding Cable of Ba tery Fiene 42-3 Disassemble the Tranimission ahd € ture fem Figue4—2—4 Disassanble the C luted A ssamb ly ) Disassembling Prepa.ation (1) Disconnect the giounding cable of battery See F igure 4-2-2 (2) Dain the cooknt of cooling systan canpktel. Disassanble he tunsnission assembly and elateh assamb iD) Lift vehicle und use suitible safely stand to sup port it () Transmission assenb ly Ramove the trnsmission shaft frm flange fork, —— Ramove the speed sensor connector —— Remove transmission assenb y. See Figure 4 -2-8 1) Yi Altention; Piotedt, speed. sénsor assem b led l'on -elaich heusing pase [tsa plastie-part ~— @ Clutch assanb ly VY Attention Forbidden liquid on clutch surface and clean the surfice if ithas liguid p lease —— Ramove pressure disk assambly. —— Remove driven disk Jse guid ing m iddle— aligner to avoid driven disk assamb ly fall down fieely, Guiding m idd le—alignes_ 55825 —3001—0, Figie4—2—5 Disassemble she Overflow Tank Hose ne QQRERMRAM AES Print symbols on flywheel and pressure disk flange so that it can be aligrment when assemb ling Loosen fixed bolt of pressure disk assamb ly and ranove chitch assembly, See Figure 4—2— Disassemble the mdiator assanb 2) () Disassemble the upper and lower hoses of m. diator (® Disassemble the overflow tank hose See Fig ei Za) ER ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figure 4—2—6 Disassemble the Radiator Assembly Pigié 442~7 |Dijgissmibie the Air Injet Tube | Figue4—2—8 Disassanble the Preheating Pag Figie 4-2-9 Disassemble the AC Compressor Assen bly () Disassemble the rad iilor assembly. See Fig ure 4—2—6 Disassamble the air inlet ube and fow mte sensof) Air flow — rate sensor is a kind of precision inst ment its status will direct affects engine opemtion During disassembling you must carefull protect it do not knock and ditty it Itneeds special safekeeping af ter disassanb ling Disassemble the heater hosé) Disassanble the hamess) Pull out hamess connectors frm canputer (ECU) and various electric equimments loosen hamess hoop and bracket disassamble the hamess | ji l Disassemble the prehea tig page) Disassemble he fuel hosé) Disassanble the fuel inlet hose and fuel retum hose, Disassemble the wire of oil pressure switelt®) Disassemble the A/C conpiessor assanb h@) () Loosen adjusting bolts of A C campressorand then disassemble the tunsnission belt (2) Disassamb le the magnetic cli tch wire connec or (3) Disassemble the A /C compressor fixed bolt and mmove A /C campressorassmbly See Figure 4—2—9.MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Disassemble the power steering pump assamb lyf) 1) Loosen adjusting bolls of power steering pump and then disassanblng tans ission belt See Figure 4 —2-10. (2) Disassemble the oi] inlet hose and oil rtm hose of power steering pump. (3) Disassemble the paver steering pump fixed bolt and remove power steering pump assanb ly. Disassemble he vacuum pump hosdif Figure 4—2—10 Disassemble the Power Swering Pump Assembly Disassemble the fiont exhaust wbdi ie (D Loosen fixed bolts fiem fiont exhaust ube of exhaustmanifok. See Figure 4—2—11. (2) Disassemble the support bolt fim fiont ex haust ube (3) Disassanble the fixed nut fiom front exhaust tube Pigure 4—2—11 Disassemble the Front Exhaust Tube (Only for reference) Dbusbemble the engine brecke KA ~~ Disaséemble“the léftand right bricketsand ‘claw pads fram Wo sides of cylinder block, See Figure 4 —2 12 Figuse4—2-12 Disasemble the Engine Bracket | . Disassemble the engine assemb sit () Carfilly lif engine by crane (2 Frntof the engine should be higher than rar F of the engine when engine after lifted. (3) Forbidden damage any oil pipe braking pipe and appliance elanentwhen take out the engine assem bly Fie 42-13 Disassenble the Ensine A ssanbly ne QRERMAM EAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE #4) Assembling Assanbk the engine assanb iff Place the engine by crane Assanbk the engine biickeS Assambk the kft and rh! bmekets of engine Tighten bricket fixed bolts to prescribed tomue See Figue 4—2-14. Ql Tighten tomue for leftand right brackets of en. gine 14 Assemble the Engine Bracket ~ I a, Figue 42> 15; ssenble, the Pont Exhaust Tube! 40 N- mis Nem Assanbe the front exhaust ubdg (D Connect front exhaust tube and tighten fixed nuts of fiont exhaust tube to prescribed tomque See Fig ure4d—2-15. (QI Tighten tomue fr fixed nuts of front exhaust tube 67 N+ mi5 Nem @) Tighten biucket bolls of font exhaust ibe Prescribed tomue 2) -Tehten-toque for bracket bolls of front ex (haust [| i ( h = 40 N-mEs Ne a = Assanbk the vacuum pump hosdbii Assanbke the power steering pump assemblyid) () Assan ble the power sleering—pump and tube bracket Dl ing pump Tighten tomue Sr fixed bolls of power sieer Pigue4—2—16 Assanble the Pover Steering Pump Assan bly 20Ne mis Nem Ta) -Assenbe He TANS SOHN Dele oF POET Ser ing—pump and adjust its tension Replace the belt if is has wom or damaged (3) Press middle part of the belt with 98 N force and cheek its tension degree Deflection standard of tansnission belt of power steering—pump 12 mm Assanbke the A AC cam pressor assanb ly Figue4—2—17 Assemble the AC Compressor (D Assemble the A C com pressorand tighten the fixed bolts o prescribed tomue See Figue 4—2—17. fe TE EE A A) Bl is SB Company ‘reat al Baoding Iteral anbuston Engine Manfecutng ComperyLinted = 1 4:9.MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE EX Tighten torque for fixed bolis of AC cam > pressor of We 20N+ mi5 Nem A (@ Connectmagnetic clutch wie connector \ (3) Assanble the tansnission belt of A /C can Ox pressorand adjust its tension Rep kce the belt if is has wom or damaged @) Press middle part of he belt wih 98 N force and check its tension degree Fiqie4—2—18 Assomble the Oi) UY Deflection stndard of tansnission be ltof A /C can pressor 8~12 mm Assanbke the wire of oil pressure switeli® Connect the wire connector of oil pressure sw itch, See Figure 4-218 Assanbk the fuel hosd?) Connect the fixe! inlet hose and firel wetum hose and ‘hen tightly tighten-the clips. See Figure 4-2—19, OO) ; ies i Assen the preheathg plug) 7 \ Connect preheating plug wire connecr See Fig ured —2—20. Assanbke the hamess) Insert every sensor plug of the hamess into engine cam shaft position sensor water tempem tie sensor en gine water temperature sensoe high—pressure fuel mil pressure sensor vacuum regulaips high—pressure fuel pump, four injectors and EGR valve Pigure4—2—20 Assemble the (1) Hiteh preheating plug teminals using fur Proheating Ping connectors of engine hamess respectively. Tighten and fixed than using four nuts w ith hexagon flange surface [A Tighten torque for fixed nuts of engine har ness 4NemiiNem (2 Insert and connect BCU into comespond ing plug of engine hamess Ensure that the serial number at bar code label of ECU is accordant with the serial number of Figue4—2—21 Assemble the Engine Hamess fe Te ES It PA a A) ll is SB 150 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company Lied engineCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE Assanbk the heater hos) Connect the healer hose and then tightly tighten the clips See Figue 4—2—22 Figue4—2—22 Assemble the Hesierilose Figuie 4 $2429 wesimb he the Air Injet Tube | Pigured4—2—24 Assemble the Radiator ssonbly Figure 4—2—25 Assenble the Upper and Lover Hoses of Rad ialor Assanble the air inlet tube and flow rate sensof) Connect the air inlet tube and flow mate sensor and then tightly tighten the clips See Figur 4—2—23, Airflow rite sensor has instilling directiog the artow is to air inlet of turbocharger VY Caution Keep the cleanness of airfbw rate sen sor Forbidden dirt and dust filling into it Assanbk the mdiatr assemb i) () Assanbk the mdiatorassenby See Figure 4 —2—24, (2 Connect upper and lower hoses of id iator See Figure 4—2—25, (9 Connect overflow tank hose Assanbe the transmission assembly and cluteh as sembly) Read relevant content in this Chapter “4.12 fy wheel and the 1™ shaft front bearing of transn ission” .MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4.3 Engine Bracket Disassamble the Sequence ® Air inlet tube ® Fan cowl ® Leftand right brackets Reassenble the Sequence Reassamble the sequence is reverse i disassmb ling sequence, Figue4—3—1 Disconnect the G munding Cable of Battery **) Disassenb ling Piepaia tion — s h ()_D iscohnect the Zqpunding table of batten” - (2)-D mii the-coo nt of coo ling-systan-canp etek. Disassemble the air inkt tube) Disassemble the air inlet tube See Figure 4— Figue 4-3-2 Disassemble the Air Inet Tube Only for reference? Disassemble the fn cow@) (1) Disassamb ke the fun cowl See 3 (2) Disassemble the upper and laver hoses of m diator Figure 4—3—3 Disassanble the Fan Corl and Ke Ujperand Lope ue of ede 152 (FE EC I BE a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figue4—3—4 Disassemb/e the and Assenbling Left and Right B rackets of the Engine Figure 4—3—6 Upper and Lower Hoses of Radiator Disassemble the lefland righ! bracket) () Disassemble the Sur bolts to fix left bracket with cylinder block and mmove left brcket See Figue 4-3-3, (2) Disassemble the four bolts to fix right bracket with cylinder block and mmove right bracket See Fig ure4—3—-4. ** Assanbling Assanbbe the leftand right bmcket@ () Fix left bracket t cylinder block by bolts (Mi4 X45, M10 X25 M10 * 100, and with spring washer EA Tighten torque br fixed bolts of left bracket M10 bolls 40 Ne misN- m M14 bolts TIO Ne m£20N°m (2) Fix right bracket to cylinder bck by bolts M10 X25, M10 X80, and wih spring washer), Bi Tebien omue forifixed, bolts of tight backel Ll I v 40N* im +5 NAm_ Assanbe the fan cow@) () Assembk the fan cowl See Pigure 4—3—5. (2) Assemble the upper and bwer hoses of rad br See Fie 4-3-6, Assanbke the air inlet ubdiy Assanbee the air inlet tube Cany out Olbwing tasks after assembling please @ Connect the ground ng cable of battery, ® Fill coolant into cooling systan. 3) Start engine and check if the coolant has leak age or notMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4.4 Intake Manifold Disessembling sequence © Air inlet connecting hose Oil cooler water conduit @ High-pressure fuel pipe @EGR cooler, water ilet foutlet hoses and EGR valve Oil dipstick duet © Intake manitolé Reassembling sequence Reassemibling sequence is reverse (0 disassembling sequence, Fee I=7=1 Disassenb ing and Asan bling Sequence for Wake Mani tea (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL. ENGINE, Figure 4—4—2 Disassmb le the Air Inet Connecting Hose Fier 4-473 Waren Conduit Digagsanble-the 0 il Cooler Figure 4—4—4 Disassemble the High— Pressure Fuel Pipe Disassonble the EGR Figure 4—4—5 Cooler W ater InletOutle Hoses and EGR Vale ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2 Duiain the cooknt of cooling systan canpkteh. Disassamble the air inlet connecting hosdi) Disassemble the oil cooler water condui®) (D Disassemble the the bolt or water conduit (2 Disassemble the oil coolerwater conduit See Pigue 4—4—3. D fesse le he hig p ashe fuel p pe), (Loosen fixed nuts at the side of h&h—pres sure fixe! rail (2) Loosen fixed nuts at the side of injector and disassembling high — pressure fuel pipe and place it at side See Figure 4—4 —4, Disassemble the EGR cooley water inlet/outlet ho ses and EGR valvéa) Disassemble the fixed bolis both of EGR cooler water inet on exhaust tube and of EGR valve of inlet pipe See Figure 4—4—8MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figue4—4—6 Disassemble he Oil D ipstick Duct Disassemble the Figue4—4—7 Iyuke Manifold I H ee Oil dipstick unit eT Vee Figue4—4—8 Assanble the Oil D ipstick Duc Fisum4—4—9 Assanble the BGR Cooler Disassemble the oil dipstick duc) Disassemble the fixed bolls and the oil dipstick duct See Figure 4—4—6 Disassemble the intake manifold®) Disassemble the fixed bolts and nuts of intake manifold See Figure 4—4—7. +4 Assembling Assanbke the intake manifold@) Tighten the fixed bolts and nuts of intake man if to prescribed omue See Figure 4—4—7, A Tighten tomue br the fixed bolts of inuke man iid : l ES Nem Assanbk the oil dipstick duc6) Install oil dipstick duct and tighten it with intake manifld See Figure 4—4—8 EX) Tighten omue for the fixed bolls of oil dip stick duct 20N- m£5 Nem Assanbk the BGR cooles water inlet/outlet ho ses and BGR valvé) ‘Tighten the fixed bolts both of EGR cooler and of EGR valve Install water inkt/outlet hoses of BGR cooler See Figure 4—4—a. io QRERMMBMA EAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE Fie 4—4—10 Assemble the H igh Pressure Fuel Pipe Figue4—4—11 Assanble the Oil Cooler Wale rConduit Assambk the high—pressue fuel p ip) (1) Connect high— pressure fuel pipe and tighten fixed nuts to prescrbed tomyue See Figure 4—4—10, 2X Tighten torque fr fixed mats 27N-mt2Nem @) Assemble the clip of high —pressu:e fuel pipe to origina! position Assanbk the oil coolerwater condui@) (D Assanbk the oil cooler water conduit See Fig we4—4—11. (2 Tighten the water conduit bracket bolts at the tear side of cylinder head. ( | ' | mb k the air inlet’ connecting hose Pigue4—4—12 Assemble the Air Inet Connecting Hose Cany out bllow ing tasks afler assembling please (D Connect the grounding cab k of battery (2) Fill coolant into cooling system. (3) Start engine and check if the coolant has leak age or not Figuie4—4—13 Connect Ground ing Cable of BatteryMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4,5 ExhaustM anifold Disassembling sequence © Fixed mats for front exhaust tube (2) Fixed bolts for installing bracket Of front exhaust tube D Gasket unit of front exhaust tube Exhaust elbow Turbocharger ae Reassembling sequence * Reassembling sequence is reverse to disassembling sequence. FEE T=5=1 Dassen bing and Awan bing Sequence Or Exhaust Man Tow fe Te ES It PA a A) ll is SB 158 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Figume4—5—2 Disconnect the Gmund ing Cable of Battery | Figs 63" D ikgisinb the Front Exbaust Tube (Only for ference) Figue4—5—4 Disssenble the Gasket Unit of Front Exhaust Tube Fige4—5—5 Disassemble the Exhaust B how ) Disassembling Pepa. tion Disconnect the grounding cable of batie, See Fig ure 4—5—2 Disassemble the fixed nuts for front exhaust tibet) Disassemble the wo fixed nuts fia the connecting position of exhaust manifld and front exhaust tube See F igure 4—5 —2. Disassemble the fixed bolts for installing bracket of front exhaust tubé®) Loosen the bolls fr installing bracket of front ex haust tube and disissmbe the font exhaust tbe ( EO ( V Disassan ble the gasket unit of font exhaust tube’) Disassamble the fixed bolts of the gasket unit of front exhaust tbe and then disassembling exhaustman fo and exhaustmanifold gasket unit See Figure 4— 54 Disassemble the exhaust elbow) Disassemble the fur bolt units take out the outlet gasket unit of turbocharger and the elbow, See Figure 4 —5—5,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue4—5~6 Disussanble the Turbocharger ‘Figuied 347" Disassdnble the Bane Manifold Figued—5—9 Assenble the Exhaust 2 bow Disassemble the tubocha get) Disassemble the exhaustmanifold®> Disassemble the fixed bolts and nuts of extaustman. fo and then disassemble the exhaustmanifold and its gasket See Figure 4—5—7, *¢ Assanbling Assanbe the exhaustman if H@) ‘Tighten the fixed bolts and nuts of exhaust mani ld to prescribed tormue See Figue 4—5—7, @Q\)_ Tighten tomue for fixed bolts of exhaustmani 2) Ne ht SNe Assambk the turbocharge fS) Phhce the turbine inlet gasket unit of tusbochamwer on exhaustman iid assemble the tibochager assem bly on exhaustmanifold and then fix and tighten it by thee bolts See Figure 4—5 —& SX Tighten tonue for fixed bolts of tibochawer 25N*m+5 Nem Assanbke the exhaust elbow@) Install he gasket unit and exhaust elbow of wrbo chargeron tuibocharger and then fix and tighten it by foarbolt units See Figure 4-5-9. QQ Tighten bmve for fixed bolts of exhaust el bow of turbocharger 20N+ m+5 Nem fe Te ES It PA a A) ll is SB 160 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE Assanbk the gasket unit of font exhaust wb@) Assemble the gasket unit of exhaust manifoK then tighton fixed bolts to prescribed tomue See Figure 4— 5-10. A) Tighten torque for fixed bolts of gasket unit of exhaustmanifold 20 Ne mi5 Nem Pique 4—5—10 Assemble the Gasket Unit of Extau stManiblt Assanbe the fixed bolts for installing bracket of front exhaust tubé2) Tighten fixed bolts Or installing bracket to pre scribed torque See Figure 4—5—11 A Tighten tomue for fixed bolts of bracket of exhaust tube 40 Ne mi5 Nem Assanh k the fixed nuts, for front exhaust, tub Figure 1B of Assemble the Fafa Exhaust Tube {) Pightbn fixed | nuts| af ftont exhaust tbe to/ pre ‘scribed oique See Figur 4—5 “11 ‘Q Tighten tomue fr fixed nuts of front exhaust tube 67 N+ mi5 Nem Connect the grounding cable of bate; ure 4—5—12, See FigMAIVTENANCE MANUAL OF GW2.8TG TURBO DIESEL ENGINE ‘Valve chamber cap lating hose of erankease ‘Gasket of valve chamber cap Figure 4—6—1 Disassembling and Assamb ling Sequence fyrValve Chamber Cap Figue 4 2 Disconnect the Gpunding Cable of Battery Figure 4—6—3 Disassemble the Valve Chamber Cap a 2 ix Sy = 4.6 Walve ChanberCap Disassemble the Sequence © Ventilating hose of crankcase ® Valve chanber cap @® Gasket of valve chanber cap Reassamble the Sequence Reassanb ling sequence is reverse W disassembling sequence **) Disassanb ling Preparation Disconnect the ground ing cable of batter. See Fig ur 4—6—2 Disassemble the ventilating hose of crankcasd1) Disassemble the ventilating hose of crankcase fram intake elbow, See Figure 4—6 —3 Disassemble the valve chamber cap2) Disassemble the gasket of valve chamber cap), { | f | ** Assanbling Assanbk the gasket of valve chamber caf) Assanbe the valve chamber cap) @) Daub oil on mekerand valve spring (@ Assemble the gasket of valve chamber cap on the valve chamber cap, (3) Gasket should be snoolh and lossless ® Tighten fixed bolts of valve chamber eap prescribed tomue ON ber cap Tighten torque fr fixed bolts of valve chan 15N+ m3 Nem Assambk the ventilating hose of crankcas&l) Connect ventilating hose of cankease with intake elbov, See Figure 4—6— Conncet the grounding cable of battery ure4—6—2 See Fig a A) il ies FS BR Zl ton ge Marfan Company inedCHAPTER 4 —1 Disissamble the Rocker Shaft Assembly Figue 4-7 Gw2.8Te TURBO DIESEL. ENGINE, 4.7 Rocker Shaft Assembly Disassanble the Sequence @® Ventilating hose of cmnkease ) Valve chamber cap ® Rocker shaft assonbly Reassanble the Sequence Reassanb ling sequence is rev sequence to disassembling Figue4—7-2, -Disennect-the G munding. Gable of Bailey ‘Ventilating hose of trankease Fiuw4—7—3 Disassanble the Ventilating Hose of Crankcase and Valve ChamberCap Figie4—7—4 Disassanble the Rocker Shatt Disassenb lng Prepamtion Disconnect the grounding cable of battery. See Fig ure 4-7-2 D beasllble the ventilating hose ofcrankcasdl) semble the valve chamber can) — Disassemble the fixed bolts &r valve chamber cap. See Figure 4-7-2, Disassamble the wcker shaft assanb | Loosen the rocker shaft seat nut and fixed bolt ac coming to the sequence shoyn as Figure 4—7—4, Then disassemble the rocker shaftassembly,MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Sequence for tightea bolls of roeker shaft —5 Assamble the Rocker Shaft Assembly Figue 4— Figue4—7—6 Tum CrankshattUntil he Piston Be al Top Dead/Centerof Cémp misbion Stok Figure 4—7—7 Check the Rest Nuts of Rocker Shaft Figued—T—8 Check Valve Clesrance by FeelerGuge 164 #4) Assembling Assanbk the iocker shaft assanb ¥3) (D Loosen all rocker adjusting screws (2) Install mcker shaft the big oil hole ¢ 4mm) should locate at the fiont of engine See Figure 4—7—5 (3) Align the seat fixed bolts with the hole on rock er shaft and then tighten the fixed bolts prescribed torque ©) Tighten tmue br the fixed bolts of rocker shaft seat 55Nem+5 Nem @) Adjust the valve clearunce. Adjusmm ent of valve clearance () Tum crankshaft until the piston of 1“ cylin der to be al top dead center of canpression stoke ie the reticle of pulley lop dead center aligns to the bulge symbol on pulley housing cover See Figure 4—7—6, | f : | y —~ (2)—Check she rest-nuts of mocker-shaft loase or not ‘Tighten all loose rest nuts of mcker shaft accord ing to the sequence of Figure 4—7 —7 before adjust the valve clearance, QQ Tighten tomue fr mcker shaft seat nuts 55N-m+5N-m (3) Cheek the push md cleamnee between intake and exhaust valves of 1*' cylinder If there is push md clearance beween intake and exhaust valves of 1‘ cylinder the piston of 1“ cylinder willbe at top dead center of canpression stmke If the push mod of intwke and exhaust valves of 1*' cylinder is at pressed status the pision of 4" cylinder willbe at top dead center of compression stroke. VY Attention: When you adjust the valve clear ance of 1 or4" cylinder the piston of this cylinder must be at top dead center of compression stroke fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE ‘The top dead venter of compression stroke of I*eylinder Figue4—7—9 Adjusts) 2", 3%, 6M Valve Clearance “The top dead center of compression stroke of 4 eylinder Pur 4—7—-10 Adjust", 5%, shy BUN Ie,C learance ‘Ventilating hose of crankcase Figue4—7—11 Assanble the Ventilating Hose of Crankcase and Valve ChanberCap Valve clearance (cold stalud Intake valve 0 35mm £0. 05 mm Exhaust valve 0. 40 mm + 05 mm (4 Loosen every valve adjusting screw as shawn as Figure 4—7—9 (5) Insert gage with suittble thickness between the rockerand valve stam as shown as F gure 4 —7—8. (® Tum the vaWve clearance adjusting screw until the gage has a little resistance See Figure 4—7—8& (D Tightly tighten locking nuts: (8 Tum crankshaft 6r360". (@) Align the TDC reticle of crankshaft damping pulley with the bulge symbol on pulley housing again (10) Adjust4", 5", 7, 8" valve clearance as shown as F gue 4—7—10, {| JAsschbk the} valve. chamber cd) y ~~ Install’valve chamber cap. (see Eig e-4=7—11) and tighten the fixed bolt tw prescribed brwe a ber cap Tighten tomue fr fixed bolt of valve cham 15Nemt3 Nem Assanble the ventilating hose of crankcase) Connect the grounding cable of battery, ure 4-7 —12. See Fig =12 Connect the G rund ing Cable of BatteryMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4.8 Valve Oil Sealing Ring and Valve Spring Disassembling sequence @ Valve chamber cap Rocker shafi assembly ® Valve spring & Valve oil sealing ring Reassembling sequence Reassembling sequence is reverse to disassembling sequence. FRURT=S=1—DmawanbIng nd ATM TAE SeqUeAce HFVENE OM SeaTRE Ring and Valve Spring fe Te ES It PA a A) ll is SB 166 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE ‘Ventitaring hose of crankcase Figure 4—8—2 Disassamble the Cylinder Head Cover Pigue 4—8—3 —Disissemble:tie Rocker Shatva smb : | Disassembling Preparation Disconnect th giounding cable of batter: Disassemble the valve chamber cajil) Disassemble the rocker shaft assambly¥2) Loosen the rocker shaft seat bolts and nuts accord ing lb the sequence shown as Figue 4—8—3 Then disassemble the rocker shaft assambly. D fesse le the va Wve! spring) Pressed valve spring by speci! tool and disassen bling valve collets as shown as Figure 4—8—4, Valve spring canpresse 9—8523 —1423—0 (J —29760) . VY Attention: Put disassambled valve nw ing the serial number of cylinder spring fol Disassemble the valve oil sealing ring) Disassemble the valve oil— sealing ring ers See Figure 4—8—5, using pli YY Caution The disassanbled valve oil— sealing ring cannot be used again Figure 4 8—5 Disassemble the Valve 0 il Sealing R ingMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Figue4—8—6 Assemble the Valve Oil Sealing R ing 7 FighreA 8/7 Assamble-the Valve Spring Sequence for tighten bolts of rocker shaft Figure 4—8—8 Assenble the Rocke Shaft Assam bly *# Assembling Assanbke the valve oil sealing ringf) Assanble the new valve oil sealing ring by special tool as shown as Figure 4—8—6 Special ool 5—8840—2033—0. Assanble the valve spring3) Placing valve spring seat on the valve spring Vv Atten tion: —— The end with paint shoul be downwarl See Figue 4—8—7. —— Input compressive air int cylinder through the hol of preheating plug io fore valve to its position —— Assanble the valve collets by special tool | Valve spring compres@k 978523714230, i \ seazep | f : | y Assanbk the icker shaft assanb ¥2) ) Loosen all rocker adjusting screws (2 Insnll rocker shaft the big oil hole ¢ 4mm) should beate at the fiont of engine See Figur 4—8—& (3) Alig the seat bolts with the hole on weker shaft and then tighten the fixed bolts t prescribed twique, EA Tighten iomue for the fixed bolts of mcker shaft seat 55Ne mis Nem (@) Adjust the valve clearanceCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Adjusment of valve cleamnee (D Tum crankshaft until the piston of 1% cylin der to beat top dead center ofcom pression stroke i & the retick of pulley top dead center aligns to the bulge symbol on pulley housing cover See Figure 4—8 —9, Figure 4—8—9 Tum the Crankshat Until the Piston be at Top Dead Cenier of Camp ression Stroke 1—Genemtor pulley 2— Path locus of pulley center 3—Waler pump and pulley housing cover assembly 4 — Inspection cover assembly 5 —Bulge symbol of pu lley housing cover 6—Top dead center reticle of pulles: 7—Crankshaft damp ing pu lley assenbly 8—Camshaft position sensor (2 Tighten all loose wst nuts of rocker shaft ac con ing to the sequence of Figure 4 —8 —10 before ad just the valve cleamnes, i. ‘ l | ~~ Tighten tomue-Br weker shaft seat nuts 55N*mt5 Nem () Check the push wd clearince between intuke and exhaust valves of 1*' cylinder If there is push wd clearance bebween intake and Figue4—8—10 Tighten the Rocker ‘ " Shaft SeatNuts exhaust valves of 1*'cylindes the piston of 1“ cylinder will be at top dead center of compression stroke. If the push md of intuke and exhaust valves of 1 cylinder is at pressed status the piston of 4" cylinder willbe at top dead center of compression stroke Y Attention When you adjust the valve clearance of ord" cylinder the piston of this cylindermust be at op dead center of canpression stoke, Valve clearance (cold stats) Inwke valve 035mm £0. 05 mm Figure4—8—11 Check Vane Clearance by FeelerGuge Exhaust valve 0. 40 mm £0. 05 mmMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE ‘The top dead venter of compression stroke of I*eylinder Figue4—8—12 Adjust 1S) 24, 3%, 6! Vale Clearance “The top dead center of compression stroke of 4 eylinder Pigue4—8—13 Agusta", 5% shy BUN eC learance ‘Ventilating hose of cramkease Figue4—8—14 Assmble the Ventilating Hose of Crankease and Valve ChamberCap Figure 4—8—15 Connect the G rund ing Cable of Batiew (Only for reference) 170 ( Loosen every valve adjusting screw as shown as Figure 4—8 —12, (S) Insert gage with suitible thickness between the seker and valve stan as shown as Piguie 4 —8— di, (6) Tum the vale cleamnce adjusting screw until the gage has a little resistance See Figure 4—8—11. (D Tightly tighten lock ing nuts (8) Tum crankshaft Br360°, (@) Align the TDC reticle of crankshaft damping bulky with the bulge symbol on pulley housing again (10) Adjusta", 5", 7", 8" valve clearance as shown as F gure 4—8 —13, ( Agsahtb the|valve chamber cdj(1)_ of (D_Daub-ailon twckerand va We~sp ring (2) Install valve chamber cap gasket on valve chan bercap (see Figure 4 —8 — 14). Gasket should be smooth and whole (3) Assanble the valve chanber cap and tighten the fixed bolt of valve chamber cap prescribed toque ®) Tighten torque fr fixed bolt of valve cham ber cap 15N- mt3Nem Connect the ventilating hose of crankcase See Fig ure 4—8—14, Connect the grounding cable of battery: See Figure 4-8-15, fe Te ES It PA a A) ll is SB ret Waving ner Combustion Ege Manet Company LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4,9 CylinderHead Assanbly and Gasket @ Oil cooler water conduit Reassembling sequence ® Bypass hose © High-pressure fuel pipe © Fuel return hose Ventilating hose of erankease © Oil dipstick duet ® Valve chamber cap » Rocker shaft assembly i2) Push rod © Cylinder head © Gasket of eylinder head Reassembling sequence is reverse to disassembling sequence Fee g=9=1 Disassan bling and Sanbiing Sequence lor Cylinder lTead Assen bly and Gasket fe TE EE A A) Bl is SB ‘reat al Baoding lteral anbuston Engine Mareficunng Company Limited = 17 1MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2) Duin the cooknt of cooling systan campkteh. Disassamble the radiator hosdl) Disassembling mdiator hose fam engine side See Figure 4—9—2, Disassemble the heater hosé3) Figure 4—9~2 Disassemble the Disassemble the heater hose fim oil cookrwater Radiator H ose conduit Disassemble the engine hanes) Disassamble the hamess connectors fim fuel in Jectox high — pressure fue! pump, vacuum regulator and various sensors and mmove the clips and take offhar ness See Figure 4—9—3 Figied 93 iBngine llamess c ‘ D iseshomb le fa¢ oil dclerwater cond uta) ~ CD Disassamble the water conduit bracket bolts at rar side of cylinder head and the clips of intake man ibd (2 Disassanble the oil coolerwater conduit See Figure 4-9-4. Disassemble the bypass hosé5) Figie4—9—5 Disassemble the Bypass [ose vo QRERMMEM SARA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Figue4—9—6 Disassembe the High— Pressure 0 il Pipe and 0 il Retum Hose Ventilating hose of cramkease Figure 4—9 ~7Disassamble the ‘Ventilating Hoss ofCjankease Figue4—9—8 Disassenble the Oil D ipstick Duet Figue4—9—9 Disissamb le the Valve Chamber Cap Disassemble the high—pressure fuel p ipg@) (1) Loosen conic nut at the side of high — pres sue fie! pump. (2 Loosen conic nut at the side of injector and disassemble the high—pressam fuel punp. See Figure 4-9-6. VV Caution Plug up the mall hole on both injec tor and fuel outlet valve to avold entering impurity Disassemble the lel retam hosé) Disassemble the fire! retum hose al the side of in Sector See Figur 4—9—6, Disassemble the ventilating hose of crankeasé) Disassemble the ventilating hose of crankcase fiam valve chamber cap, See Figue4—9—7, ; ‘i ‘ Dbassemible thé oit dibstick auc) Disassemble the ofl dipstick duct fem intake man iol, See Figue4—9—8 Disassamble the valve chamber capil) Disassemble the fixed bolt of valve chamber cap, See Figure 4—9—3,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figure 4—9—10 Disassanble the Rocker Shatt Assambly Pigure 4—9—11 Tead Bolt hecond jag % Sequence Disassanble the Cylinder Figue 4—9-12 Disassamble the and Assamb ling Cylinder] cad Gasket Figure 4—9—13 Measure the Bulge of Piston Top ta (TE EC I ME a SO 2 ret Wong ner Combustion Ege Mnetecting Cn Disassemble the rocker shaft assem b lyf Loosen the seal bolis very slowly, the sequence as shown as F gure 4—9 — 10, VY Caution It is possbe to damage the mcker shaft if do not loosen the seat bolis very slow ly and fol owing the sequence Disassanble the push mdi Disassanble the cylinder head Loosen cylinder head bolts very slow quence as shown as Figure 4—9—11, the se V Caution It is possible to damage the lower surface of cylinder head if do not bosen the bolts very slowly and follwing the sequence Disassamble the gasket of cylinder headiig Disassamble the gasket of cylinder head and dowel +4) Assanb ling Assanbk the gasket of cylinder head The choice ofeylinderhead gasket depends on the | bulge of piston lop, to vaper surface |of cylinder block ‘Ther-are thee’ kinds gaskets with d ifferent thick ness to inprove engine perfmance Choose one gasket fiom thee groups acconi ing tp following sequence please Clean the accumulated caibon on piston top and up per surfice of cylinder block befbre measurement clean the used gasket surface toa YY Attention Align the gasket holes of cylinder head with the cylinder holes of cylinder block as shown as Figure 4—9—12. Measure the bulge of piston top (1) Measure the bulge of piston top using mi crmeter (2) Measuring posilion of the bulge of piston top is shown as Figure 4—9—13, A ll measuring positions should be as close to cylinder hole as possible LinedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE (3 Measure the pointD@@® and obtain wo difference values for each cylindee (1) —@) and @) — @. See Figure 4—9—14, Calculate the average value of the bulge of piston top Br every cylinder (4) Obtain the maximum bulge of pistm twp ac cowl ing t above calculation and choose required gasket group accord ing to follwing tub le Gaskel thickness of cylinder head Figure 4—9—14 Measure the Bulge of Piston Top Figure 4—9—15, Assemble the Gylinderifead Gasket CRAG] Bue orn oy [OTE 7) 0. 7430 ~0. 8400 mm 1.500 mm (B) 0. 8401 ~0, 9400 mm 1. 550 mm © 0. 9401 ~1. 0550 mm 1. 600 mm Y Attention The measured difference betveen maxinum and minimum bulge of piston top cannot ex coed 1 0mm, Assenbke the cylinder headiif (1) Install the dowel of eylinder head’ to eylinder’ Lobek |! , l y (2) Histall eytinder head: gasket “ls” lop -symbo! must be upward See Figure 4—9—15 (3) Clean the matching surface between cylinder head and cylinder block, and then pice cylinder head lightly. (4) Daub oil on the screw thread of cylinder head bolt and matching surfice (5) Tighten cylinder head bolt to prescribed torque dividing into two steps according tb the sequence of Figure Pigue4—9—16 Tighten Cylinder Head Bolt Acconling th Sequence 4-9-16 Sequence for tighten bolts of rocker shalt |) Tighten torque br eylinder head bolt Sept 7] Step2 | 75N-mtoNem l0Nem Assanbke the push wodif Daub oil on push mod and insert it into cylinder head. Assanbke the rocker shaft assanb Ni () Loosen all adjusting screws of weker shail Fiue4—9—17 Assanble the Rocker Shaft Assam bly (2) Install wekes its by oil hole ( 4mm) should fice the fiontof engine See Figure 4—9—17, RERRA MHS ARRAS Hanh Congy ‘reat Wal Bading Interval anbusto Engine lines «= 1 75.MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figue4—9—18 Assmble the Valve Chamber Cap Figuie 4919 “Assamble the Oil Dipstick Diuct Figue 4—9—20 Assemble the 1 igh— Pressure 0 il Pipe and Fuel Retum Hose Figure4—9—21 Assemble the Bypass Hose ve QQREREREM ret Wa ating mera Conbstion Eng Manta Assanbk the valve chamber capi) () Daub oil on mekerand vaWe spring (2) Install valve chamber cap gasket on valve chanber cap See Figue 4—9—18 (3) Gasket should be smooth and whole (4) Tighten the fixed bolt of valve chamber cap © prescribed tomue Bl Tighten torque Hr fixed bolt of valve chan ber cap 15Nemi3 Nem Assanbe the oil dipstick duc) Tighten the fixed bolt of oil dipstick duct to pre scribed tomque See Figure 4—9—19. SY Tighten torque for fixed bolt of oil dipstick 20 Ne mi5 Nem Assan the ventilating hose of crankcasé®) Agsahb b the fue! rem m hose) ¥ —~ Assanb ke the fielrein hose atthe side of injec br See Figure 4—9—20. Assanbke the high— pressure fue! pipd®) (2) Install the fixed nuts at the side of high — pressure fiel pump and high—pressure fuel mil and the side of high—prssure fel and injector ® Téhien the fixed nuts 1 prescribed tomue See F gure 4—9 —20, EX Tighten tomue for fixed nuts of high — pres sure fue! pipe 20Nem+2Nem For high—pressure fel pump For high—pressure fel mil | 27Ne m£2Nem For injector 27N+ m+2N-m (3) Install the fasten ing keeper of high— pressure fuel pipe under prescribed tomue Assanbk the bypass hosd) lis SRR Bol ring Copan LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figure 4—9—22 Assemble the Oil Cooler W ater Conduit Figur 4—9—23 Assmble the Engine Hamess Fie 4—9—24 Assemble the Heater Hose Assanbke the oil coolerwater conduit) Tighten the bracket bolls of oil cooler water con duit to prescribed tormue See F igure 4—9 —22, 2X Tighten true for the bmcket bolts of oil cooler water conduit 20N- m+5 N+ m Assanbke the engine hamess) At first fix the engine hamess at the wire fermles of genemtoradjusting bracket} lower/upper case of ther mostat and tightly clip the rules The second, fix four hamess fermiles of engine atone hamess bracket of upper case of themostat one hamess bracket of upper case of inlet joint and two hamess brackets of high — pressure fuel mil respectively now fixed seven wire fer miles bllly After fixed the hamess of enging come sponding insert the plug of the hamess into engine can shaft position sensos water temperature sensor (for in stumend. engine water tmpemtre sensor (for ECU conto, figh—pressure fel mail pressure sensor vacu un gubtoy high—pressurefel pump magnetic. valves “four injéetprs magnetic valves and EGR-valve “See Hi ured —9= 23, ' ~ ~ In addition “hiteh preheating ping term inals using four connectors (not plug) of engine hamess respec tively, Tighten and fixed than using four nuts with hex agon flange surface ® Thien tomue fr fixed nuts with hexagon flange surface 4NemilNem Assanbk the heater hosé2) Conneet the heater hose and then tightly tighten the clips See Figue 4—9—24,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanbk the radiator hosél) Assanbke the adiaior hose and then tightly tighten the clips See Figure 4—9—25, Assemble the Rad iar ove Cary out Sllwing tasks after assembling please (D Connect the giunding cable of battery. See Figur 4—9—26, (2 Fill coolant into cooling system. (@ Start engine and check if the coolant has leak age or not Figure 4—9~—26 Connect the G rund ing Cable of Batley Only fr reference)CHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4.10 Timing Pulley Disassembling sequence crankshaft damping pulley © Water pump. pulley housing assembly and inspection cover ® Tensioner, transition wheel and belt ® High-pressure fuel pump and high- __ pressure fuel pump pulley ® Camshaft timing pulley ® Crankshaft timing pulley Assembling sequence Assembling sequence is reverse to disassembling sequence, Fue 4=10=1_Disassan bing and Assan bing Sequence lor Tin hg Pulley fe TE EE A A) Bl is SB Great Wal Banding itera Combustion Engine Marfactving ConpanyLinitee «1 7SMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE ) Disassembling Prepaw tion (2) Disconnect the grounding cable of battery (2 Duiain the cooknt of cooling systan canpkteh. Disassanble the fn cow 4) Disassemble the air inlet duct and air flow mte sensof2) Loosen paver steering pump bracket bolts and ad justing bolts then disassemble the transmission belt Disassemble the altemator trans ission be 16) Loosen aliemator bracket bolts (ower side) and locking bolts for adjusting phis then disassambe the tansn issn belt Disassemble the cooling fin assanb 4) (electric fan did not on the engine) Disassemble the locking nuts and disassemble the damping pulley assanbly and water pump transnission belt See Figure 4—10—3 Figure 410-3 Disassemble the Fan Astenbly D bassentble the damping pu lle) — — ~~ Loosen ciankshaft damping pulley -bolts and d isas sable the assembly: See Figure 4—10—4. Disassmble the water pump pulley housing assen by and inspection cove) Disassamble the water pump pulley housing assan bly and inspection cover Disassmble the tensioner transition wheel and belt?) Figure 4—10—4 Disassemble the Cranksha—Demping Pulley Disassanble he high —pressure fie! pump and high —pressure fuel pump pulley@) () Disassemble the pulley holi—down plate (2) Disassemble the pulley fastening— bois, (3) Disassemble the pulley Y Attention Do not lose the wood uff key on the shaft of high—pressure Sze] pump. G@) Disassemble the fisten ng—bolts of h igh —pres sure fuel punp (5) Push out the high—pressare fuel pump and high —pressure fuel pump ped Figure 4—10—5 Disassmble the H gh— Pressure Fue! Pump and Pulley 180 (TE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 Gw2. STC TURBO “DIESEL ENGIVE Figure4—10—6 Measure Camshaft AxialClearince Pigue 4—10—7 Disassemble the ThnistPiate Pigue4—1)—8 Disassemble the Crinkshaft Pin ing Pulley Assemble the Can shaft Timing Pulley Figure 410-9 0 050~0. 114 mm Disassemble the camshafl tin ing pulley) () Measure cam shaft axizl clearance using mi crmeter See Figure 4—10—6, Do this work before disassamb ling cam shaft tin ing pulley. Rephice font gasket seat Cor the flange of can shaft tin ing — pulley depending on the wom degieed) of camshaft ifmeasured vale exceeds prescribed Jin it Cam shal axial cleamnee Standard Linit 0. 20 mm (2 Disassemble the hold —down plate of pulley, (3) Disassemble the fasten ing—bolls of camshaft tin ing— pulley frm camshaft Vv Attention Stably fix the camshaft and do not let it uming (fix the pulley using technique bolts for cam shaft installation) . (@ Pullout camshaft tm ing— pulley assembly2) using geneal pullefi)., See Figuie4—10 —7. Genejal pulley ‘5 8521 —0002 ~o. Vy ~~ Gy Disassen ble\ the: fionit gasket sea of cam shaft Disassamble the crankshaft tin ing pulley) Pull out crankshaft tm ing — puley using special tool There are to bolt hoks for pulling out the crank shaft tin ing—pu lley #4) Assembling Assenbke the crankshaft tin ing pu lleyii) (@) Assanble the cainkshaft tin ing—pulley. See Fisuw 4—10—8 () Assenbk the crankshaft tin ing— pulley by cruiksha ft pulley eree tor ‘The gap symbol of crankshaft tin ing —pulley should be outward Crankshaft pulley erectoe 5—8 0020-0. Assanble the camshaft tin ing pullexS) @) Assemble the front gasket seat of camshaft on pulley housing See Figure 4—10—9.MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figuit 4-10 Pulley.HoW Down Phe 1D | AsSerpbile the cmt n Figue4—10—11 Assmble the I igh — Pressure Fue] Pump and Pulley YY Attentiom Press front gasket of camshaft and ‘outside rund O —seal ring into gasket seat before as sambling font gasket Daub punchy sealant on outside wund during pressing Daub a little clear oil on sear gasket and outside mund of O — seal rng (2 Tehten the fixed bolt of font gasket seat of camshaft to preseribed mua Al Tighten tomue for fixed bolt of front gasket seat of cam shaft 20N* mt5 Nem (3) Assan ble the can shaft tin ing—pulley assen bly on camshaft (4) Tighten the fixed bolt of camshaft tin ing — pulky to prescribed torque See Figuw 4—10—10. ©N Tighten torque for fixed bolt of camshaft tin ing—pulky 110N+ mt10N+m (5) Assemble the camshaft pulley hold—down pki See Figure 4-10-10 | j : ( y —~ Assanbe the fi igh—pressurefel-pump-and “high —pressure fuel pump pulleys) () Assemble the high—pressure fel pump, and tighten fastening bolts VY Attention Daub a litte clearoilon outside round of 0 —seal ring of high —pressue fitel pump shaft be fore assemb ling fhigh— pressure fiiel pump. Then hiteh high—pressure fie] pump pad, the oil drainage notch at the section of pad should be downwaxl align shaft hole and insert in pulley housing (2) Install the woodmff key on the high — pres sure fuel pump shaft See Figure 4—10—11, (3) Assemble the high—pressure fuel pump pul ky on high—pressure fuel pump shaft @ Tighten he fistening bolt of high — pressure fuel pump pulley. Q Tighten tomue Or fixed bolt of high— pres sure fel pump pulley 70N- mis Nem (D Assemble the pulley hold—down plate aR Za ng mera Conbstin Eng Manfactring Crary inkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figue4—10—12 Assanble the Tensioner and Transition W heel Pigue 4-10-13 Assanble he W ater Pump Pulley Housing Cover Figure 410-14 Assonble the Water Pump. Pulley Housing Cover Assanb ly Assamble the tensioner tansition wheel and bel@) (1) Fix timing pulley tansition wheel on pulley housing using one dowe! bolt with hexagon flange See Figure 4-10-12. (2) Fix tensioner unit using one dowel bolt with hexagon flange and one bolt with dowel skiré do not tighten the dowel boltw ith hexagon flinge p.ovisiona Lly and ensure the tensioner unit timing freely, See Figure 4-10-12, Ql Tehten tomue for fixed bolt of dowel bolt with hexagon flange MI2 bolt TiO N- mLl0N- m MB bolt 20 N+ mi5 Nem (2) Assanble the tining belt and tighten the belt (& Assamble the camshaft and high — pressure fuel pump pulley hold —down plate Assanble the water pump pulley housing assem bly and inspection coved) (Assemble. two studs on crankshaft hole jright { side! Of pullley housing and the hole gn Water pum p| tp:, See Figure 41018. _ - (2 Clean water pump, pulley housing cover as sambly and pulley housing matching surface Place wa ter pump seal ring into seal groove horizontally and daub 587 sea hat on seal ring even. (3) Align water pump, pulley housing assanb ly with studs and lightly knock than to their position Then tighten and fix then using bolt unit (M8 X70, M8 55), hexagon flange nut and hexagon socke head screw. EX Tighten omue for bolts nuts and screws of waler pump pulley housing 20N* m£5 Nem Wal Bad terval onbasion Engine Manufacturing Conparylinted = 1 2SMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanb ke the crankshaft damp ing pulley) Tighten crankshaft damping pulley bolts to pre scribed que See Figure 4—10—15. EX Tighten tomue for fixed bolls of crankshaft damping pulley 210 Ne m£15 Nem VY Attention Fix flywheel ring gearand forbidden cruikshafl tuning when lighten canksha ll damping pul ey bolls Assanbk the cooling fin assamb M4) (electric fan did noton the engined) Assmble the water pump pulley and cooling fan as senbly on water pmp and tighten locking mut pre scribed toxjue QL Tighten tomue Or locking nut of water pump pulley and cooling fan Figure 4-10-15 Assanble the Cmnkshall Damping Pulley 8SNem Assenbk the altemator transm ission bel€) (D Assembk. the-eltemator yansy ission-belt ard * ag.hist Welt tension’ dégree, ( (2) Press the midd te! part of the belt with 98 N ‘forees A ltemator tansm ission belt deflection 8~12 mm Assemble the paver steering pump transnission belt Figur 4—10—16 Assanbe the Power (D Assamble the power steering pump tansnis Steering Pump Pulley Assan bly sion bell and adjust belt tension degree See Figure 4 10-16, (2) Press the middle part of the belt with 98 N forces Deflection of power steering pump transmission belt 8~12 mm Assam! the air inlet ductand air flaw mite senso) Assanbk the fan cowdl) Assanble the fan cowl and overfloy tank mbber pipe See Figure 4—10—-17, Canty out Slowing tasks after assembling please () Fill coolant into cooling system. (2) Start enghe and check if the coolant has leakage or not fe Te ES It PA a A) ll is SB 184 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company Lied Figure 4—10—17 Assmble the Overfow Tank Rubber Pipe (Only for reference)CHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Water inlet hose Oil cooler OG Water Gutlet hose: Figue 4—11—1 Disassembling and Assonbling Sequence for Pil FilterA ssanbly Figure 4—11—2 Disassemble the 01] Filler Figure 4-11-32 Check Safety Valve 4.11 Oil Filter Assanb ly Disassanble the Sequence © Cooling water hose of oil filter ® Oil filter ® Fixed bolt of oil cooler @ Oilcookr Assamb ling Sequence Assanbling sequence is reverse to disassembling sequence, **| D isassanb ling Prepamtion () Disconnect the gmund ing cable of battery (2) Dmin the cooknt of cooling systam canp ktely. (3) Place a container under the oil filter i receive the overfkwed lubrication oil VV Attention Avoid scalded by hotoil appmpri ate treat old ofl and pitect environment (-y \Dibassamble te cooling water hose of oil fltee) \_) Disassemble the cooling water hose-of oil filter and water cutlet See Figure +—11—1. — ae Disassemble the oil filte@) Disassemble the oil filter using oil filter spannee See Figuie 4—11—2 Filler spannee 5—8840 —0200 —0, Disassemble the fixed bolt of oil coole®) Disassemble the oil cooleft) U8) Check () Check Safety Valve — Install one ofl manometer at the oil passage near oil filter — Startengine to check ‘he starting pressure of safety valve Starting pressure of safely valve Hel Bad terval onbasin Engine Maafacting Conparylimted 1 25MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE ‘Input compressive aie (19.60 KPa) Figuie4—11 4 Check Oil Cooler Figue4—11—6 Assanble the Oil Filler Ekment Figue4—11—7 Assmbie the Cooling Water Hose eo QRERMMBMA EAR ZA ret Wong ner Combustion Ege Mnetecting Cn (2) Check 0 il Cooler —— Check the water leakage of oil cooler water passage Plug up ane end of oil cookrwater passage — hnmerge oil cooker into water See Figure 4 11-4, Input canpression air (19. 60 kPa) in an other end of oil coolerwater passage the water passage leaks if same air bubbles out of water level ** Assanbling Assanbke the oil cole) Install O —seal ring on oil filler and assemble the oil cooler Assanbk the fixed bolt of oil coolef8) ‘Tighten fixed bolt of oil cooler to prescribed tomue a ten torque fr fixed bolt of oil cooler 20. Ne m5 Nem { 1 ' [ Acsanb b the oil filter ee be VY Caution ‘the oil filter ekment is one— tine used part and forbidden to use itagain () Daub thin layer oil on © —seal ring of ofl fil ler See Figue 4—11—6 ©) Screw oil filter ekment int oil filter seat by hand until the surface contact with 0 — seal riag (3) Tighten oil filter elm ent into oil filter seat by oil filter spanner for 1. 25 cycle Assanbk the cooling water hose of oil filtefi) Connect cooling water inlet and outlet hoses of oil filler See Figure 4—11—7. Canty out ®llow ing tasks after assembling please (D Connect the grounding cab ke of battery (2) Fill coolant into cooling system. (3) Start engine and check if oil has leakage or not fem oil filter LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4,12 Flywheel and Front Bearing of Transn ission 1 Shaft Disassembling sequence @ Transmission assembly and clutch assembly Front bearing of transmission Ist shaft Flywheel Assembling sequence Assembling sequence is reverse to disassembling sequence. Fgie f 121 Dinssenbing and Assen bling Sequence tor Flywheel and Pron Bearing of Transmission 1°! Shaft fe Es 1 YW a iG Fe Sl ‘reat Wal Bading Interval anbusto Engine 187MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Fige 4—12—2 Disconnect the G und ing Cable of Battery Fieve uOi2—8 |p iissahble the Bimfism igs ion A ase bly | Figure4—12—5 Disassemble the Front Bearing of Tranan ission 1*' shaft | Disassembling Pepa. tion Disconnect the grounding cable of batters, Disassemble the Lansmission assembly and clutch assem b ly) Lift vehicle and use suituble safety stand tb sup port it () Transnission assanb ly ——— Ramove the tanmission shaft fim flange fork. Ramove the speed sensor connector —— Ranove tmnsn ission assanb ly. YY Attention protect speed sensor assembled on clutch housing please It is a plastic part (2) Clutch assembly \Y Attention Forbidden Liquid on clutch surfice and clean the surfice if it has liquid p lease —— Ramove pressure disk assambly. —= Ranove-driven disk |Use auiiing m ddle—aligner to dvoid driven disk assamb ly fall down. fively. = Guiding m idd le—alignee_ 55825 —3001—0. — Print symbols on flywheel! and pressure disk flange so that it can be alignment when assamb ling —— Loosen fixed bolt of pressure disk assanb ly and mmove clutch assembly See Figure 4—12—4, Disassemble the front bearing of transmission 1°! shaf®) Disassemble the front bearing of tunsnission 1“ shaft by bearing knockout and sliding hammer See Figure 412-5, Bearing knockout of front bearing of transn ission 1* shafk 5—8840—2000 —0. Sliding hanmee 5—8840—0019—O. eo QRERMMAMA SAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Disassemble the flywheel) () Instill fywheel retainer (2 Loosen flywheel fixed bolts divided into wo steps llbwing the sequence of Figure 4—12—6 and then disassemble the flywhee! Figue4—12—6 Disassemble the Flywheel int . SE EEE ** Assembling Assanbk the flywheel) (D) Tum crankshaftuntil throws of 1*' cylinder be at the top dead center of canprssion stoke and now install the fywheel with upward and central posi tion of “Il sgmbol into crankshaft (2) Daub oil on the flywheel bolts (3) Use angle tighten method to tighten flywheel bolis to prescribed tomue d ig into two steps ac co ing lo the sequence of Figure 4—12—6, ie Flywheel QA -Tightentomque br flywheel bolts Siep 1 Cclingy BmuO | Step 2 China toad 75N+m£5N+ m 120N+m£10 N+ m Assmble the fiat bearing of tansn ission 1" shaft) Assanbke the font bearing of tansm ission 1° shaft by bearing erector See Figure 4—12—8 Bearing ewetor of front bearing of uansn issn 1“! shaft 5—8522—0024—0, Figue4—12—8 Assanble the Fant Bearing of Transm ission 1% shaft Assanbk the transmission assembly and clutch as sem bl¥D) Cinteh Assembly () Driven disk assembly —— Daub multi— function molybdenum disulfide grease on the splines in driven disk hub of clutch Assemble the driven disk assembly using guiding middle—aligner See Figure 4—12—9, Guiding m iddle—alignes 5 —5825—3001—0. Figue4—12—9 Assmble the Clutch AssemblyMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (2) Pressure disk assan bly —— Tighten pressure disk assembly bolts to pre scribed que acconl ing to the sequence of Figure 4— 12-10, @&) Tighten torque for pressure disk assembly bolts 20N- m+5 N+ m —— Disassanble the gui ing m Hdle—aligner Figue4—12—10 Assanble the Chitch Pressure Disk Assenbly Y Attention Inv pressure disk has been used, after tighten pressure disk assmbly bolls to prescribed torque the line protect diaphragn spring must be re moved. (3) Transmission assembly —— Assanble the tmnsmission assanbly. See Fig we 4—12—1L —— Assanble the transmission shaft Figue4—12—11 Assenble the ‘Transm isin Assan blyCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4,13 OilPump Assanbly Disassembling sequence @ Oil hose of vacuum pump @ Left and right brackets of engine Reinforcement and rubber pads @ Oil sump assembly © Oil pump assembly Assembling sequence [Assembling sequence is reverse to disassembling sequence. Figed=13=1 Disssanbling and Assanb ling Sequence TorO i Pump Assanbiy fe TE EE A A) Bl is SB ‘reat al Baoding lteral Canbuston Engine Marefecunng Company Limited = 1 1MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Fige 4—13—2 Disconnect the G und ing Cable of Battery Oit hose @ Fieme at 13\-3j Disassemble the Oil Hoge vfYacuum Punp | Fie 4—13—4 Disassemble the Left and Right Brackets of Engine Figure4—13—5 Disassemble the Aluminum Alloy 0 il Sump A ssen bly ) Disassembling Prepa.ation (1) Disconnect the giounding cable of batters See Figure 4-13 -2 (2) Lift the vehicle @) Drain ofl (lubrication) fm lubricathg sys tem. YY Caution Avold scalded by hot oil appropriate treat old oil and protect environment YY Attention New washer should be used when instlldmain screw, ®) Tighten tomue Srdmin screw 83N- m+5 N- m Disassemble the oil hose of vacuum pump) (D Disassamble the oil hose fim oil sump). See Figure 4—13—-3 (2) Disassanble the oil hose fan cylinder bck). ( | ; 4 ( AY Dsassenb le-the eh ant right brackets of engin) Loosen bicKet bolts of engine and disassmble the beftand right bmckets of engine See Figure 4—13 — Disassmble the rinforeanentand mbber pad @) (1) Disassemble the exhaustmanifold bracket (2 Disassemble the reinforcement fim oil sump. (3) Take out mbber pads Disassamble the oil sump assanb bi) (1) Lift the engine upward around 50 mm. (2) Disassanble the oil sump fron cylinder block, See Figure 413-5, Disassemble the oil pump assanb Disassemble the oil pump assanby fem cylinder block ico QRERMMBMA EAR ZA ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE Figue 413-6 Assanble the Oil Pump Assanbly Figure 4513/7, Daub! Vaulted A/a Figure 4— Assanble the 0 ilSunp and Gasket Optionad Figure4—13—9 Assemble the Reinfiranent ** Assembling Assanbk the oil pump assembh (Daub oil on 0 —seal ring of ol pipe and in stall it into O —seal ring groove of cylinder block (2 Assemble the oil pump and oil pipe on cylin derblock and tighten fixed bolts prescribed toryue See Figure 4—13—6 2X Tighten torque fr fixed bolts of oil pump 20N- m+5 N-m () Tighten sleeve nuts 0 prescribed tomue EX Tighten torque br sleeve nuts 20N* mis Nem Assanbk the oil sump assanbh@ () Daub mcanmended liquid sealant or equiva kent on the vaulted areas both of 5” bearing housing and of tin ing pulley housing aswell as the gmove See Figure 4—13—-7. (2__ Insert. the. rearlip of seal gasket into5" gioove, f (}-Bnsuye the lip of Seal gasket tightly gontaet “the groove } 1 ‘ 7 ~~ @Assenble the ofl sump on cylinder block (5) Tighten fixed bolts of oil smp tw prescribed torque See Figure 4—13—8. Tighten torque Br fixed bolts of of sump 20N* mi5 Nem Assanbe the reinforeament and tubber pads) () Assemble the mbber pads (D Assemble the left and right reinforeament and tightens fixed bolts to prescribed iomue See Figure 4 13-8, A) Tighten torque Gr sie bolts of cylinder block of engine 37N+m45Nem Q) Tighten tomue br side bolts of clutch housing 78N+ m£5 Nem (3 Assamble the exhaustmanifold fe TE EE A A) Bl is SB ‘Great al Baoding Iteral anbustoa Engine Marfecuang ComperyLinted = 1 93MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanbk the lef and right biackets of enging) Assanbk the kfland right bmckets of engine and tightens bracket bolls prescrbed tomue See Figue 4-13-10. Ql Téehten tomue br sile bolts of left and right brackets of engine 40 Ne mi5 Nem Figure4—13—10 Assmble the Left and Assambk the oil hose of vacuum pump) Connect oil hose to oil sump and cylinder block See Figure 4-13-11. Figure 41311) Assemble aa 3 - = = — ves Hose of Vacuum Punp Canty out low ing tasks after assembling please () Connect the grounding cable of battery See Figue 4-13-12, (D Fill coolant into cooling system, (3) Pill oil (lubrication into lubricating systan. (@ Start engine and check if cooling system has leakage or not Figure 4-13-12 Connect the G rounding Cuble of BatteryCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4.14 OilSump Assenbly Oil hose Disassembling sequence & Oil hose of vacuum pump © Left and right brackets of engine Reinforcement and rubber pads Oil sump assembly Assembling sequence Assembling sequence is reverse to disassembling sequence. Figued TdT Disisvanb Ing and Assan ing Sequence Tor OT Sump Assmbly fe TE EE A A) Bl is SB Great Wa Banding internal Combustion Engine Marfactving CompanyLinitee = 1 OSMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE oithose D Figue4—14—2 Disassemble the Oil Hose of Vacuum Pump Figie 4—14—3 Disassemble the Left and Right Bracket Supporting Bolts of Engine Pigued—14—4 Disissembie the Let and Right Reinforcement ico QEREZAS, ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2) Lift the vebicle (3) Dmin oil fim wbricating system YY Caution Avoid scalded by hot oil appropriate treat old oil and protect envimnment VY Attention New washer should be used when install drain screw, EX Tighten torque Srdrain screw 83N- mis Nem Disassemble the oil hose of vacuum pumpi) (1) Disassamble the oil hose fim oil sump] See Figure 4—14—2 (2) Disassemble the oil hose firm cylinder b locl®) . Disassamble the left and. right brackets of eng iné2) (| \Loosgn ‘eft and ‘1ieh rbmcket bplis of engine | ang disassantble the eft/and right biuckets of engine | See Figue 4—14— Disassemble the winforcementand rubber pad 3) (D Disassemble the exhaustmanifold bmcket (2 Disassemble the reinfscanent See F igure 4 14-4, (3) Take out mbber pads Mais am Zal Comp on age Naat Company LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Disassemble the oil sump assenb by) () Lift the engine upward around 5) mm, (2) Disassamble the oil sump fron cylinder block, See Figue 4—l4—5, Figure4—14—5 Disassemble the Aluminum Alby Oil Sump and Front/Rear Gaskets 4) Assembling Assanbk the oil sump assamb hi) ) Daub recommended liquid sealant or equiva kent on the vaulted areas both of 5" bearing housing and of tin ing pulley housing aswell as he gioove See Pigure 4—14—-6 (2 Insert the rear lip of seal gasket into 5" groove, (3) Ensure the lip of seal gasket tightly contact the ginove Fjeye 4-4-6 Daub Seabnton inured A pea ' \ \ an i ‘ (4 Assembké the oj] sump_on ‘cylinder block See Fiure 4=14—7 md Figure 4—14—-8— - (5) Tighten fixed bolts of oil sump to prescribed tomue Figue4—M—7 Assanble the O1lSunp Tighten tomue Hr fixed bolts of oil sump Mi 20N- m+5N-m Figue4—M—8 Assanble the Alum inun Alby Oil Sump and Pront/Rear Gaskets QREIRNNERBRE ,., GreatMAIVTENANCE MANU Figue4—14—9 Assemble the Reinforcement and Rubber Pads Figue4—14—10 Assamble the Left and Right Bracket Supporting Bolts of Engine Figed—14—11 Assamble the Oil Hose of Vacuum Pump AL OF GW2.8TC TURBO “DIESEL ENGINE Assanbke the reinforcement and nibber pad) () Assemble the mbber pads (2) Assemble the reinforcement and tightens fixed bolls to prescribed torque See Figure 4—14—9, BQ) Tighten tomue Hr sie bolts of cylinder block of engine 37 Ne mt5 Nem Ql Tighten tomue for side bolts of cluteh hous ng 78N+mt5 Nem Assanbke the left and right backets of enginé2) Assembk the kftand right brackets of engine and tightens bracket bolts preserbed wmue See Figure 4-14-10. Ql Tiehten torque br side bolts of left and right brackets of engine ( | 40 N+|mt5 Nem Assanbk the oil hose of vacuum pump) () Assemble the lubricating of] inlet pipe and Jacket of vacuum pump, add copperwasher and tight ens pipe joint tightly @ Assemble the oil—retum pipe and jacket of vacuum pump and then lighUly tighten than by spring hoop. Canry out llow ing tasks after assembling please (D Connect the grounding cab k of battery (2) Fill coolant into cooling system. (3) Fill oil Cubrication int hbricating systan. (4) Start engine and check if cooling system has leakage or not Figure 4—14—12 Connect the G munding Cable of Battery Only Sr Refeenced ico QRERMMAMA SAR ZA ret Waving ner Combustion Ege Manet Company LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4,15 Camshaft and Tappet Disassembling sequence @ Transmission assembly and clutch assembly @ngine assembly Cylinder head assembly and gasket @ Cooking fan assembly amping pulley fater pump, pulley housing caver and inspection cover @Oil pump assembly © Camshalt and tappet Assembling sequence Assembling sequenee is reverse to disassembling sequence. Fie d=15—=1 Disisanbiing and Assmb Ing Sequence for Cumshall and Tappet RECMMMSSRAA (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Pigue 4—15—2 Disassemble the Transmission and Chuteh Assembly os fl i Fisuie #71573, ‘Disassemble the Pi 4—15—4 Head Assembly and Gasket Disassanble the Cylinder Figure 415 Cooling Fan Assan bly 5 Disassemble she 200 fg Se ES I Os i 1S BR 2 ret Wong ner Combustion Ege Mnetecting Cn ) Disassembling Prepaw tion (2) Disconnect the grounding cable of battery (2) Dwain cecknt fram cooling systan of the en gine YY Caution Avoid scalded by hot oil appropriate treat old oil and protect envimnment (3) Drain oil frm lubricating ofl systen of the engine YY Attention Nev washer should be used when install drain screw, @) Tighten tomue Srdmin screw 83Ne mis Nem Disassemble the transnission assembly and chatch assem b if?) Disassemble the engine assembly2) Read relevant content tn this Chapter“4, 2 engine © agscrbly"| j : ( D isassamble the cylinder head assambly and gas kets) Read relevant content in this Chapter “49 cylin derhead assen bly and gasket". Disassemble the cooling fan assenb J) (not elec wie fan) Loosen bck ing nuts and then disassanble the cool ng fan assambly and water pump pulley, See Figure 4— 15-5. LinedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE Figue 4—15—6 Disassemble the Damping Pulley Disassemble the damping pulley) Disassemble the fastening bolts of damp ing pulley and pull out damping pulky. See Figuw 4—15—6, Disassanble the water pump, and inspection covei@) () Disassanbe the connector of canshatt posi tion sensor pulley housing cover YY Attention Carefiilly protect the shell of can shaft position sensog it is a plastic part (2) Disassanble the water pump pully housing cover assembly, See Figure 4—15—7, Pique 4—15—7 Disassemble the W ate Pump, Pulley Housing Cover and Inspet tion Cover, Figure 4— Disassemble the Tin ing BeltU ; (3) Disassemble the inspection cover | ee D bassonible-the titihe belt Ante) Disassemble the camshaft tm ing pulley®) (1) Measure cam shaft axial clearance bym exm See Figure 4—15—9. Measurement should be done before disassanb le the camshaft tin ing— pulley Rephce the fiustplate ifmeasured cam shaft axial clearance exceeds prescribed limit eier Cam shaft axial cleamnee Standard Linit Pigue4—15—9 Disassemble the Can shaft Tining Pulley 0. 050~0. 114 mm 0, 20 mm 4 IBN Pal 8K A i fs FS BR Wel Bad rterral Combustion Engine Moafactving Compr Lined = 201 @éMAIVTENANCE MANU ‘© 1 ll Figure 4—15—10 Disassmble the Camshaft Tin ing Pulley Pigue4—15—12 Disassemble the 0 iL Pump Assanbly Fleur 4—15—13 Take OutTappet Fon the Tappet Hole of Cylinder B lock AL OF GW2.87C TURBO AMESEL ENGINE ( Disassambe the camshaft tining pulley assan bly fam camshaft (3) Disassam ble the fastening bolt of signal ion and push out signal ion (4) Pull out the camshaft tin ing pulley assanb ly using genem| pullefl). See Figure 4-15-10, General pulls 5—8521—0002—0. ® Disassamble the front gasket seat of camshaft) Disassemble five fixed bolts for front gasket seat of camshaft and then disassemble the gasket seat See Figue 4-15-11, D keshentble th bil Samp asdanb 5G) (D7D isassanble the turbocharger and oil hose of vacuum pump fiom oil sump. (2) Remove reinforcement and tubber pads fam two sides of oil sump. (3) Disassanb le the oil sump bolts and disassen dle the oil sump frm cylinder block. Disassemble the oil pump assanb hiif Disassemble the oil pump assanby fem cylinder block See Figure 4-15 —12. Disassemble the camshaft and tappe fi () Disassemble tre camshaft fiom cylinder block Forbidden to damage camshaft bearing (2 Take out tappet fiom the tappet hole of cylin derblock See Figure 4—15—13 V Attention If the tappet can be used again, mari the position symbol at tuppet please 2 CDRESRARN MEA ZA ret Wa ating mera Conbstion Eng Manta ring Copan LinedCHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Figue4—15—14 Assanble the Cam shaft and Tappet Figie4—15—16 Pump Assanbly zy a IN ail e Figure 4-15-17 Daub Sealant on Vaulted Awa *# Assembling Assanble the camshaft and tappefif () Daub oil on fappet and its installing hole of cylinder block (2 Putaway the tappet acconting » the marked position symbol during disassembling (if you want © use the tppet again). See Figure 4—15—14. \Y Attention Install he tappet before installing cam shat (3) Daub oil on camshaft and camshaft bearing (4) Assemble the camshaft on cylinder block See F gure 4-15-15, \Y Attention Forbidden to damage the camshait bearing during assenb ling Assanbie the oil pump assemb iii Daub oil on 0 —seal ring of oil pipe and ih stall it into 0 —seal ring grove of cylinder block, (2) “Assemble-the-oil pump and oil pipe on cylin [dérblock hind tighten fixed bolts tl prescribed toraue, See Figue 415-16. —! ®&) Tighten tomue fr fixed bolts of oil pump 20 Ne m+5 Nem (3) Tighten sleeve nuts io prescribed torque Q) Tighten torque Sr sleeve nuts 20N+ mt5 Nem Assanbke the oll sump assembly () Daub reconmended liquid seakint or equiva lent on the vaulted areas both of 5" bearing housing and of tin ing pulley housing aswell as fhe gioove See Figuie 415 —17,MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Fire 4—15—18 Assmble te 0 ilSump and Gasket Optionad Pieur4-15—19—Assqnble-the A hm inn Ally Oil Sump’ and Front/Rear Gaskets Pigue4—15—20 Assanble the Front Gasket Seat of Camshaft Figure 4—15—21 Assanble the Camshan ‘Timing Pulley (2) Insert the rear lip of seal gasket int 5" groove @) Ensure the lip of seal gasket tightly contact the givove (@ Assemble the oil sump on cylinder block, () Tighten fixed bolts of oil sump to prescribed torque Tighten tomue fr fixed bolts of oil sump 20N* m+5 Nem Assanbke the fiont gasket seat of cam shaft) 1) Daub punchy sealant on outside round of front gasket of camshaft (2 Fore the font gasket of camshafl ino the in ner hole of fiont gasket seat of camshaft (3) Hitch O — seal ring into the outside round seal ring groove of front gasket of camshaft and daub a lite eearr oil on outside round of sea! ring @) Assemble the front gasket|sedt of can sha fon ‘the pulley housing and tightens fixed bolts ®t fwont gas Ket seat of canshatt to prescribed torque See F —15—20, ®) Tighten torque for fixed bolts of front gasket seat of can shaft 20N- mi5 Nem Assanbk the camshaft tin ing pulle¥s) (D_ Install the tin ing pulley of camshaft on can shaft See Figure 4—15—21, (2) Tighten the fixed bolts of camshaft tin ing pulley to preseribed torque Tighten torque fr cam shaft tin ing pu ley 110 Ne m+10N+m YY Attention Daub Letai 587 silicon pastem ¢ venly on two planes of plane washer when tighten the fixed bolts of camshaft tin ing pulley. fe Te ES It PA a A) ll is SB 204 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 Gw2. STC TURBO “DIESEL ENGIVE Poise 850K £0.10ke / Poise4.20kg, 0.1088, Figue 4—15—22 Assumble the Timing BeliUnit Figure 415-23, Assanble the Water Pump Pulley Cover Damping pulley Figue4—15—24 Assanble the Damping Pulley Figure 4—15—25 Assmble the Cooling Fan Assanbly Assanbke the tining belt uni@ The assembling of tin ing belt —— The timing gap of outer edge of crankshaft lining pulley shoul align the “1” type mised symbol of pulley housing cover —— Téehten the installing locating technique bolt (diwing Na 1006101 E06 anong te part list of the engind ino the installing iocating technique bolt hole of pulley housing through the installing technique hole of camshaft pulley. Sinilarly high— pressure el pump pulley also Is cated used technique beating bolt —— During he belt installing the sequence of the belt to rg is as following @ crankshaft tin ng pul key @) camshaft tming pulky @ transition wheel G high pressure fue! pump pulley and 6) tensioner The belthas direction gmbol forbidden reverse assembling VY Atientio: Foubidden the phenomena such as umvanted teeth and incorrect teeth bebyeen cam shaft tin ing pulky and high —pressure fuel pump pulley Forbid den oil dit orwater on belt and bend the tin ing belt —— Tension the tin ing belt Assapble the water pump. pulley housing cover and “Gaspection covet)’ ; Assanbk the damping pulley5) — Tighten the fixed bolt of danp ing pulley to pre scribed tique See Figure 4-15 —24, SJ Tighten tomue fr fixed bolt of damping pulley 210N+ mt15Nem VV Attention When tightens the bolt of damping pulks, fwheel ring gear should be fixed Or avoiding cranksha fs unning Assanbk the cooling fin assamb 4) fa) Ordinal install water pump pulley and coolng fan assembly on water pump shaft Tighten the locking nut to prescribed tomue See Figure 3—15—25, (ot eetric SX Tighten tomue for docking nuts of water pump pulley and cooling fan 8Nem TE ES Dd 2 A) ll is BR a Badg terval onbasion Engine Manufacturing ConparyLinted — 205MAIVTENANCE MANU AL OF GW2.8TC TURBO DIESEL ENGINE Figure4—15—26 Tighten the Bolis of Cylinder H ead Following Sequence DiWid ing into Two Steps Assanble the cylinder head assanbly and gaske® () Install the dowel of cylinder head on cylinder block, (2 Assemble the cylinder head gasket and let its top upward, (3) Clean the matching surface of cylinder head and cylinder block (4 Install the cylinder head lightly. (5) Daub oil on bolt screw thread of cylinder head and the matching surface (6) Tighten the bolts of cylinder head flowing the sequence of Figure 4—15—26 dividing into wo steps © prescribed tomue QQ Tighten tomue fr fastening bolts of cylinder head Figue4—15—27 Assonble the Engine A ssamb ly Figue4—15—28 Assemble the Tiansnission and C luich A sembly Step 1 Step 2 75Nem+5Nem 100 N+ m+5 Nem Assanble the engine assanb i®) Assanbk the engine by crane Assanb ke the transmission assembly and clutch as sem bl¥t) Read relevant content in this Chapter “4, 12 fly wheel and front bearing of tunsn ission 1°! shaft’.CHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4.16 Piston and Connecting Rod Assembly Disassembling sequence @ Valve housing cap (© Connecting rod bushing © Piston and connecting rod assembly Assembling sequence Assembling sequence is reverse to disassembling sequence, Faure t=T0=1_ Disassembling and Assam bTing Sequence Tor Pision and Connecting Rod Assamb f fe TE EE A A) Bl is SB Great Wa Banding internal ombustn Engine Marfactving Company Linitee 207MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figure 4—16—2 Disassemble the Cylinder Head A ssemb ly Figure A163, -Disissamblethe Ak ine Alloy Oil Sump’ and Front/Rear Gaskets Figure 4—16—4 Disassemble the Oil Sump Assamby Figue4—16—5 Disassanble the Oil nection Pipe W ekiment ) Disassembling Prepaw tion (2) Disconnect the grounding cable of battery (2) Drain coolant fran cooling systan. (3) Dmin oil fim wbricating oil system YY Attention: New cooper washer should be used when install dmin screw. AA! Tighten tomue rdmin screw 83Ne mis Nem Disassemble the valve housing cap{0) Disassemble the cylinder head assanb 52) Loosen fastening bolts of cylinder head flibwing sequence See Figure 4—16—2, \V Caution Loosen fastening bolts of cylinder head following this sequence very slowly please other wise itmake against with the lower surface of cylinder head, D tsaskomble the ofl samp assomh bS ~~ (Lift heengine-upwarl Greround-50-mm. (2) Disassemble the oil sump fion cylinder b inck See Figure 4—16—-3 Disassemble the oil pump assanb Iv) Disassemble the oil pump assanbly fem cylinder block See Figure 4-16 —4, Disassemble the oil injection pipe wekdment Ranove one—way valve and oil pipe See Figure 416-5 2s \RESEARM MEA Za ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE @ Disassemble the connecting rod bush ingS) Hang a symbol at each bearing if you want to use the disassembled connecting md bearing again (See Figure 4—16—6), sign the cylinder serial numberand installing position during disassembling Figue 4-166 Disissemble the Connecting Rod Bush ng 666@ SSA Figured =1657\) C teatfoutt fhe Accum Gatbon'on Uppet Part oCylinderW pu Fiue 4—16—8 and Connecting Rod Nol] Figure 4—16—9 Sign Connecting Rod Bearing Disissenble the Piston Disassemble the piston and connecting md assem bk@ Q) Cleanout the accumulated caibon on upper part of cylinder wall by scmper before disassemble the piston and connecting md See F igure 4—16—7. if : ( iG : ( # (2+ Move +he pisten “lo cylinder’ top; —push ‘the ower part of connecting red upward using hammer han dle or other sinilar pol Then take out piston and con necting wd. See Figure 4—16—& (3) Hang a symbol at each bearing if you want © use the disassanb ed connecting md bearing again (see Figure 4-16 —9, sign the cylinder serial number and installing position during disassemblingMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Figure 4—16—10 Disassmble the Piston Ring ® Champ the connecting md using pliers Y Caution Do not danage the connecting md. (9) Disassemble each piston ring by the dilator of pision ring See Figure 4—16 —10, VY Caution Forbidden w ty fr using other tool disassembles the piston ring Excessive tension of pis ton ring willdecrease the elasticity of pision ring Figuied 16 -Lt, Disassemble the Pigion Pin-+ lacking Ring (® Disassemble the piston pin— locking ring by need le nose pliers See Figure 4 —16—11. | ; ; ; (Slightly knock ‘out the ideltind ting by Hanmer’ ‘and copper id. See Figuie4—16—12 ~ VY Attention Hang a symbol at piston and piston pin if you want to reassam ble the piston and piston pin, sign the cylinder serial mmber and installing position during disassembling ** Assembling Pigue 4-16-12 Disassendle the Piston Pin A Fieure 4-16-13 Assemble the Piston and Connecting Rod A ssemb ly Assamb le the pision and connecting md assembly) (D W eigh each piston and connecting wd assen be ‘The choice of p iston and connecting wd unit should ensure that the change of the assanbly mass difference ®r different eylinder is within prescribed range, Prescribed vale for the mass difference of piston and connecting 10d match ing unit <3 (2) Clamp the connecting rod using pliers Y Caution Do not danage the connecting md fe Te ES It PA a A) ll is SB 210 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Fige 4-16-14 Assmbk the Pisin Pin Locking R ing Rigi {19-415 | Asemb the Pisitn on \Catnecting Rod Figur 4—16—16 Assemble he Piston Pin Fie 4-10-17 Assemble the Pision Pin Locking R ing (3) Assanbke the piston pin— heking ring into the grove of piston pin locking ring by needle nose pli ers See Figur 4—16—14, VY Attention Do not change the piston /p iston pin unitwhen change piston /eonnecting md unit @ Assemble the piston on connecting wd. ‘The font smboi) at piston top should be at the same direction of the symbol) at connecting md See Figure 4-16-15. { | ' : | (5) Daub Oil on piston pin and pisin pin seat hole Push piston pin into piston pin seat hole using fin gers until it contact with piston pin locking ring See Figure 4—16 —16. (® Exert press piston pin locking ring nto pis ton locking ring gmove See Figure 4—16—17. Check connecting rod ums at piston pin flexibly or notMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE LOP symbol —~ (Il gas ring) Figue 4—16—18 Surface with Symbol of Compression Ring Shoutl be Upward 1 compression ring JY toonmesion surface Surface with symbol SS Pie 416-19 Assmbiing Sequence for Piston’ ing ; | compression ring ‘Surface with symbol is upward 20 Assanble the Pison Ring Screw spring Teer support opening a s oi LEY “TE Compression ring, Figure 4—16—21 Assembling Positions fr Piswn R ing Opening no QSEAEN MERE ret Wong ner Combustion Ege Mnetecting Cn (@ Assanble the pision ring using piston ring di bloc TOP symbol should be upwari when install p iston ring See Figure 4-16-18 (8) lnstalling sequence of piston ring is as follow D Oil ring Gwith spiral cup rng). @ Ucampression ring (printed smbol “TOP” is upward. @® compression ring (printed symbol “CYPR” or “CCC” is upward). TOP symbol (letter symbod should be upwart when install compression ring Wy Altes ton! 1 ( —= The siinbol sfiduld be upwarl witen install compression ring See Figue 4—16—19, ‘Two compression rings cannot be interchanged. —— Compression rings cannot be wa ed. —— Forbidden disfigurement or impurity inside ring grove —— Insert spiral cup ring int oil ring giove and ensure that both sides of spiral cup ring have no clearance befpre assanbke the oil ring ( Daub oil on piston ring surface (10) Check if piston ring mnning flexible inside ring groove (11) Correct place the opening assembling posi tion of piston ring as shown as Figure 4—16—21, FyCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, (12) Carefitlly cleanout various inpurities on both the back of bearing and matching surface of bearing housing of connecting md See F gure 4 —16—22 (13) Daub oil on upper bearing surface and cylin derwall Figure 4—16—22 Cleanout Impurities on Malching Surface of Bearing Housing of Connecting Rod (14) Front symbol at piston top should face to the front of engine during assembling Canpress piston ring using piston ring compres sor Piston ring compressor 5 —8840 —99018—0 (J —8037) (15) Push piston into cylinder using hanmer han dle (See Figure 4—16—23) until connecting ind con . cling with cunk pin AL the sme ting um the Fide 416-29 ASamb i te Pigon | CmNkshatl until crank pin o be at Ye bolt dead cen, I ‘or (BDC). ¢ 1 Assanbke the connecting rd bush ingS) foo™ (1) Front symbol at connecting md bushing should fice engine font ( Assanble the connecting wd bushing A lign the serial number at connecting md bushing lo the serial mmber at connecting rod See Figue 4— 16-24, Front symbol Fie. 16-2 ANSnD Brie Gomectng (3) Daub oil on the screw thread of connecting Rod Bushing od cap bolt and matehing surface (4) Use angle tightening method to tighten con necting md cap nut to prescribed torque divided into two steps. Tighten tomue reconnecting md cap nut Step 1 (clingy omue) Step 2 (final torue) V Attention ‘Tum the crankshaft by hand to check Figue4—16—25 Assmble he Connecting ‘if the crankshaft running flexible or not after tighten the Rod Bushing connecting rod cap nut RECNAMM SSAA Company (Great aang teal onbstin Engin Mneactring Company LitesMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assambk the oil injection pipe weldment unit (1) Install oil injection pipe we ment unit cyl inder block See Figure 4—16—26. (2) Twhten pipe bolt and pressure regular © prescribed torque ©) Tighten tome for oil injection pipe weld ment unit fixed bolt (M8 XT. 25 We 4—16—26 Assemble the Oil @ M6 XT. 00 Iniection Pipe W ekiment Uni QJ Tighten tomue broil pressure regulator 46N*m+5 Nem VY Attention Slowly tum the crankshaft io check if there is obstmctive between piston and oil injection pipe Assanbke the oll pump assembly) (Daub oil on 0 —seal ring of oil pipe and in Pigue4 1 Assemble the Oil 2 ‘ SELL if into O = sealvitig grove of eylinder block, Pump Assam bly \) Assemble the oil pump andl 031 p pe on, cy in der block-ahd tighten Mixed bolls prescribed tomud % See F igure 4-16 —27. 2Q Tighten torque Sr fixed bolts of oil pump m 4) Zh (3) Tighten sleeve nuts ip prescribed torque Figure 4—16—28 Daub Sealant on ®) Tighten torque ®r sleeve nuts Vaulted Area 20N* mi5 Nem Assanbe the oil sump assanbly8) () Daub reconmended liquid sealant or equiva knton the vaulied areas both of 5" bearing housing and of tin ing pulley housing aswell as he gmove See Figure 4—16 —28. (2) Insert the rear lip of seal gasket into 5" grove () Ensure the lip of seal gasket tightly contact the groove Fire 4—16—29 Assemble the 0 il Sump and Gasket (ptionad fe Te ES It PA a A) ll is SB 214 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, @ Assemble the oil sump on cylinder block (5) Tighten fixed bolts of ofl sump to preseribed torque See Figure 4—16 —29 and Figure 4 —16 —30. 24 Tighten torque ®r fixed bolts of oil sump. 19N+m Figure 4-16-30 Assemble he A im inun Alky Oil Sump and Front/Rear Gaskets Assambk the cylinder head assem bly2) (Instill the dovel of cylinder head on cylinder block (2 Assemble the cylinder head gasket and let its top upward, @) Clean the matching surface of cylinder head and cylinder block Install the cylinder head lighth: Daub oil on bolt screw thread of cylinder head and the match ing surface (5) Tighten. the bolts of cylinder head folowing L, L the sequehce! of Fisue 4-16 —31 dividing into Wo 1621 Assmbé the Cylhder’ ~sleps 1 pwesctibed-tonue- Ft NS Head Assamb ly Fie 4 Ql Tighten toque Br fastening bolls of cylinder head Step 1 Step 2 75Nemi5Nem 100N- m+5N-m Assanbk the valve housing cap) Read relevant content in this Chapter “4. 6 valve housing cap”. Figur 4-16-32 Valve Housing CapMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4.17 Front Oil Seal R ing of Crankshaft 2) Transmission belt of power steering pump & Transmission belt of alternator @ Cooling fan assembly © Crankshaft damping pulley © Water pumys pulley housing cap assembly and inspection cover © Front oil seal ring seat of camshaft, camshaft timing pulley assembly and camshaft timing belt © ‘Transition wheel, tensioner © Crankshaft timing pulley and high-pressure fuel pump. @ Pulley housing @ Front oil seal ring of crankshaft YO) Assembling sequence “Assembling sequence is reverse to disassembling sequence, Feu d=17=1 Disassanb ling and Assan bling Sequence tr Front0 Tl Seal Ring of Cank shall fe Te ES It PA a A) ll is SB 216 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 Gw2.8Te TURBO DIESEL. ENGINE, ye4—17—2 Disassemble the Fan Cow! Pure 4—17—3 Disassemble the ‘Trung jssion Belt of Bower Steering Pump Figure 4—17—4 Disassmble the Cooling Fan Assanbly Figure 417-5 Disissemble the W ater Pump, Pulley Housing Cap A ssemb iy ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2) Drain coolant fran cooling systan, \Y Waming Coolant is poisonous and must be stomwd inside original container Fotb dden people contact it Disassemble the fin cowd]) Disassemble the overflow tank hose and fan cow! See F gure 417-2 Disassemble the tensnission belt of power steer ing pum p2) Loosen both the bmicket and adjusting bolts of paver steering pump and then remove transmission belt See Fig ure 4-7-3, Disassemble the transn ission belt of altemato@) Loosen bracket bolts (lower side) of allemator and lock ing bolts of adjusting pute then move tans mission belt D Butgdtnbr hd cooling. fin Seber baa Loosen the check nuts of fin and disassemble the fan assembly and water pump transn ission pulley See Figue 4—1l7—4. Disassamble the crankshaft damp ng pull Loosen the bolts of crankshaft damping pulley. then disassemble the cranksha—danping pulky. Disassemble the water pump pulley housing cap assambly and inspection covefé) Disassemble the water pump, pulley housing as sanbly, and seal rng See Figure 4—17—5MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figure 4-176 Disussemble the ‘Transition W hee | Unit and Tensioner Figure 4-17 —7 —Digassem bse, the H-igh— ProssareTuel Pupp Pu liey Pigue4—17—8 Disassemble the Pulley Housing and Its Gasket Figure 4—17—9 Disassemble the Front Oil Seal Ring of Cminksha ft Disassanble fhe finnt oil seal ring seat of camshaft camshaft tim ing pulley assanbly and canshafl ming belf?) Disassemble the transition wheel tensioneffi) () Disassemble the fistening bolts of transition whee| and take out transition wheel (2) Disassanbke the pulley— locating skirt bolts for tensioner gu id ing bracket (3) Disassemble the fastening bolts of tensioner and take out tensioner Disassemble the crankshaft tin ing pulley and high —pressure fel pump) () Pullout the timing pulley through two disas sambling technique bolt holes (M6, screw thread depth 15) on crankshaft tin ing pulley (2) Disassemble the pulley hold — down plata disassemble the fastening bolts of high — pressure fuel pump and pull out h igh—pressure fuel pump. VV Attention The wood uf ath gh—pressure fuel pump shaft is transition fit carefully to keep itdue, to, it rwould los sametine te h Disassemble" the pullléy housing Disassemble the fastening bolts of pulley housing, and disassamble the pulley housing and pulley— hous ing gasket See Figure 4—17—8 Disassemble the front oil seal ring of cranksha fEip Slightly knock around the oil— seal ring of cmnk shaft by plastic hammer and screwdriver and take out front oil— seal ring of crankshaft fim pulley housing See Figure 4—17—9, Alten tion: Do notdamage the matching surface of the front oil seal of crinkshaft and the pulley hous hg ns QRESEIEM MEA Za ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, ** Assembling Assanbk the fiont oil seal ring of cmnk shally () Assemble the front oil seal ring?) on pulley housing by fiont oil seal ring e1ecto®). See Figure 4— W710. Front oil seal ring erector 5 —8840 —2361—0. (2 Note the installing depth®) of fiont oil seal ring shown as Figure 4—17—10, The dept) is 1 mm. (3) Daub punchy sealant on outside round of fiont oil seal ring Figuie4—I7—10 Assamble the Pont 0 il (@ Daub a little clean oil on the Lip of oil seal Seal R ing of C ranksha fl ring Assanbk the pulley housingi) () Assemble the pulley—housing gasket align the dowel and crankshaft and then push it into crank shaft (2) Tighten the fixed bolt of pulley housing to pre scribed tomue QJ Tighten tomue fr fixed bolt of pulley housing 20 N+ m45 Nem Pigure 4-47 -L1-Assanble the Cmnkshatt Tin ing Pulley ni (| ‘Assahbe the}crankshaft tin ing pulley and high Diessiwe fuel pumip-pulley®) ot @) Align the keyway of emnkshaft pulley to the plane key of crankshaft knock int the crankshaft by cooper hammer or install the c1nkshaft tm ing—pulley by crankshaft pulley erector The tin ing gmbol Cout side edge gap) of crankshaft tin ing pulley is outwax (2) Assemble he high —prssure fhe! pump pul key on high — pressure fuel pump shaft fix the pulley by fastening bolts of high — pressure fel pump and tighten the fastening bolts igs ay rae) eset aH I= ®\) Tighten tomue for fasten ing bolts of high — Pressure Fuel Pump Pulley pressure fue! pump 75N* m£5 Nem Assanbk the transition whee| tensionef) @ Assanble the trinsition whee} and tighten fastening bolts of transition wheel EX Tighten iomue Or fastening bolts of trunsi tion wheel 110 Ne m£10N+m Fieure4—17—13 Assanble the Trinsition W heel and ‘Tensioner GSRERRA Mas AR Zo Get jon gine Mara Wall Bang tera Comb Conperylintes = 219MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figured 17-14 Assanble the Water Pump Pulley—Housing Assembly Figure 4-17-15 Assmble the Cooling Fan Assanbly Pigued—17—16 Assendle the Transn ission Belt of A lemator fg Se ES I Os i 1S BR 2 220 ‘Great Wal Baoding iteral Combustion Engie Maufactung Cong () Assemble the tensioney tighten the pu lley— locating skirt bolts for lensioner guiding bracket EX Tighten torque fr pulley—localing skirt bolts fr tensioner guiding bracket 20 N+ mi5 Nem Do not tight campletely tighten the fixed bolts of ten sioner Assanbk the finnt oil seal ring seat of canshaf can shaft tin ing pulley assanbly and canshaft tining belt) Read relevant content in this Chapter “4. 15 can, shaft and tappef’. Assanbk the waterpump pulley housing cap as sembly and inspection cove fi) Assanbk the crankshaft damp ing pu lle: Tighten the fixed bolts of crankshaft damp ing pul ky to prescribed toque RX) -Tishen-tomue for fixed bolts of emnkshalt ‘démping plalley| | (x i ON: miI5N-m VY Attention Pix the flywheel ring gear and pre vent crankshaft tuming when tighten the fixed bolts of crankshaft damp ing pulley. Assanbk the cooling fin assenb hi) Assmble the cooling fan assambly and water pump pulley to waler pump shaft tighten the check nuls to pre scribed toxjue See Figure 4—17—15 @) Tighten torque Sreheck nuts SNem Assambke the tansn ission belt of altemato®) Assambke the tmnsnission belt of altemator and adjust the tension of its belt See Figure 4-17-16 LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Assanble the tansnission belt of power steering pum, Assanbk the transnission belt of power steering pump and adjust the tension of its belt Assanbk the fan cowf) Assable the overflow tnk hose and fan cow! (see Pear 4-17-19. Figue 4-17-17 Assamble the Fan Cowl Only forReterenced Cany out Sliowing tasks afler assembling please (1) Connect the grounding cabk of batter, See Figure 4-17-18, (2 Fill coolant into cooling system. yy \ G)-Start engitte ‘andscheck (if cooling system has | eakiage-or not |! ' ( F Pigue4—17—18 Connect the G wunding Cable of Battery (Only for Reference)MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4,18 RearOil Seal R ing of Crankshaft Disassembling sequence © Transmission assembly and elutch assembly 2) Flywheel © Rear oil seal ring of crankshaft Assembling sequence Assembling sequence is reverse to disassembling sequence. Fae d=18=1 Dissenting and Assanb Ing Sequence lor RearOl'SeaTR hg of Cranksharl oo RESEREM MEA ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 Gw2.8Te TURBO DIESEL. ENGINE, Figue 418-2 Disassemble the Teansmission and Clutch A ssambly Figure 4-183 Disassanble the Fyyheel Figure 4—18—4 Disassemble the Rear Oil Seal R ing of Cmnksha ft ) Disassembling Preparation Disconnect te grounding cabe of batter, Disassemble the Lansmission assembly and clutch assembly) Read relevant content in this Chapter “4. 12 fly wheel and front bearing of tunsmission 1°! shaft’. Disassemble the flywhee®) () Assamble the fywheel mtiner (2) Loosen the fixed bolts of flywheel liwing the sequence of F igure 4—18—3 divited into wo steps and then disassan ble the flywhee| Disassemble the rear oil seal ring of crankshaft) Push the rear oil—seal ring of crinkshaft inner and install special bol llow ing Figure 4—18—4 at the same tine so that ip disassamble oil seal ring Rear oil seal ring knockout 5—8840 —2360 —0. \Y Attention Do not damage the surface of the crankshaftand the rear oil— seal ring seat when d isas sable the rear oil seal ring of crankshaft ** Assanbling Assanbke the rar oil seal ring of cmnkshaf®) @ Assambk the rar oll seal ring of crankshaft on cylinder block by rar oil— seal ring erctor See Fig ure 4—18—5. Rear oil—seal rng erecloy 5—8840 —2359 —0. (2) Clean and semape the steel mast and chipping caused by pressing into the rar oil—seal ring VV Attention The direction & press the oil— sealMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (3) Install the connectors of special tool to the {125 mm40.3 mm, war end of crankshaft using wo bolls (@ Install the oil—seal ring at outside round A (5) Insert the sleeve into connector park and tighten the bolt (M121, 75, L=70) until end sur t fice of connectorw ithstanding the sleeve (@ Disassemble the connector and sleeve, IB | (@ Check the installing size after assembles the oil—seal ring as shown as Figure 4-18 —5, Standard instlling size for rar oil seal rng of Figure 4—18—5 Assemble the RearOil crankshaft Seal R ing of Crankshaft 12 5~12 8mm Assanbk the fywheef) () Tum crankshaft until thews of Ist cylinder © be at the top dead center of compression stoke and now install the flywheel! into crankshaft when its “T” sumbol is upwaid and at central position (2) Daub oil on the flywheel bolts (3) Use angk tighten method to tighten flywheel bolls to prescribed lomue dividing inio Wo steps ac coming: %) the sequence of Figure 4-186, h { EA~ Tighien tomue Wr fywheeT bolts Figue4—18—6 Asomble the Flywheel oe embry Step 1 (clingy bud | Step 2 (final torqued 80 N+ m£5N- m 120N+ m£10N- m Assambk the transm ission assembly and clutch as sembly) Read relevant content in this Chapter “4, 12 fly wheel and front bearing of tunsm ission 1°! shaft’. 18-7 Assemble th and Clutch Assembly rang issionCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, 4.19 Crankshaft and Main Bearing Disassembling sequence @ Transmission assembly and clutch sembly igine assemb) © Cylinder head eembly and gasket @ Damping pulley Timing pulley housing © Oil sump assembly il pump assembly @ Piston and connecting rod assembly @ Flywheel and rear connecting plate of cylinder block @ Rear oil seal ring of crankshait © Crankshaft and main bearing housing Assembling sequence Assembling sequence is reverse to disassembling sequence. © (Aluminum alloy oil sump) 8 Figie d=19=1_Disassanb ing and Assan bling Sequence Tor Ciankshall and Main Bearing RERMAMMASSRAA ‘Great Wall Banting Inter Combustion EngineMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE ) Disassembling Prepaw tion (2) Disconnect the grounding cable of battery (2) Drain coolant fran cooling systan. (3) Dmin oil (lubrication fem lub ric tng sys tan. Figure 419-2 Disassemble the Trinsm ission Assam bly Figure 4—19—3 Disissemble the C hutch A soamb ly Figure 4-194 Disissamble the Engine A ssmb iy 2s QRESEREN MEA Za ret Wong ner Combustion Ege Mnetecting Cn Waming Avoid scalded by hot oil appmpri ate treat old oil and protect environment Disassemble the transmission assembly and clutch assamb if) Lift vehicle and use suitable safely stand to sup port it (D Transmission assenb ly —— Ranove he transmission shaft fun flange fork —— Ranove trnsn ission assembly (2) Ciuteh assembly Y Attention Forbidden liquid on clutch surface and, clean the surfiee if it has liquid please {) HE JP ressuré disk assembly ( ~ += Diriven_aiske ONS —— Use guiding m #éle—aligner to avoid driven disk assambly fall down freely Guiding m idd le—alignee 5—5825 —3001—0. —— Print symbols on Apwheel and pressure disk flange so that it can be alignment when assemb ling — Loosen fixed bolt of pressure disk assanb ly and remove clitch assembly. See Figue 4—19—& Disassemble the engine assemb\¥2) (D Carefiully Lit engine by crane (2 Fiontof the engine should be higher than war of the engine when engine after lifted (3) Foubidden damage any oil pipe braking pipe and appliance elenentwhen take out the engine assem be LinedCHAPTER 4 Gw2. STC TURBO “DIESEL ENGIVE Figure 419-5 Head A ssemb ly Figure 4-196, Disussemble the Tin ing Pull Housing ; Disassemble the Cylinder Figue4—19—7 Disassanble the Oil Pump assembly Front symbol GW symbol ~ Figue4—19—8 Disssendle the Pision and Connecting Rod A ssemb ly Disassemble the cylinder head assambly and gas ke®) Loosen bolts of cylinder head following the se quence of Figure 4-19 — VY Caution Loosen fastening bolts of cylinder head follow ing this sequence vey slow ly please otherwise it make against with the lower surface of cylinder head, Disassemble the damping pulley) Read relevant content in this Chapter “4. 15. fly wheel and tappet’. Disassemble the tin ing pulley housings) Disassemble the pulley housing after disassembled the water pump pulley housing cover and inspection cover tining belt camshaft tin ing pulley crunkshaft tin ing pulley, high—pressure fuel pump pulley, tan sition wheel and tensioner Disassemble the oil sump assenb h@) (D Lift the engine for about50 mm. (2 Disassanble the oll samp fim eylinder bipck, Reid) relevant content= this Chas ter, 14 oil “samp assembly”! Disassemble the oil pump assanblyz) Disassemble the oil punp assembly frm machine hull See Figure 4—19—7. Read relevant content in this Chapler “4 13 oil pump assembly” Disassemble the oil injection pipe weldment Disassemble the one—way valve and oil pipe Disassamble the piston and connecting md assan bh Read relevant content in this Chapter “4. 16 pis ‘on and connecting wd assembly".MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figure 4~19~9 Disassmbie the Flywheel and RearConnecting Phite of Cylinder B lek 9=10_Disassmble the Rear iiSeol Rife of Cankshat Pigue 4-19-11 Disassenble the Main 1g Housing and ThmstW asher Figue 4-19-12 Main Bearing of Crankshaft 2s QREREAEM NAM ZE ret Wong ner Combustion Ege Mnetecting Cn Disassemble the flywhee]and rear connecting plate of cylinder b lock (D Install flywheel retainer (2 Loosen flywheel fixed bolts and then disas samble the fhwheel (3) Disassemble the rear connecting plate of cyl inder block See Figure 4—19—9, Disassemble the rear oil seal ring of cranksha Mit) Push the rear oil— seal ring of crankshaft inner and install special tol following Figure 4 —19—10 at the sane tine so that to disissamble oil seal ring Rearoil seal ring knockout 5—8840 —2360 —0, VY Attention: Do not damage the rear connecting plate and the seal surface of emnkshaftwhen disassan ble the rear oil seal ring of crankshaft D fastattble-the! dammkshaftadd méin bearing has. hg ~ ~ 7 ~ (1) Disassemble the man bearing housing and thrustwasher See Figue 4—19—11. (2) Carefully disassemble the crankshaft (3) Disassemble the upper beating of crankshaft *¢ Assanbling Assmble the crinkshaft and main bearing housings @) The upper bearing of crankshaft has one oil hole and one oil groove lower bearing has nothing (2) Carefillly clean various impurities on bearings (3) Daub new oil on both upped and bower bear Y Attention Do not daub oil on the back of bear ings and matching surface of bearing housing of cylinder bbek LinedCHAPTER 4 Gw2.8Te TURBO DIESEL. ENGINE, Figure 4-19-13 Assambke the Main Bearing of Crankshaft Assamble the ‘ThiwstW gsher Figure 4—19—14 ® Figae4—19-15 5" Bearing Housing (® Assemble the main bearing of cmnkshaft on cylinder block and main bearing housing See Figure 4 19-13, VY Atention Ensue that hemai bearing oferank shafthas stalled on right position (S) Carefiilly assenbe the crankshaft (® Daub oil on thustwasher ‘D Assemble the trust washer on 3" main pur nal See Figure 4—19—14, VV Attention Oil gwove of the thustwashermust fice crankshaft (8) Daub rcanmenked liquid, seakint or ediva’ “ent on 5 beariig housisg of cranksWaft See Figure 4 —19—15 (9) Daub reconmended liquid sealant or equiva Jent on matching surface between 5" bearing housing of crankshaftand cylinder block See Figure 4-19-16, V Aten tion —— Foztbidden any oil on main bearing housing before daub recammended liquid sealant Do not bbek the screw thiead hole of cylin of Crankshaft £0 e_|_le @ a? > LAS Hf oes Figue4—19—16 Daub Seglant on (10) Maiching Surface Between 54 Bearing Housing of Ciankshal and Cylinder Block der block and bearing by liquid sealant The amow symbol on every bearing— hous ing top must face to the engine direction when installing main bearing housing fe TE EE A A) Bl is SB Great Wa Banding internal ambustin Engine Marfactving Company Linitee_ «= 229MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE GD Daub oilon every bolt ofmain bearing hous ng 2) Vew sbw and carfill tighten the balts of a main bearing housing to prescribed torque follow ing the Ome, ano sequence of F igure 4—19—17 divided into two steps el a] a Footie Oe, A) Tighten tone for the bolts ofmain bearing housing Step 1 | Step 2 95 N+ m5 Ne Nemt . San Fem nome SSN mESNEM [TONS ETON m Crankshaft Bearing Housing \Y Attention Tum the cnkshaft by hand to check if the crankshaft timing flexible or not Assanbke the sar oil seal ring of crankshaft) (D Assemble the rear oil seal ring of crankshaft Remap iat on cylinder block by war oil— seal ring erector See o Figure 4-19 —18, Rear oil—seal ring erectoy 5—8840 —2359 —0, (2 Clean and scrape the steel rust and chipping caused by pressing into the rear oil—seal ring {| Walter tion; The dimpetion to|press tie oil geal sing “~~ = os Slt NS (3) Install the conneetrs of special tol 1 the war end of crankshaft using two bolts Seal Rng nf Cenkit: (@) Install the oll—seal ring at outside ound, () Insert the sleeve into connectr part and tighten the bolt (M121, 75, L=70) until end sur fice of connector ithstanding the sleeve (6) Disassemble the connector and sleeve (D Check the installing size afer assembles the oil—seal ring Figure 4-19-18 Assanble the RearO il Standart installing size for war oil seal ring of crankshaft 12 5~12 8mm Assanbke the flywheel and rear connecting plate of cylinder b lock®) () Align the rear connecting p hte dowel of cyl inder block See Figure 4—19—19. Fie 4-19-19 Assmble the Rear Connecting Plate of Cylinder Block fg Se ES I Os i 1S BR 2 230 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, ® Tighten the fixed bolls of wear connecting plate of cylinder block ! prescribed tomue Q) Tighten tomue for fixed bolts of rear con necting plate of cylinder block 85 N+ mil0N+m () Use hart wood plug crinkshaf for prevent it mnning (@ Thiows of I cylinder are at the top dead cen ter and install the flywheel into crankshaftwhen its “T” symbol is upwarl and at centmal position, () Daub oil on the screw thread of flywheel dolls (@) Tighten fywhee| bolls to prescribed tomue di viding into Wo steps accom ing to the sequence of Fig ure4—19 20. ®) Tighten torque fr flywheel bolts Step I (clingy bmue) Step 2 Cfnal torque) ~ 80NemE5Nem | 120N-mE10N- m ‘| Assenbble the piston ahd connecting ind assamb Ise) ~~ Weigh each piston and connecting wd assem Figie 4-19-20 Assamble the Fhwheel yyy ‘The choice of piston and connecting md unit should ensure that the change of the assambly mass difference Sr different cylinder is within prescribed range Prescribed yale for the mass difference of piston and connecting od matching unit <38 (2) Clamp the connecting rod using pliers Y Caution Do not damage the connecting 10d (3) Assemble the piston pin locking ring int the groove of piston pin locking ring by needle nose pliers See F gure 4—19 —21. Figure 4-19-21 Assamb ie the Piston ¥ Attention: Do not change the piston /p iston p in Pin Locking R ing unitwhen change piston /connecting md unitMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE () Assemble the piston on connecting wd. The front symbofi) at pision top should be at the same direction of the “GW” symbol2) at connecting wd See Figure 4—19 — Figure 4-19-22 Assmbke the Pistcn and Connecting Rod (5) Daub oil on piston pin and piswn pin seat hole Push piston pin into piston pin seathole using fin gers until it contact with piston pin locking ring See f Figure 4—19 —23, Figie4 19-29 Assgnkie the Piston Pi \ 7 ( (6) Exert' press pisjon pin Idcking ring, into pis! ton locking ‘ring: groove “See Figuré4—19 —24 Cheek connecting rod tums at piston pin flexibly or not Figure 4-19-24 Assemble the Pisica Pin Locking R ing (D Assanble the piston ring using piston ring di bior See Figure 4—19 —25 ‘The symbol of canp ression ring should be upwant, Figure 4-19-25 Assemble the Pision Ring Using Piston Ring D thtor oso QRESETEM MEA ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE ‘TOP symbol ~ (I compression ring) Identify the symbol of canpression ring as shown as Figure 4—19—26, (8) The sequence to install the piston rings is as shown as F gure 4—19—27, 19=26 TOP Symbol Shou id Be Upwanl Figure 4 1 compression ring Surface with symbol, So, TT ltcompression sirtace KR Vom Oil ring a @ oil (with spiral cup ring. @ Ucampression ring (printed smbol “TOP” is upward. @® Lcampression ring (printed symbol “CYPR” or “CCC” is upward). Y Attention The symbol should be upwarl when install compression ring See Figure 4—16—19, Two canpression rings cannot be inter changed, —— Insert spiral cup ring into oil ring gwove and ensure that both sides of spiral cup ring have no clearance, defor assemble the oil ring . h Bigued-1927 Assemb Ing Seaubnce For Piston R ing Fie 4-19-28 Assamble the Oil Injection Pipe W ckiment id I Piston-rings. cannot be waped: — Forbidden disfigumment or mpurity inside ring gmove Assanbke the oil injection pipe weldment (® Install oil injection pipe weitment to cylinder block See Figure 4—19 —28. (2) Tighten oil injection pipe bolts and pressure regulator to prescribed omue A Tighten tnque fr oil injection pipe weldment fixed bolts () M8X1, 25 20N+*m+5 Nem (2) M6X1, 00 10N+m+2Nem A Téehten torque broil pressure regulator 46Nem VY Attention: Slowly tum the crankshaft io check if here is obstmetive beween piston and oil injection pipe fe TE EE A A) Bl is SB Great el and interral Conbstin Engine Marfactving ConpayyLintes = 233MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figiw4—19—29 Assanble the Oil Pimp Pigue4—19—30 Daub Seaknton the Vigulled A reas Fie 4—19—31 Assmble the Oil Sump and Gasket Optionad Figue4—19—82 Assemble the A um inn Alby Oil Sump and Front/Rear Gaskets 234 Assanbk the oil pump assambl (1) Daub oil on 0 —seal ring of oil pipe and in stall it into O —sea ring grove of cylinder block (2 Assemble the oil pump and oil pipe on cylin derblock and tighten fixed bolts prescribed torque See F gure 4-19-29, Tighten torque fr fixed bolts of oil pump. 20 N+ mi5 Nem (3) Tighten sleeve nuts io prescribed torque EX) Tighten torque dr sleeve mits 20N+ m£5 Nem Assanb k the oil sump assanblyé) () Daub mcanmended liquid sealant or equiva fenton the vaulted areas both of 5" bearing housing and of tn ing pulley housing aswell as fhe giove See Figuie 4—19—30. ‘ (2)—Insert the rear lip-of seal gasket.into'5" gwove, \) @ Lnaate the lid GF seal gabketstightiy contact the groove = = sf = (® Assanble the oil sump on cylinder block See F gure 4—19 —31 and Figur 4—19 —32, (S) Tighten fixed bolts of oil sump to prescribed torque ©) Tighten torque fr fixed bolts of oil sump 20N- m+5N-m fe Te ES It PA a A) ll is SB ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE ve Figure 4~—19~33 Assanble the Tining Pulley of Crunkshait Head Gasket, 24_Assambe the Cylinder Assanbk the timing pulley housing5) () Assemble the timing pulley See Figure 4— 19-33, Read relevant content in this Chapter “4 17 front oil seal ring of crankshaft’. (2) Assemble every pulley and pulley unit Read relevant content in this Chapter “4. 15 can shaft and tappet’, Assanbk the damping pulley) Read relevant content in this Chapter “4. 17 front oil seal ring of crankshaft’. Assanble the cylinder head assanbly and gasket) (@) Install the davel of eylinder head on cylinder block ( Assemble the cylinderhead gasket and let its top symbol upward, See Figure 4-19 —34, () Clean the lower surfiee of cylinder head and the match ing surface of cylinder block. (4) Install the cylinder head lightly, () Daub oil on bolt screw thread of cylinder head and the matching surface Fie 4—19—35 Accoaling tp Sequence lo Tigh en Cylindertl cad Bolts D ivid ed Into Two Steps (6) Tigh tem the bolts-of cylinder head ~OLowing \the /sequence \of Pignie 4! 19-35. dividing. into yo ‘steps © Prescribed tome” = = Q) Tighten tome fr fixed bolts of cylinder head Step 1 75NemiS Nem Step 2 100 N+ mi5 Nem Assanbke the engine assanb ¥2) Read relevant content in this Chapter “4, 2 engine assembly”. Assanb ke the transmission assembly and clutch as san bl) Read relevant content in this Chapter “4. 12 fly wheel and fiont bearing of tansm ission 1°" shaft’. Figue4—19—36 Tmunsnission and Clutch Assembly Assenble theMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 4,20 Cylinder Block Assanbly © @ Disassembling sequence @) Transmission assembly and clutch assembly Engine assembly )Colinder head assembly @ Alternator Engine bracket Oil filter assembly © Water pump, pulley housing cover assembly and __ inspection cover @Crankshatt timing pulley ‘Timing pulley housing sump assembly DOI pump assembly 2 Piston and connecting rod assembly 6&8 Flywheel and rear connecting plate of cylinder block @ Rear oil seal ring of crankshaft (9 Crankshatt Assembling sequence _ Camshaft and tappet Assembling sequence is reverse to disassembling sequence. Cylinder block Fine J=20=1Dimsan bling and AwaIO Ing Sequence lor CyMnder WRK ASNT fe Te ES It PA a A) ll is SB 236 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figure 4—20—2 Disassemble the Clutch | Disassembling Prepamtion ( Disconnect the ground ing cable of batter: (2 Drain coolant fiun cooling systan, VY waming Coolant is poisonous and must be stored insite original conia ner Forbidden peop b con tuct it (3) Drain oil Gubrication) fm hubricating system. VV Waming Avoid scalded by hot oil appmpri ate teat old oil and protect environment YY Attention: New washer should be used when in stall drain screw. SAL Tighten tomue Srdmin screw 83N- mi5 Nem Disassemble the transmission assembly and chitch assemb hf) Lift vehicle and use suitable safety stand to sup port it (1) Transm ission assanb ly —— Ranove the twnsmission shaft frm flange fork = \Ranove lansh sion ass@nbi: (2)-Clutch-assanb ly ' Y Attention: Forbidden liquid on clutch surfice and clean the surfice if it has liquid p lease Figure 4—20—3 Disassemble the Engine Assembly Figure 4—20—4 Disassanble the Cylinder Head Assambly Disassemble the pressure disk assembly —— Disassanble the driven disk —— Use guiding middle—aligner to avoid driven disk assamb ly fall down freely Guid ing m idd le—aligner_ 5 —5825—3001—0. Print symbols on flywheel and pressure disk flange so that it can be alignment when assemb ling Loosen fixed bolt of pressure disk assanb ly and nmove clutch assambly. See Figure 4—20—2 Disassemble the engine assembly) (D Carefully lift engine by crane (2 Frntof the engine should be higher than rar of the engine when engine after lied (3) Forbidden damage any oil pipa buking pipe and appliance elanentwhen take out the engine assen bh: Disassemble the cylinder head assamb ly) Loosen bolts of cylinder head following the se quence of Figure 4-20 4. fe TE EE A A) Bl is SB Great el ard interal Conbstin Engine MarfactvingConperyLimtes 237MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE YY Caution Loosen fastening bolts of cylinder head TT follow ing this sequence very slowly pleaso othemw ise it Il eye make against with the bower surface of cylinder head. sittestet F Read relevant content in this Chapter “A 9 cylin eG derhead assembly and gasket’. er tt ! oo oleh. Disassemble the altemao® = y (1) Disassemble the wire connectors of allema 2 ‘tb Oil howe © r (2) Disassemble the oil hose fran oi! sump, See Figure 4—20—5, (3) Disassanbke the oil hose@) fiem cylinder block, (@ D isassanb le the fixed bolts for adjusting plate of altemator (5) Disassemble the fixed bolts of altematyr Figure 4—20—5 Disassemble the A ltema ior Disassemble the engine bracke®) Disassemble the left and right brackets of engine fram cylinder block See F gure 4—20—6. Read relevant content in this Chapter “4. 3 engine bracket’, Figure 4 -20—6_, Disassmble the Engine Rieke! ; \ ( | ‘7 Disassamble the oil fitter assenb ~ Disassemble the oil Tilter using Oil filter spanner See F gure 4—20—7, Filter spanner 5 —8840 —0200 —0, Read relevant content in this Chapter “4, 11 oil filler assamb hy”. Disassemble the water pump, pulley housing cover assembly and inspection covet Read relevant content in this Chapter “4, 15 cam shaft and tappef’. Disassemble the crinkshaft tin ing pulley Read relevant content in this Chapter “4. 10 tin ing pulley”. Disassemble the tm ing pulley housing) Loosen the fixed bolts of tin ing pulley housing and disassemble the timing pulky housing and its gasket fiam cylinder block See Figure 4—20—8, Figure 4—20—8 Disassemble the Tin ing Pulley Housing and Its Gasket 2s QREREREM MAM Za ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Disassemble the oil sump assenb hi) () Lift the engine fr about 50 mm, (® Disassemble the oil sump assanbly fu cyl inder block See Figure 4—20—9 Read relevant content in this Chapter “4. 14 oil sump assembly”. Figure 4—20—9 D isassambie the A luminun Alby Oil Sump and Front/Rear Gaskets Disassemble the oil pump assamb kit Disassemble the oil pump assanby fem cylinder block See Figur 4—20 —10, Read relevant content in this Chapter “4. 13 oil pump assembly”. Piguee 20-—10-—D isussemb le the-O ik Pump Assam bly i | \ Dbussemble the oil jection pipe woldnent ~~ Disassamble“the one-way valveand oilpipa See Figure 4-20-11, Fie 4-20-11 Disussemble the 0 iL Injection Pipe W ekiment Disassemble the piston and connecting md assan bhi 1) Cleanout the accumulated caibon on upper part of cylinder wall by scmper befor disassanble the piston and connecting md. See Figure 4—20—12 Fie 4—20—12 Cleanout the Accumulated Carbon on CylinderW allMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (2) Move the piston to cylinder ton push the lover part of connecting md upward using hanmer han dle or other sinilar tool Then take out piston and con necting wd, See Piguie 4-20-13. Figue 4-20-13 Take Out Pision and Connecting Rod (3) Hang a symbol at each bearhg if you want © use the disassamb led connecting md bearing aga (see Figure 4—20 —14), sign the cylinder serial number and installing position during disassan bling Nol Figur-4;-20—14—Hang-« Symbol at Each Connecting, Rod Bea ring f (4_ ban. the joonnbeting-wa using pliers VY Caution Do not danage the connecting md (5) Disassam ble each piston ring by the dilator of piston ring See Figure 4—20—15, Y Caution Forbidden tp ty fr using other tool disassembles the piston ring Excessive tension of pis ton ring will decrease the elasticity of piston ring Figue4—20-15 Disussanble the Piston Ring (6) Disessamble the piston pin beking rng by needle nose pliers See Figure 4-20-16, Fleur 4—20—16 Disassamble the Piston Pin Locking Ring b40 (TE EC I ME a sO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, @ Slightly knock out the locking ring by hammer and copper wd. See Figure 4—20—12 VY Attention Hang a symbol at piston and piston pin ifyou want to reassan ble the piston and piston pin sign the cylinder serial number and installing position during d isassamb ling Figue4—20—17 Disassemble the Piston Pin D isassanble the flywheel and rar connecting plate of cylinder blocl& (Install flywheel wtainer (® Loosen fixed bolts of flywheel and disassen ble the flywheel See Figure 4-20-18, jl ( (® Disassonble the-rear connecting plate of ¢yl nder block’ See Figur 4-20-19. Figued—20—19 Disassemble the Rear Connecting Plate of Cylinder Block rc Disassemble the rear oil seal ring of crankshaft Push the rar oil seal ring of crankshaft inner and install special wol follow ing Figuie 4 —20—20 at the same tine so that to disassemble oil seal ring Rear oil seal ring knockout 5—8840 —2360 — VY Attention: Do not damage the crankshaft seal surface and the rar connecting plate when d isassanb le the war oi] seal ring of crankshaft Pigue4—20—20 Disassemble the Rear Oil Seal Ring of Cmnksha ftMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 20-21 Disassen ble the C rankshad 3 Hs 2 2 Figure 4-20-23 Disassanb le and Assanble the Cylinder B lock Pigue4—20—24 Assemble the Camshaft Disassemble the crinksha ig Read relevant content in his Chapter “4, 19 crank shaft and main bearing”. Disassemble the camshaft and tappe fig (1) Disassamble the camshaft fim cylinder block VV Attention: Do not damage canshaft bearing (2 Take out tappet fem the twppet hole of cylin derblock See Figure 4—20—22 Disassemble the cylinder b lack ** Assanbling (| \Assanbe the'cylinder block ( V ~_ leah matehing’ surface oT eylinder block.’ cheek water and oil passages blocked ornot See Figure 4— 20-23, Assanbke the camshaft and tappeki (Daub oil on tappet and its install cylinder b lock (2) Put away the tappet acconting to the marked position symbol during disassembling (if you want © use the tappet again) . hole of \Y Attention Install he tappet before installing cam shaft (3) Daub oil on camshaft and camshaft bearing, (4) Assemble the camshaft on cylinder block See Figure 4—20 24, \Y Attention: Forbidden to damage the camshaft bearing Read relevant content ih this Chapter “4, 15 cam shaft and tappef’. a2 QRESEIEM NEAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Figure 4 Crankshaft Bearing Figure 4-20-26. Assanble the Cmnkshaft Maia Bearing! Figure 4—20—27 Assenble the ‘ThmstW asher Ab Figue4—20—28 Daub Sealant on 5" Bearing HI cusing of Crank shaft Assanble the crankshaft and ma in bearing (1) The upper bearing of crankshaft has one oil hole and one oil gmove lower bearing has nothing (2) Carefully clean various impurities on bearings (3) Daub new oil on both upped and lower bear ngs VV Attention Do not daub oil on the back of bear ngs and matching surfice of bearing housing of cylinder bbock (@) Assanble the main bearing of crankshaft on cylinder lock and main bearing housing See Figure 4 —20—26, YY Attention Ensure that the main bearing of crankshaft has installed on right position (5) Carefillly assembke the crankshaft @ baub vil of sieletnashen (D Assemble the thst washer on 3" main pur nal See Figure 4—20 —27, YY Attention 0 il groove of the thrustwashermust face to crankshaft (8) Daub recanmended liquid sealant or equiva kent on 5" bearing housing of crankshaft See Figure 4 —20—28MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE o Figure 4—20—29 Assmble the Main Bearing Housing (9) Daub recommended liquid seaknt or equiva kent on matching surface between 5" bearing housing of crankshaftand cylinder block See Figure 4 —20 —29, Vv Atten tion: —— Forbidden any oil on main bearing housing before daub recommended liquid sealant — Do not bbck the screw thread hole of cylin derblock and bearing by liquid sealant (10) The armow symbol! on every bearing—hous ing top must face to the engine direction when installing main bearing housing (11) Daub oil cn every bolt ofmain bearing housing (12) Very skw and careful tighten the bolts of main bearing housing of crankshaft © prescribed wmque follow ing the sequence of F igure 4—20—30, S) Tighten torque for the bolts ofmain bearing housing Step 1 Step 2 Step 3 Pigye¢--20-—20, Tighten the Bolts of MainBearhg Housihe df Crankshaft Wy thsi | Pigue4—20—31 Assmble the Rear OilSeal Ring of Crankshaft Set ee Ee Pe ee YY Attention Tum the crankshaft by hand to check ifthe crankshaft tuming flexible or not Assapbb tie: war dil’soa | ring of cwnkshafthu He (D-Assanblé the rar'oil-seal ting Of crankshaft on Sylinder Block by tear oil—seal ring eitetor See Pigure 4 —20—31 Rear oil—seal rng erecr 5—8840 —2359 —0, (2 Clean and scmpe the steel nist and chipping caused by pressing into the rar oil—seal ring Y Attention: The direction b press the oil— seal ring (3) Install the connectors of special tol tthe war end of crankshaft using two bolts (4) Install the oil— seal ring at outside round of connectors: (5) Insert the sleeve into connector pass and tight ea the bolt M121. 75 L=70) until end surfice of connector withstanding the sleeve (6) Disassemble the connector and sleeve (@ Check the installing size after assembles the oil—seal ring Standart installing size for war oil seal ring of crank shaft Fleur 4—20—32 Assamble the Fhwheel and Rear Connecting Pte of Cylinder 8 bck 244 wand ewe tywheel and rear connecting plate of cylinder b lock fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Assamble the piston and connecting 1od assamb vi () Weigh each piston and connec ting wd assem bly ‘The choice of piston and connecting wd unit should ensure that the change of the assanbly mass difference Sr different eylinder is within prescribed range Preseribed vahe for the mass difference of piston and connecting td match ing unit Fieure 4—20—33 Assemb ie the Piston and Connecting Rod A syemb ly Figure 4-20-34 -Assenble the Pistn Pin Logking Ring <38 (2 Clamp the conneeting rod using pliers YY Caution Do not danage the connecting wd (3) Assemble the piston pin locking ring in the gnove of piston pin locking ring by needle nose pliers See F gure 4—20 —34, VV Attention Do not change the piston /piston pin unitwhen change piston ‘connecting md unit ‘Assemble. the piston A eotmectingtod The front smbofl) at piston top should be at the same direction of the “GW” symbol2) at connecting wd See Figure 4 —20 —35, Figue4—20-35 Assanble the Pision and Connecting Rod (5) Daub oil on pision pin and piston pin seat hole Push piston pin into piston pin seathole using fin gers until it contict with piston pin locking ring See Figure 4—20 —36, Fired —236 Assemble the Piswn P inMAIVTENANCE MANU AL OF GW2.8TC TURBO DIESEL ENGINE Fieure 4—20—37 Assemb ie the Piston Pin Locking Ring Riguiy A220 $38) A siqnble) the Piston.R ing. ‘TOP symbol “~~ (LI compression ring) Figure 420-39 Klentifjing Symbol of Canpression R ing 1 compression tn Surface with symbol z = is upward WW Alcompression surtac: wig a ZA 20 Figure 4 40 Assembling Sequence For Piston R ing 246 S (© Exert © press pision pin locking ring into pis ton beking ring grove using fingers See Figure 4—20 —37. Check connecting md tums at pision pin flexibly or not (@ Assanble the piston ring using piston ring di ior See Figure 4 —20—38 ‘The gmbol of conp ression ring| should be upwan’ Identify the sym bol of can pression ring_as’ shown as Figure 4—20 —39, (8) The sequence to install the piston rings is as shown as F gure 4—20—40, @® Oilring (with spin] cup rng. ® Heanpression ring (printed symbol “TOP” upward). @® 1 cumpression ring (printed symbol “CYPR” or “CCC” is upwaml). VY Attention: Two canprssion — rings cannot be inter changed, —— The symbol of campression rng should fice to piston ip. —— Piston rings cannot be warped — Forbidden disfigurement or impurity inside ring groove Insert the spiral cup ring into oil ring groove and ensure that both sides of spiral cup ring have no clear ance before assenble the oil rng (9) Daub oil on piston ring surface fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO, DIESEL. ENGINE, Surface with symbol is upward RX 1 compression ring, Conic suriace aR Ww a De | Oilting eo Figure 4—20—41 Check the Tuming of Piston Ring Flexible or Not Serew spring= 1 Compression ring support opening ¢ s 4 i ring ee Fie 4—20—42--Assemb jing Position of, Pisa RingOpating Figure 4—20—43 Daub Oil on Upper Bearing Surface Figure 4-20-44 Assanble the Piswn R ing, (10) Cheek if piston rhg running flexible inside ring gmove See Figure 4—20—41, (LD Conect place the opening assembling posi tion of piston ring as shown as Figure 4—20 —42 \ a2 | cave tly cleanout various impurities on both ‘he back“ of bearng and“matching suiface of beating housing of connecting rod (13) Daub oil on upper bearing surface See Fig ure 4—20—43, Daub oil on cylinder wal (14) Front symbol at piston top should face io the fiont of engine during assembling Campwss pision rng using piston rng campressoe Seo Figur 4—20—44 Piston ring campressos 5—8840—99018—0 (I —8037). (15) Push piston ino cylinder using honmer han die until connecting wd contacting with crank pin At the same time tum crinkshaft until crank pin i be at the bottm dead center (BDC). fe TE EE A A) Bl is SB Company (Great a Bandera Combustion Eg MneectvingConpayLimtes 247MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figured 20-45 Assemble the Oil Inc tion Pipe W ekiment ° al Figue4—20—47 Daub Sealnton the Vaulted Areas Figied—20—48 Assemble the Oil Sump und Gasket (Optionad as QRESEIEN MER ZE ret Wong ner Combustion Ege Mnetecting Cn Assanb ke the oil injection pipe weldment (1) Install oil injection pipe we ment to cylinder block See Figure 4 —20 —45. (2) Tighten oil injection pipe bolts and pressure regulator ty prescribed omue A) Tighten tomue for oil injection pipe weld ment fixed bolts (M8 Xt, 25 (@) Mb x1. 00 20N-mi5N+m 10N+mi2Nem S40” Tighten tongue broil pressure regulator 46.N mi5N m YY Attention Siwly tum the crankshaft check if bere fs obstuctive between piston and oil injection pipe. Assanbk the oil pump assamb hii (1) Daub oil on O —seal ring of ofl pipe and in stall it into O—seal ring etoove of eylinder block (2 Assembly the oll pump and oll pipe on cylin derblock and tighten fixed bolls © prescribed lomue 500 Figue 4-90 46, \ k ‘lL tligh'teh toque ‘ein fixed, bolis oF oil pump 20 N+ m£5 Nem (@) Tighten sleeve nuts prescribed torque QJ Tighten torque Hr sleeve nuts 20N*-mt5 Nem Assanb the oil pump assanb@ () Daub mcanmended liquid sealant or equiva knton the vaulted areas bob of 5" bearing housing and of tin ing pulley housing aswell as the gimove See Figure 4—20 —47. (2 Insert the rear lip of seal gasket into 5" gioove (3) Ensure the lip of seal gasket tightly contact the gmove (® Assanble the oil sump an cylinder block See Fue 4—20—48 () Tighten fixed bolts of oil samp to prescribed tomue 2X Tighten torque fr fixed bolts of oil sump 20N* m45 Nem LinedCHAPTER 4 GW2.8TC TURBO DIESEL ENGINE, Assanbk the timing pulley housing) Read relevant content in his Chapter “4, 19 crank shaft and main bearing”. Pigue4—20—49 Assanble the Tining Pulley Housing Assanbk the tin ing pulley of crankshaft) Read relevant content in this Chapter “4. 10 tin ng pulley”. Assamble the water pump pulley housing cover as sanbly and inspection covet?) Fign@ 420-50) A sable) the Timing Pulley fC mankshar ( | j - ( | Assenb b the oil filter (Install the O — seal ring on oil filter and as semble the oil cooler See Figure 4—20 —51, (2 Assamble the oil cooler fixed bolts Tighten fixed bolts of oil cooler © prescribed tomue. @) Tighten tomue fr fixed bolts of oil cooler 20N* mi5 Nem 20-51 Assanble the Oil Cooler Figur 4 (3) Assemble the oil filler VY Caution The spiral oil filter ement is one— tine used partand forbidden to use it again —— Daub thin hyer oil on 0 —seal ring of oll fil ter See Figure 4—20—52, —— Screw oil filter element into oil filter seat by hand until the surface contact with O—seal ring Tighten ofl filler ekment int oil filter seat by oil filter spanner fr 3 A cycle clockwise Figied—20—52 Assemble the Oil Filter EkmentMAIVTENANCE MANUAL OF GW2.8TG TURBO DIESEL ENGINE Figure 4-20-53 Assamble the W aterH ose Figure 4—20—54 Ehwing Bfucket Assanble the Oit hose GD Figure4—20—55 Assemble the A liemmator A ssemb ly Figure 4-20-56 Tigh ten Cylinder ead 250 —— Connect cooling walter inlet and outlet hoses of oil filter See Figure 4—20—53, Assanb ke the engine bmckets) Install the left and right brackets of engine and lighten fixed bolts of bracket to prescribed torque See Figure 4—20 —54, 2A) Tighten tomue fr fixed bolts of engine bracket 40 Ne mt5 Nem Assanbke the altemator assembly) Q) Provisionally tighten fixed bolts of alemator f (2) Connect oi] hose) of vgcuum pump to joi samp. See Figur 4—20—55. ~ (3) Connect oil hos€3) of vacuum pump to cylin der block (4) Connect wire connecior of altemator Assanbke the cylinder head assem b 4) (D Install the dovel of cylinder head on cylinder block (2 Assemble the cylinder head gasket and let its top symbol upward () Clean the lower surface of cylinder head and the upper surfice of cylinder block (4) Install the cylinder head on cylinder block lighth. (5) Daub oil on bolt screw thread of cylinder head and the matching surfice (6) Tighten the bolts of cylinder head flowing the sequence of Figure 4-20 —56 dividing into wo steps to prescribed torue A) Tighten torque Sr fixed bolts of cylinder head HT SNe mESNe mM | TOONe mESN+ mi) Recheck fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 4 GW2.8TE TURBO DIESEL ENGINE t Assembly Fain Figure 4—20—59 Tighten Pressure Plate A svemb ly Bolts Assanbk the engine assanb K2) () Put away the engine by crane ( Assanble he engine bracket and tighten fixed bolls of biacket to pieseribed wique SQ) Tighten torque fr fixed bolts of engine bracket 40 N+ mt5 N+ m Y Attention Forbidden damage any oil pipes ap Pliance elanents and sensors when assamble the engine Assanbe the tranam ission assembly and clutch as sem bly) () Assemble the clutch Driven disk assembly —— Daub multi-function molybdemm disa fide grease on the splines in driven disk hub of clutch Assanble the driven disk assembly using guid ingm iddle~aligner {| Guiding middle alignee 59825 —3001 —0.), Pressure disk assembly — Tishion pressure disk assembly bolls wo pre scribed true accor! ing © the sequence of Figure 4— 2058 Tighten toque fr pressure disk assanbly bolts 20 N+ mis Nem —— Disassemble the gui ing m Hdle—aligner \Y Attention Ifnew pressure disk has been used after tighten pressure disk assembly bolts © prescribed torque the line m proteetd iaphmgn springmustbe re moved, (2) Transnission assembly —— Assmble the tansnission assanbly. See Fig ue 4—20—60 —— Assanble the tansn ission shaft Figure 4—20—60 ‘Transm issicn Assam bly Assenble theMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CHAPTER 5 FUEL SYSTEM 5.1 Summary V Attention People engaged with the maintenance of fuel supp ly systam must always keep fim ly inmind the fllow ing items @) Atany ting when fuel supply system is wouking battery—ground ing cab ke should be dis connected exclid ing the testing requiring power supply fam batlem (2) Always prepare diy— type chamie fire extinguisher (class B) around the operation location please (3) Use the same fuel pipe and spare parts to replace the disassembled fel pipe and spare parts (4) Release the pressure inside pipeline at first before maintaining any part of the fuel supply system. (5) Do not repair the fuel supply systan if you haven t read the manual and check against the drwy ings concemed w ith wpairing FeUR S=I=1_P pele of he Fuel Supp y Syst 1 Fuel anke 2—Fuel filtey 3—Fuel rem valve 4—Three—way for fuel retmm: 5~—Masnetic valve of high—pressuw fuel pump, 6—CPIH high—pwessure fuel pump, 7—Fuel pump, S—Pressure sensor of high Pressie fel mail (RPS); 9—High—pressure fuel mit 10—Injeclor 11—EDC 16C39 conun! unit GW 2, 8TC turbo—diesel engine adopts CRS 2. 0 electric contml high— pressure fie! rail ype fuel supply systam developed by Gemany BOSCH Canpany. This firel supply system mainly consists of various sensors ECU, various actuators and connecting hamess and so on the pressure for fuel oo QREEAEN NEAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTERS FUEL SYSTEM supply can be up to 145 MPa and the fuel supply process is autma tically con olled by BOSCH EDC 16C39 electric contol unit (ECU). Apart fron direct contol relevant actuators inside fuel supp ly syst, it also contol other system s working pmcess concemed with the diese! engine operation such as BGR systan, A/G electric fan ete 11 igh—pressure fuel mil ype diesel engine mainly consists of sensors ECU, actuators and the connecting hamess i» connect then and so on Sensors include water tmpemture sensor engine speed sensog camshaft phase sensor foot pedal position sensog atr—flow mte sensor high—pres sure fuel mil pressure sensor and so on Actuatrs mainly consists of low — pressure fel way and high— pressure fel way low—pressure fuelway consists of fie! tank, fuel supply pipe fuel filter fiel pump, and lov —pressure area of high—pressure fuel pump, low — pressure fuel way consists of high— pressure ara of high— pressure fuel pump, high —presswe fuel rail high— pressure fuel Pipe injector and so on 5. 1 1 High—Pressure Fuel Punp GW 2, 8TC tuibo—diesel engine adopts BOSCH CP1H3 high—pressue fuel punp. thwwe ram — type pumps with 120—degiee angle distribution evenly canpress fuel to provide high— pressure fuel b fie] mil the flow rate of high—pressure fielway is con tolled bymagnetic valve (fivel inletmeas ure proportion valve) and step —exceed ing valve. ECU opemie the magnetic valve forcontmlling the fuel flow (high—pressure fuelway) ofeach mm— ype pump. see Figue §5—1—2 BOSCH CPIH3 high—pressure fel pump has gear—type fel pump (low —pressure fuel way) . Magnetic valve Fue! inlet valve To Bi pressure joint of high-pressure fel ral => Ram of fuel pump Man; % Pressure control valve shaft with, eccentric eam. Fuel supply fuel way a Thole 3 uel return Fie 5=1=2- 1reh=Pressure FuelPump: fe TE EE A A) Bl is SB Great Wa Banding internal ombustn Engine Marfactving Company Linitee §— 253MAIVTENANCE MANUAL O OF GW2.8TC TLNBO “DIESEL ENGINE ~ Fuel outlet joint ‘Manual fuel MS pump: Puc! inlet joint Fuel tank filter element Drain serew —4 Fuel Filer fe Te EE I a a A al Low —pressure fuel way provides enough fuel for high—prssure fuel way the operation of fel pump is to provide enough fuel for high—pressuze fuel way. At vari ous working status and different pressure rquimment as well as within whole working lifa the requirmentmen tioned above must be meet GW 2 8TC wibo—diesel engine adapts gear— type pump that incorporsted with high — pressure fuel pump as shown as Figure 5—1—3, Main parts are two rever sal— uming gears and lhey are meshing during wok ing fuel is sucked into pump body and anpty chanber among gears and pumped tp outlet at pressum sie The meshing line anong gears ensures excellent seal and prevents fuel retm The fuel supply mte of gear— type fuel pump is with direct pmportion engine speed. The thivttle at inlet end or the overflow valve at outlet end linits the fuel supply rate of gear—type fue! pump. Gear— type fuel pump ismaintenance fre Befre the first starting or the fuel inside tank exhausted cam pletely, the air inside fel tank system should be ex hausied before the first startng When exhausting ais use manual fuel pump ip p1ess and provide fuel until no tir side fue! wax, Manual Tuel punp.and diese! titer are neomontive ntanwfachired- F 5.1.2 Fuel Filter and Fuel—W ater Sepamtor The impurity inside fel will damage high— pressure fuel pump parts fuel outlet valve and injector There fre fiel filter should be installed Fuel filter shoud meet the special requinment of injection system, or the nomal operation of the fuel supply systan and the working life of relevant unit cannot be ensued Fuel has dissolubility emulsion or free water (for exam ple cooling water Or tanperature changing), if this water entered injection system itwill cause hole cord ing aR Za 254 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPT FUEL SYSTEM GW2, 8TC turho—diesel engine equips fuel filler with fuel—water sepamtog this separatorcan dmin wa Fuel inlet dieselenging the water level of water collector of the Sy fuel filer will reach to fixed height the autmatic a ming lamp at the panel of cab will be bright driver should din out the water collector timely at this tine bape Nes Loosen the drain screw is to drain, tighten it is > screw tightly the dmin screw; the directions to loosen and lhlen should be the same direction w ith the bolt Papety ekmentof fuel fillermust be replaced tine. a Replace itwhen new vehicle has nin for 4, 000 ~5, 000km, and then replace it for every 25, 000 ~ 30, 000km, Wat collector Drain serew Figure 5-1-5 Fuel Filler 5.1.3 Injector High-pressure connection Pivot disk Ball valve —} Fuel release hole ~ Needle vale control ~ ‘chamber Fuel inlet Nowaleshati needle Bearing chamber of needle valve fa) (b) Fue 5=1=0— nee GQRERMN BIAS RAG (Great al Bard interal Conbstin Engine MarfactvingConparyLimtes 255MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE GW 2, STC uibo—diesel engine adopts BOSCH CRD. 0) injector Injeclorwith electric wigger controls the adjusment of injection tine and mle Injector consists of hole nozzle hydraulic seo sysien and magnetic valve Fuel canes fam high—pressure fel rail and flows to injector through fuelway and ane fuel release hole contiolled by magnetic valve W hen closed fiel release hole the hydraulic foree acted on the wp of needle valve exceeds the hydraulic fice on bearing of need e valve there bre the need |e valve will decrease in valve seatand sop f el injection When themagnetic valve of injector is touched offand the fue! tease hole is opened, the pres sure inside needle contol chamber will decrease and also the pressure acted on the top of need le valve will decrease Once the pressure deciease lo be lover than the bie on bearing of needle valve the needle valve will be opened, fuelalso will inject into cambustion chanber Itadopls a set of hydraulic enlarging system, magnetic valve opens the fuel release hole and deciwase the pressure of needle contol chamber so that cause the fuctuatio pressure difference of rm, and this pressure difference opens the need valve Moreover fuel also leaks frm places of needle valve and control ram, and the leaked fue lw ill flow retum to fuel tank with retum fuel fm high—pressuze fiel pump through fel retum pipe 5, 1.4 High—Pressure Fuel Rail OD* ttigh-pressure ON Pressure sensor of ‘uel ral hign-pressare fe rl 7 : BD a ee CL ee iAP TO Pa vena el fom bigs fall ¥ Figure 5-1-7 Wigh Pressure Fuel Rail GW 2 8TC wrbo—diesel engine adopts BOSCH LW R2 high—pressure fuel wil High — pressure fuel rail stores high— pressure fuel At the same ting the high — pressure sue caused by fiel supply of high — pressure fuel pump and injection of injector has attenuation in side high—prssure fixe! mail cubage so that ensure the injecting pressure fr keep ng stable value when injector opened. H igh—pressure fvel rail also has the function of fuel distributor IH igh—pres sure fuel rail is equipped the pressure sensor of high— pressure fue! rail formeasuring the pressure of fiel supply: The high—pressue fuel canes fium high—pressure fuel pump getting in the fuel inlet of high—pressute fie! mil Fuel enters into high—pressure fie! mil and is distributed 1 each injec tor though fuel inlet The pressure ismeasured by the pressure sensor of high—pressure fuel mail and is adjusted to required pressure value by ECU and the magnetic valve of high — pressure fel pump. Though flow restrictor high —pressum fuel is pressed to injectos and the flow restrictor can prevent superfinous fixel into can bustion chamber when injector closed incampletel: oo QRESEREN NEA Za ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTERS FUEL SYSTEM Fuel with pressure is filled with inside high—pressure fuel mil tinelessly. Fuel condensab ility under h gh— pressure is used provide pressure siomga when fuel is sent to injector for injecting fan high-pressure fiel mil even if there is larger fuel capacity injected the pressure inside high —pressure fuel mil is kept at fixed pressure value practically To inputa voltage Sr ECU in allusion w prescribed fuel pressure the pressure sensor of high — pressuie fiel riil should measure he fuel pressure inside high—pressure fuel mil at any moment ‘The pressure sensor of high— pressure fuel wil shoul! ensure enough precision and tespond ing speed. Pressuw sensor of high—pressure fel rail consists of {lbw ing parts (@) Integrated sensor (2) Printing cireuit panel equipped with electronic checking loop. (3) Sensor housing equipped with electronic plag— type wire Fuel flavs to pressure sensor of high— pressure fue! mil though a snail hole at the high— pres sure fel rail. its end is sealed with sensor film, Fuel with pressure arrives at the sensor filn thmugh one blind hole One sensor component (sen conductor device) switching pressure signal into elec tric signal is installed at this film, the signal produced by sensor is inputted into a checking loop for enkuwing collection signal and ECU. The working process of presse sensor of high— pressure fuel mil is as following when fin shape changing the resistnce t connect fins also changes The establishment of system pressure causes fim shape changing (about Imm at 150, 000kPa), the changed resistance value will cause the vollge changing though 5V electric bridge Voltage changing range is0~-70mV (depend ing on using presume), and is increased 0, S~4, 5 V by enlarging circuit Precise voltagemessured val ue is necessary condition Or precise working of he systan, W ithin main working range the meas ured, prephign ky ajound 246 of fuel pressume read ng data Jf pressure sensor of high — pressure fyel mil is damaged ECU) will = uigen stop fanetign, \ ( h xmponents welded al the pressure devices 5.15 Sensor 1.5.1 Hull Effect Phase Sensor Comotted [aL Magnetie tield Either of following two voliage Oe Rotary se Gott 7 direction ny ‘omputer = Tabet Sang et Nowe os EA Permanent Tenton switch] “] fxepve ia magnet Blade cirehit EA EA Window” Compare “ “NH, receptive QN Sat Volos of alletor suit seis Trugigor poeta 5 when ai eh Stich Waruur fomawich'on ‘Weak analog “Amy Cutoff: De ‘Switch on change 10 cut-ofF signals converse signal igital] Vy Sith [siznet Collector ——_ mplifier tigesr ag Sender Switch transistor Figure 5—1—8 Hull Effect Phase Sensor RECN EMSA Great el and interalConbstin Engine Marfaclving Compa LitesMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE GW 2. 8TC trbo—diesel engine adopts PG3. 8 Hull effect phase sensor See Figure 5—1—8. Hull effect phase sensor adopts Hull effect principla one steelmagnet triggerwheel rotates fol lowing camshaft Hull effect integrate ciruit is installed between trigger wheel and pemanentmag, net and pemanentmagnet produces the magnetic fled peipendicular to Hull canponent Ifone of trigger whee! fingers passes canying lnear— type sensor camponent (san iconductor wafed, it changes the magnetic field intensity perend icular © Hull component so that the electron driven by voltuge along long shaftd irection will drift off to the direction pempendicu lar to current and produce voligge signal at mV grade its amplitude concems the sensor speed relative wo trigger wheel ‘The calculating citeuit integrated with sensor Hull integrate circuit treats the signal and out put itwith square wave signal 5.1.5 2 Meat—Fimn Type A inflow Rate Sensor GW2 8TC turbo — diesel engine adopts BOSCH “Terminal of measuring HEM6 heat— fin type aliflow mate sensor component Inegrase cicuit Teat—filn type airflow mie sensor is an airmass Stggocaeat. “S sensor with bgic output To obtain airflow rate, middle i casi gga — installed heating resistance heats sensor film at sen 7 Sensee sor component filn s tamperature distribution is meas S ured by the tmpemtm resistance installed pamllel i heating resistince The airflow passed sensor changes the fiin s temperature distribution so that the resistance difference produced betyeen two tmpemture resistances, : ‘K “0a! | The resistance difference depends upon fhe airflow di Bonet housing, Touiperatate rection and mig therefore the aiiflow mie sensor has higher equiment b git directipm~and mt, A ini let tmpertuie serisor can be installed” inside sensor measure air inlet pent if necessary. ~~ \ Bigs 19 teats ftin/type Athtow Rate Sensor 5.1.5 3 Engine Speed Sensor GW 2 8TC tutho—d ese] engine adop is DG6 speed 4g i: ae sensor a Wi St E ‘The installation of engine speed sensor is just fice NPE [Sensing coll | NT} to lhe uigger wheel of seelmagnet body and smaller Oo ak air clearance spaces out them. A soft inn cor is inside I the sensor and is surrounded by coil and also connects with a pemanentmagnet Magnet field of pemanentmagnet is transfered © trigger wheel though soft iron core, the magnet clear ance between trigger wheel and sensor affects the mag net field intensity. The magnet field intensity will stron gerwhen triggerwheel fingers close to sensog the mag net field intensity will weaker when trigger wheel fir gers away finn the sensor A Itemating magnet field w ill produce when triggerwhee! rotates as wellas hemag netic coil will produce one sine inductive voltage the amplitude of altemating vollage will increase fbliw ing the trigger wheel speed Caw m+ >100V). It is re quired that suitable voltage signal can be produced with in 30 rimin at least a A) il ies FS BR Zl ton ge Marfan Company ined Alternating current sine wave + Voltage 0 = Voltage Figure 5—1—10 Operation Princip le of Engine Speed Sensor o Ex i zCHAPTERS FUEL SYSTEM 1.54 Coohnt Tempemture Sensor GW 2, STC tuibo—diese! engine adopts TF—W water temperature sensor See Figure 5—1—I11. Semicon ductormeasuring resistance changed lbw ing kmpem ture in installed inside sensor ‘TP—W water tanperture sensor adopts tanpemture resistance with negative resistance coefficient (NTC). Electron ousing join Flue 5—1—11 Coolant Tempemture Sensor The temperature resistance of coolant tmpemture eo sensor is as one part of 5 V voltage distribution circu it the wo ends of coolant tempem ture sensor are connect ed with voltage bearing circuit When the tmpemtur resistinee of coolant temperature sensor changes follow ng tenperaturs the volage of voluge bearing ciruit also changes this vollage is inputted into ECU inter 8 fice moduk transition circuit The charcteristic curve 5 of beween voltage and cument relationship is stored in 8, Viemperature, ® ito, ECU, \ Characteristi¢ curve of coolant L | f 1 | temperature sensor (MTC) - - — — — $s Figue 51-12 Coolant Ten pemtsre Sensor and Its Chameteristie Curve 5.1, 55 Potentioneter Type Foot Pedal Position Computer Sensor Sv GW 2 8TC turbo — diesel engine adopts FFM po [+—t}- “VW_ ‘tentimeter type foot pedal position sensor Benclimaris Potentimeter type foot pedal position sensor works — accor! ing to voltage distribution cireuit principle and a B ccmputer supplies 5V voltages # sensor circuit Foot a 1 pedal is connected with sliding theostat brush inside Vokage sensor through steering shal} the voltage between brush Lapping roa LHS and ground ing will change when the position of potenti iil I ameter ype foot pedal position sensor changes and the a q D voltage bearing circuit inside com puterw ill tansfer the voltage into position signal of foot pedal W ork ing prin ciple of fot peda! position sensor is as shown as Figure FigueS—1—13 Working Princple of = 5 —] 13, Potentimeter Type Foot Peda | Position SensorMAIVTENANCE MANUAL OF GW2.8TG TURBO DIESEL ENGINE lectrie Contr! uw Figure 5—1—14 Unit Figure 5—1—15 Engine Hamess 1 Connect with ECU; 2 —Connect w ith air flow rate sensor unig 3 Connect w ith camshaft position sensoe 4 —Connec engine water tmpemtre sensor 5—Con nect with water tmpem ture sensor 6 — Connect wih vacuum sensor 7—Connect with speed sensor 8 —Connect with EGR vale 9—Connectwith 3 cylinder 10— Connect with 4 eylindeg 11 — Connect with 18! cylindee 12 —Connect with 2"4 cylindee 13 —Connectw ith high — pressure oil mil, 14—Connectw ith high — pressure rel a 260 REEMA 1.6 Electrie Conol Unit ECU) GW2 8TC turbo — diesel engine adopts BOSCH EDC16C39 electric contm! unit (ECU). See Figure 5—1 -u4 EDC (Electric Diesel Contro) electric contml unit sensors provide current working infornation of diesel to EDC electrie contol unit (ECU), then electric contol unit analyzes sensor signals at first and gives con tolling signals t control fuel injection capacity, injection start ing point waste gas reycle and electric heating plug syslen and so on in accordance with scheduled control strategy, Through the signals such as fe! injection ca pacity engine speed and cooling water tempemture and so on EDC electric control unit detem ines the optinal injection starting point and sends correspond ing control signal tomagnetic valve inside high—pressure fue! pump. H igh— pressure fuel mil type electric contol diesel engine control device (EDC) mainly consists of three system modules (1) The sensors and prescribed value producer to collect operation conditions and expectation They can uansbm different physical parmeters into electimnic sig mas \ » i ‘ (2. key ‘ueats infomation inko électionic output, ‘Signals aeconliig-© spécificaly mattrana tical caleuh tion methods (3) Actuator transfoms the electronic output sg nals of ECU into mechanical parameters Apat fiom direct contol relevant actuators inside contml fue! supply systen, ECU also contmols other sys tems working piocesses such as EGR systan, A/C, € kectric fan ete they all relating to diesel engine oper tion 5.1.7 Engine Hamess Sensors connected with GW 2, 8TC turbo —diesel engine hamess are water temperature sensoy engine speed sensor camshaft phase sensor foot pedal position senso air floy rate sensog high—pressure fuel mil pressure sen soretc See Figure 5—1—15, Mais am Zal Comp ret Waning mera Combustion EgeCHAPTERS FUEL SYSTEM Jesaicl-oquny, SOIL 91-1-s 2mNB LA DUS ZMD, — 2s pus may Pismo is ooezoT a0)MAIVTENANCE MANUAL OF GW2.8TC x NS Manual fuel ‘pump Fuel outit joint Fuel infet joint— TURBO DIESEL ENGINE 5 2 Repair in the Vehicle 5.2.1 Fuel Filter Assanbly Disassamb ling Sequence @ Fuel hose Fuel filter 3) Drain seww of fiel—water sepamior Assamb ling Sequence Assanb ling sequence is reverse tp disassam bling sequence. Poel tank filter BOSCIL vlement @ a Brat setew 4 Fiure5—2—1 Fuel Filer Figue 5—2—2 Disassemble and Assan ble the Fuel Hose | Disassanbling Prepa mation Disconnect the grounding cable of battery Disassemble the fuel hosdi) G)- Disassemble ‘he fle! hose of fuel flee) See \Flgure 57252) 5 1 —~ (Blocking hose end to avoid-fiel overflow. Disassamble the fuel filtet Loosen fixed bolts of fuel filter bmeket and then disassemble the fuel filler Disassemble the dmin screw of fuel—water sepa ra tors) ** Assambling Assanble the drain screw of fuel—water separainf) Assanbk the fuel filte® Assanbk the fiel filter and tighten fixed bolts of bracket Assanble the fuel hosél) Connect the fiel hose with the fuel filter Cany out blowing tasks after assembling please (D Connect the grounding cab k of battery (2) Supply fel t high— pressure fuel pump by prime fuel pump to mmove the air inside fuel supply system, ret Wa ating mera Conbstin Eng Manfactring Crary Linked ooo GRESEAEN MERE ZECHAPTER 5 FURL SYSTEM Figure 5—2—3 Disassamble the Fuel Filler Ekment = Fuel Filter I —Pilter tank filler ekment 2—Puel inlet Joint 3—Manual fael pump, 4—Fuel out let joint 5—E leciric socket 6—D min screw Figure 5—2—5 High—Pressure Fuel Pump 1 High — pressure uel pun, 2 —Fuel eum jont 3 —lHoop 4 — Fuel retum hosg 5—Fuel ium thee—way 6—Fuel inkt joint 5, 2.2. Filter Bement of Fuel Filter **) Disassembling Loosen and move the drain screw and soe itwell for next usage Disassanble the filter ekment of fuel filter by span net See Figure 5—2—3 Filter spanner 5 —8840 —0253 —0 J—22700) . ** Assambling (D Cleanout the matching surface of filler ele mentof fuel filer body so thal the filler element can jointwell (® Install drain screw on new filterelament See Figue 5—2—4, (3) Daub oil on O seal ring of new filter ekment (@ Pill fuel into new filter elanent to mmove air (S) Tighten new filter element until the O — seal ting of new filter elament contact with seal surface Camiully please prevent fel spill @ Tighten the filter element for 1 8 —28 cy cles by filler spanner Filter spanner 5 —8840 —0253 —0 (J—22700) Deflation. ‘CDQ pem® the martial fiel/pyp press thejair inside the fuel subpiy. system ct ‘high’ > pressure fuel pump. ~ (2 Disassemb ke the fel retum pipe of high—p ws sure fuel punp (see Pigue 5—2—5) and opemteman ual fuel pump until rmove all air bubble camp le, (3) Assemble the jie! retum hose of high —pres sure fuel pump. (@ Stwrt he engine if the engine cannot be started within 10 seconds repeat deflation mentioned above please (5) Ensure no fiel leakage and tightly tighten manual fiel pump cover Drainage When the water inside fiel—water separator arrives ‘ prescribed level the alam ng lamp of cab panel will bright Diminage should be carried out as follow ing steps (D Loosen dian screw, the direction Or loose ning and tightening should be the same as screw. (2) Operate manual fuel pump for tine after tine for drainage () Tighten the drain screw after dminage ( Operate manual fie] pump for tine after tine to check fiiel leakage (5) Check if the alam ing lamp is dark fe Es 1 YW a iG Fe Sl (Great el and interralConbstin Engine Compa Lites 263MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 5.23 Injector Disassembling sequence Harness joint of injector magnetic valve Assembling sequence Assembling sequence is reverse to disassembling sequence. Fguie 3=2=0 Disassanb Ing and Assan bling Sequence or injecorAa ssanbly fe Te ES It PA a A) ll is SB 264 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 5 FURL SYSTEM Figure 5— Joint of InjectorMagnetic Valve Figur Pressure Fye| Pipe —7 Disassmbk the Hamess 8 Disissemble;the High— ) Disassembling Pepa. tion Disconnect th giounding cable of batter: Disassemble the hamess joint of injectormagne tic valve) Apart be engine hamess joint flan the injecbrmag netic valve plug See Figure 5—2—7, Disassemble the high—pressure fuel p ipe2) Loosen four connecting nuts of high—pressure fuel pipe with four injectors at first then bosen the connect ing bolts beween hgh— pressure fuel pipe and high— pressure fiel mil and disassamble the high — pressure fuel pipe See Figure 5—2—8, D fesse le the fuel retin hive Of injeeto) Push out the clip spring by tol at fist and then pull out the connectors of fuel retum pipe fiom every injector See Figure 5—2—9, Pigue 5—2—9 Disssanble the Fuel Retum Pipe of Injector Disassamble the hod—down pile of injectof) Disassemble the bolts of hoki — down plate of in Jector and tke out hold — down plate of injector and washers of hold —down plate of injector See Figure 5 —2-10 Y Caution Washers of hold—down phite of in Jector are inside the concave hole of cylinder head bolt they aie very small and can not be loosen W ithout the Figure of Hold —10 Disassendle the Bolts Dawn Plate of Injector parts needle valve of injector wou be abnomal womed fe TE EE A A) Bl is SB ‘Great Wa Banding itera Combustion Engine Marfactving Company Liniteg 2SMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Pigue 5—2—11 Diszssamb be the Injector Piguie5—2—12 Assmble the Injector 2-13 Assanble the Hold — DownP hte of Injector Figue 5 Disassemble the injecto®) Slightly pull out four injectors fram injector holes and then make symbol at than. for corespond ing cylin derl, 2 3and4 VY Attention (D Forbidden pollute or damage the need k hole of injector when tke out injectors Repair or rp hee mlevant parts if injector has been womed heavily or damaged (2) Every injector has WA code and this code has input in ECU, Therefor every injector and ECU (canputed has one— to one comespond ing relation shi forbidden replacing fieely as wellas its installing position Othenvise engine cannot work nomally (3) Injector after repair should be signed QA code again when use the injecbrwith different code of high— pressure oil pump, input new injector code into ECU, The same when replace ECU, current injector IA code should be input 1) Check and Repair Check injectorby KTS650 diagnostic tester or spe cial instunent™ Injector nozzle can be replaced. \ ( i | +A ssembling: Assanbk the injecwé Install O — sea! ring of injector into and then according i» the symbol 1, 2 3 and 4 on the injector insert than int the comesponding cylinder L 2 3 and 4, 1 seal groove, Assanbke the hold—down p late of injecto&) Use the open end of hoki —down phe of injector clip injectog another end is pressed at cylinder head bolt Place the washers of hold — down plate of injector into the concave hok of cylinder head bolt align the bulge at the bottm of hok —down phe of injecior © washers concave hole of hold — down pile of injector and also do not um the washers now fix the hold — down phie of injector by fastening bolt of injector When assanbling washer concave of hold —down plate of injector should be upward, and the line frum “V” sambol at the washers of hoki —dawn p late of injector the center of concave hole is pemendicular to the axial line of crankshaft or let the nearest side of outside round of washer fo concave center facing engine s rear end To help locating position daub a littk of oll on the bot tom of hoi—down plate of injector in advance please ooo QRESETEM NEAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 5 FURL SYSTEM Figure 52-14 Assanble the Fuel Rewm Pipe of Injector Fim 5—2—15 Assemble the H igh Pressure Fuel Pipe Figue 5—2—16 Assanble the Hamess Joint of InjectorMagnetic Valve EQ Tighten torque for fixed bolts of ho —down plate of injector 25N- m+5N-m Assanb be the fuel retum pipe of injecto®) Renove upper dust cap of injector insert ur short joint of fuel rewm pipe in four upper holes of injectors respective. Use the elip spring to tight clip, other one long joint is installed into fuel retwm three — way of high—pressure fiel pump and tightly clipped by one snall size metal strip type hoop. Assanb}e the high— pressure fuel p ipe2) Install five ends of high — pressure fuel pipes at five end openings of high— pressure fuel mail at first and then install another end ofm iddle high — pressure fuel pipe on high— pressure fiel pump (see Figure S— 2-15), another ends of furhigh— pressure fiel p pes are installed on injectors respective h: \) BAL I ighten ‘tome Sr high Ipressam fel! punp md 4 = Moe 20 Ne m£2 Nem QJ Tighten tomue br injector end 27N+ mt2Nem ®) Tighten torque Sr high —pressure fue! mil end 27N+ mt2Nem Assanbk the hamess joint of injector magnetic valvéD) Insert engine hamess plugs into ur injectors re spectively: See Figure 5—2—16. VV Attention: Do not insert incorrect positionMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 5.24 High—Pressure Fuel Pump Assanbly @Water pump, pulley housing cover assembly Disassembling sequence @ Fuel retum hose D Engine hamess @High-pressure fuel pipe @Fan assembly ©Timing belt, crankshaft @Power steering pump and A/C and cam: compressor transmission belt pulley, trans @ Alternator transmission belt and tensioner © Inspection cover @Tligh-pressure fuel pump Assembling sequence Assembling sequence is reverse to disassembling sequence. FUR S=2=17 Disassan bing and A ssanbing Sequence for H gh —Presure Fuel Pump A sanbly fe Te ES It PA a A) ll is SB 268 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 5 FUEL SYSTEM Figur 5—2—18 Disassemble he Fan Assam bly Figure 5+ 2-19 Power Steering Pump. and 41 Comiresot/Tansm ssi Bolt | Disassenbling Preparation @® Disconnect the gounding cable of battery ® Drain coolant fam cooling system. \Y Waming Coolant is poisonous and must be stomwd inside original container Fotb dden people contact it Disassemble the engine hamesdi) Disassemble the fin assan bly2) Loosen locking boltg disassemble the fan assem: bly and water pump pulley. See Figure 5—2—18, Disassamble the pover steering pump and A /C can pressor tainsn ission belt) Loosen adjusting bolts of power steering pump and disassemble the transmission belt See Figure 5—2— 19. Locking bolts D Bassemble~the altema tor tranim ission be1@) Loosen fixed bolts lower side) of altemator and fastening bolts of adjusting pte and then disassamb le the transm ission belt See Figure 5—2—20. Figure 5—2—20 Disassemble the Transm ission Belt Figure 3—2—21 Disissemble the Inspection Cover Disassamble the inspection covet) Loosen fixed bolis of inspection cover and then disassemble the inspection cover See Figure 5—2— 21MAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE Figure 5—2—22 Disissemble the W ater Pump, Pulley Housing Cover Assanb ly Fiuw 5—2—23 Disassamble and Assomble the High— presi Fuel Pump Figure 5—2—24 Assemble the Fuel Retum Hose 1-H igh—pressume fie! pump, 2—Fuel e tum pipe joint 3—Hoop 4—Fuel tum hos 5—Fuel retum thee—way 6—Fuel inket joint REK Gina 270 Disassemble the water pup, pulley housing cover assanb¥@) Loosen fixed bolts of water pump pulley housing cover and then disassamble the water pump, pulley — housing cover See Figure 5—2—22, Disassemble the fuel retum hosé7) Loosen fixed hoop of fuel retum pipe opening of high— pressure fiel pump, and then pull out hose See Figuie 5—2—23 Disassamble the high—pressure fel piped) Loosen the muts between high—pressure fel pump and high—pressure fuel mail and then disassanble the high— pressure fuel pipe Disassemble the tm ing belt crankshaft and can shaft tin ing pulley, transition wheel and tensione®) Disassamble the high—pressure fel pump) () Loosen the hexagon nuts to tighten high — pressuze fuel pump tin ing pulley and take out high — pressure—fiel pump ‘tin ing-pulley assambly-and | then take out the woodriff inside the aan ‘of high> pres” Sue fretpunp — ~ ~ ~ (2 Loosen three bolts with locating wd to tighten high— pressure fue! pump and high— pressure fuel pump pads on pulley housing and take out high—pressure fi el pump and high— pressure fel pump pads (3) Take outh gh— pressure fire! pump pads frm high—pressue fuel pump. VY Attention Covers every fuel hole at high — pressure fiel pump by mbber cap (or sinilar goods) for avoiding impurity enters inta ** Assanbling Assanbk the high—pressure fuel pun pid (1) Daub a little of oil both on inner wund of high —piessuie fel pump pads and on seal ring of high — pressure fuel pump, and then force high— pressure fuel pump pads into high — pressure fuel pump Align the holes of hgh—pressure fuel pump to the holes of high —puessure fuel pump pads The fuel release givove at pad end surface of high—pressure fuel pump should be downward, Fad S28 A] il ics FS BR Bang eral Conbston age Naf Company LinedCHAPTERS FUEL SYSTEM Poise & S0kg ++0.10k; Posers 29h £0.0Ke | When use new timing belt Figure 5—2—25 Assemble the Tin ing Pulley and Tin ing Belt Figure 5—2—26 Assemble the Fuel Reum Pipe Hose (2) Install the high — pressure fuel pump and high—pressuse fuel pump pads on pulley housing and tighten the thme bolts Gwiti spring washed with loca ting wd Finally install the wooduif inside the keyway of high— pressure fue! pump, (3) Tighten and fix the high—pressure fuel pump pulley by one hexagon nut (with spring washed . A lign the keyway at camshaft pulley flange to the wood nif at high— pressure fuel pump when assembling (4) Install one end of oil retum hose on the outlet pipe opening of high—pessure Mel pump, Connect an other end with fuel retm thiee—way and then clip it by two smallmetal strip ype spring hoops (11 7). Preserving the dust cap on the outlet pipe opening of high— pressure fuel pump for ensuring the clean of fuel pipeline EX Tighten tomue M16 nut 70N+mi5Nem M8 bolt 20N*mt5Nem Assanb k-the-tin ing belt cmnkshaft and camshaty { tip ihg pulley, traisitn whee! and fensione'®) f Assdnb k the highpressiie fiiel pipé8y Install one end of high—pressure fuel pipe on the middle opening of high— pressure fuel wil and another end on the top end opening ofhigh—pressure fiel pipa @A Tighten tomue forhigh—pressue fuel pump end 20N* mi2Nem A Tighten torque for high — pressure fuel rail end 27N- m+2N-m Assanbke the fel eum hose) Ramove the dust cap of the upper end of high— pressure fel pump, and then install one end of fuel tum hose on the upper outkt pipe joint at war end of high— pressure fuel punp and connect another end with the thick end of fuel retm three-way and then clip itby snallmetal str type spring hoop tightly fe Es 1 YW a iG Fe Sl ‘reat Wal Bading Interval anbusto Engine Conperytinites §— 271MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue 5—2—27 Assanble the Water Pump, Pulley Housing Cover A ssemb ly Inspection Cover Tosking bos | Figure 5—2—29 Assanble the A ltemator Transm ission Belt Figure 5—2—30 Assanble the Power Steering Pump and A/C Compressor Tmnam ission Belt oo QRESETEN MEA ZA ret Wong ner Combustion Ege Mnetecting Cn Assemble the water pump, pulley housing cover assembly@) () Assemble two studs on crankshaft hole right side of pulley housing and the hole on water pump twp ‘by special tool (2) Clean water pump, pulley housing cover as sembly and pulley housing matehing surface Place wa ter pump seal ring into seal giove horizontally and deub sealant 587 on seal ring even x (3) Align water pump, pulley housing assanbly with studs and lightly knock then ( their position Then tighten and fix than using bolt unit (M8 X70, M8 X55), hexagon flange nutand hexagon socket head screw. A Tighten tomue for hexagon socket head screw 20N- m+5 N-m Assanbk the inspection covet) Tighten and fix the inspection cover assanbly on pulley housing using bolt unit see Figure 5 —2 —28, EX Tighten tonue for fixed bolts of inspection cover 6 Ne m+] Nein Assanb the altemator tansn ission bel@ Assanbk the power steering pump and A/C can pressor trans ission bel) () Assemble the paver steering pump and A/C campressor transmission belt and adjust belt tension de gree See Figure 5—2—30. (2 Press the middle part of the belt with 98 N forces to check its tension Transm ission belt deflection 8~10 mm (3) Tighten the fixed bolts for power steering pump and A/C canpressor b prescribed torque BQ) Tighten tomue br fixed bolts of power steer ing pump and A/C compressor 27N+ mth Nem LinedCHAPTERS FUEL SYSTEM Figure 5 31 Asse! Fan Assan bly 2A Sse: Engine Hamess ble the ble the Assanbk the fan assembh®) Ordinal install walter pump pulley and fan assem bly on water pump and tighten the locking nuts b pre scribed toque See Figure 5—2—31, ®&) Tighten tomue br locking nuts SN-m Assanble the engine hamess!) () At first fix the engine hamess at the wire fer tules of genemior adjusting brackek lover/upper case of hemostas and then tightly fix fourhamness Rennes of en gine at one hamess bracket of upper case of themostat one hamess bracket of air infet pint and wo hamess bmeckets of high—pressure fuel mil respectively (2 After fixed the hamess of engina corespond ing insert the plug of every sensor of the hamess int cam shaft position sensor water tempem te -sensox en “gine wate} tmperiture sensor high pressvre fuel fil pressure sensor vacuum rezulaips high —p wssuire fuel pump, and bur injectors (3) Hitch the preheating plug teminals usng bur connectors of engine hamess respectivels and then tight en and fixed than using fur hexagon flange nuts BA Tiehten tomue drhex flange nuts 4N+mittN-m (4) Insert and connect ECU into conesponding plug of engine hamess Ensure that he serial nunber at bar code label of ECU is accomlant with the serial number of engineMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 525 Fuel Tank isassembling sequence @ Fuel tank shield Fuel filler cover @ Aeration rubber pipe of fuel filler @ Rubber pipe of fuel filler (5) Drain serew (© Damping pad of fuel tank @ Fuel sensor ® Strainer Fuel outlet rubber pipe of fixel tank 40 Fuel retum rubber pipe of fueltank: 1) Puel outlet pipe of fuel tank ‘12 Fuel return pipe of feel tank _ 43 Fuel pipe holder. — ie 14 Fuel tank Assembling sequence Assembling sequence is reverse to disassembling sequence. Figure 5-283 Disassembling and Assembling Sequence rFuelTank (Only fpr reference) ** Disassanb ling Preparation Disconnect he grounding cable of batter. Disassanble the fuel tank shie HI) Disassemble the fuel filler cove®) Disassanble the aemtion mbber pipe of fle! fillef) Disassemble the mbber pipe of fuel fille@ Disassemble the dmin screw (D Loosen drain screw and drain the fuel (2) Tighten the dmin screw prescribed tomue afler fuel drainage Sd D isaseanb is te Fadl EA. Tighten torque Hrdmin screw Tank Shield Figure 5 29N+m fee te DA a is 274 Ae ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTERS FUEL SYSTEM Figue 5—2—35 Disussemble the Fuel Sensor Figure 5—2—36 Assemble the Fue! Tank Pucl outlet pipe “oy of fel tank et ae j . “ou! Pipe holder Elie retum pipe oF fel tank 37 Disassemble the Fuel Pipe Disassemble the damping pad of fuel tank@) Disassemble the fxel sensof7) Disassamble the fuel sensor fam fel liquid level ind ieator Disassemble the stm ine®) Disassamble the fuel outlet mbber pipe of fhe! tank) Disassemble the fuel retum rubber pipe of fuel tan KIO) Disassemble he fel outlet pipe of fuel tantsif Disassemble the fie! retum pipe of fuel anki Block the fuel pipe joint for preventing fue] leak age aflerdisassenbles the fuel pipe fim engine side Disassemble the tel pipe holde#it Disassemble the fuel taki ** A ssambling Assanb ke the fuel tankiig VV Attention: Damping pad of fuel tank must be installed on fram ing before assanble the fue! tank on fram ing See Figure 5 -2—36 | [ Saheb the’ filel pipe noes - Tighten the fixed bolts of fuel pipe holder to pre scribed torgue Q) Tighten tomue for fixed bolts of fuel pipe holder 19Nem Assanbk the fuel mtum pipe of fel tani Assanbke the fuel outlet pipe of tel tunis Connect fuel outlet/retum pipes of fuel tank on en gine and tightly tighten the joints by holders See Figure 5-237, Assamble the fuel retm mbber pipe of fie] tank) Assanble the fuel outlet suber pipe of fuel tank) Assanbke the strainet® Assanbk the fuel sensofa) Connect the fuel sensor with the fuel liquid level indicatorMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanble the damping pad of fuel lanl Assanbk the drain screwS) Assambk the mbber pipe of firel filles) Assabk the aemtion mbber pipe of fuel fille®) Assanbk the fuel filler cove) Assanbk the fuel tank shiek) Tighten the fixed bolts of fuel tank shield to pre seribed torque See Figure 5 —2—38, ag Fuel tank shield 24) Tighten tonque fr fixed bolts of shield 55 Nem Figue 5—2—38 Assemble the Fuel Tank ShieK Follow ing works can be done after assenbling () Fill tel into diel tank, (2) Connect ground ing cable of battery. 5.26 Fuel Liquid Level Indicator Disassembling sequence @ Fuel sensor © Fuel liquid level indicator Assembling sequence ‘Assembling sequence is reverse to disassembling sequence. Fine 5—2—39 Disassembling and Assembling Sequence for Fuel Liquid Level Indicator fe Te ES It PA a A) ll is SB 276 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTERS FUEL SYSTEM +] D isassenb ling Preparation Disconnect fhe giounding cable of batien: Disassemble the fie! sensofl) Disassemble the fuel sensor fm fel liquid level indicator See Figure 5—2—40, Disassemble the fuel filler cove) Disassemble the fixed bolts of fue! liquid level in dicator and fhel liquid level indicator See F gure 5 —2 —40 YY Attention Covers the fuel tank mouth by cot ‘on cloth or plastic fr avoiding impurity or dust enters into the tank after disassemble the fuel liquid level in dicator *¢ Assembling Figure 5—2—40 Disassemble and Assemble the Fuel Sensor and Fuel Liquid Assanble the fie! filler covet) Level Indiesor Assenbk the fuel liquid level indicator on fuel lank See Figure 5~2—40, { I 1 l —~ Assanb ke the fuel sensof) ~— ves Assanbk the fiel sensor on the fuel liquid level indicator See Figure 5—2—40. 5,27 Electron Accelerator Pedal The accelerator control of GW 2 8TC turbo— diesel engine is carried oul by election acceleior pedal har ness and ECU. ECU caleulates the fuel supply capacity of the engine in accorlance with pedal disp lacanent signal of pedal position sensor The disp lacanent sensor of potentimeter type ae celemator pedal works acconiing t voltage distribution circuit principle and ECU (canputed supplies 5 V voltiges to sensor circuit Election accelerator pedal is connected with sliding theostat bmsh inside sensor 41 Election Accelemior Pedal through steering shaft the voltage between brush and ground ing will change when the position of elecirmn ac celerator pedal position sensor changes and the voltage bearing ciruit inside ECU (computed will transfer the voltage into the position signal of election accelerator pedal FigueMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figure 5—2—42 Disassemble and Assam bling the Hamess Inside vain Figure 5—2—43 Disassemble and Asamble the Election Accelem|or Pedal Figure 5—2—44 vs QSEREREM Disassamb ling Sequence @ Uamess ® Exectmn accelemtor pedal (insite cab in Assamb ling Sequence Assanb ling sequence is reverse to disassanbling sequence, ** Disassenbling Disassemble the hamessi) Loosen the joint between hamess and electron ac celerator pedal position sensor D-isassem bie the election accelerator peda! inside, ; : ( V Disassemble_the installing bolts at-cabin_floor and ‘take out pedal assembly. ** Assambling Assmble the election accelemtor pedal (inside cab He Assanble the hames¢i) Connect the pint between sensor plug and elec tn accelerator pedal position sensor mise ER ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 6 COOLING SYSTEM CHAPTER 6 COOLING SYSTEM 6.1 Summary GW 2 8TC tutho—diesel engine adopts pressured cycle cooling systan. It consisis of water pump themostat fan rad iatoy water supply tank and other parts and camponent Cycle coolant also cools the oil inside the oil filter — Cylinder head — [Lx] aa Water supply tant" i—Ty = otrallaoe “ = Thermostat “L — i ier Raditor . ae \ ( FBT VST = 1 SKEET OF EERE COUE SPST fe TE EE A A) Bl is SB ‘Great al Baoding Iteral anbustoa Engine Marfecutng ComperyLinted — 27.9MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figure 6—1—2 Water pump Fieure 6 280 Shaking valve 14 Assanble the of Themostat Fig 6—1—5 Radivwr (OnWy Br welerence) 61.1 WaterPump W ater pump is centrifugal impeller ype (see Fig ure 6—1—2) and driven by V — tangm ission belt 6.1.2 Themostat Themostat is wax pellet type and its valve has sha king snail valve (shaking valve). See Figure 6—1—3. ‘Thempostat is’ installed-on its Yody” See Figure 6 61.3 Radiator Radhior is tube—belt type See Figure 6—1—5. To incwase the boiling point of coolant a valve with cover is in installed on the radialor This valve opens when presse is88~118 kPa fate te i A al ie ae Aol ret Waving ner Combustion Ege ManetCHAPTER 6 COOLING SYSTEM 61.4 Antifreeze (D Relationship beween mixture mtio and freez ng point Mixture ratio (46) The freezing point tanperatue of engine coolant 0.10 20 30 40 50 changes following coolant proportion in water Correct t mixture ratio can be detem ined acco ng » Figure 6 —1-8 I (D Caleuktion ofm ture ratio M ixtie ratio=Coolant (L) Cooknt (L) +W ater a B VY Attention: Coolant (L) +W ater (L) (total capacity of cooling system) . Pees L-s Anthea Mii Beto If total capacity of cooling systm = 10L follows Mike mili Co) Cookint d) DD Waer D o 1 5 05 a5 10 Lo a0 15 15 a5 20 20 a0 25 BS 1 ES { ol j mo CEL Cao ve 35 26 I AS 40 40 40 45 45 55 50 Bo 80 Mixture rato @) Mixture sitio tegref Measure the coolant specific weight inside engine sone coolant system frm 0(C ~50'C by absorbed densine tes and then check the curves of Figure 6—1—7 and are. detem ine coolantm ixture ratia Cooknt is high—grade ethane glycol (—35C ) coolant Specific weight 1 0 1 20 30 40 50 60 70 Coolant temperature (2) Figure 6 7 CookintM Wise RatioMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 6.2 Repair in the Vehicle Water Punp Disassembling sequence @Fan cowl ® Cooling fan assembly Power steering pump and A/C compressor transmission belt @ Ahernator transmission belt ©Crankshaft damping pulley © Water pump, pulley housing cover assembly ‘and inspection cover Assembling sequence Assembling sequence is reverse to disassembling sequence, Fegre 011 Disassembling and Assan bling Sequence rw wer Punp ooo RESRARM MEA ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 6 COOLING SYSTEM Figure 6—2—2 Disassmbe the Overfiaw Tank Hose Only for reference) Figum-6 22, Disassanble-the Pan Cows (Qnty Hr reference) Figure 6—2—4 Disassenble she Fan A ssanbly Figure 6 Steerin D isassemb le the Power g Pup Transmission Belt ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2) Drain coolant fran cooling systan, VY W am ing Coolant is poismous and must be stored inside original container Foibidden people contact it Disassemble the fin cow@ Disassemble the overflow tank hose and fan cow | See F gue 6—2—2 and Figure 6—2—3, { | ; { D Bagsanble~the cooling fin assem bly) — Loosen lbelcing bolts of fan and then disassanb le the fin assambly. See Figure 6-2-4, Disassanble the paver steering punp and A /C can pressor trinsn ission bel) Loosen adjusting bolts of power steering punp and then disassemble the transmission belt See Figure 6— 2-5MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Figue6—2—6 Disassemble the AJC Compressor Disassemble the altemator transmission bel@) Dapkling balls Loosen both fixed bolts (oven of altemator and locking bolts of adjusting plata and then disassanb le the tana ission belt See Figure 6—2—7. Flam 6-277, Disuss ‘Trinsn fission, Belt i ‘lp isussomble the enunlshat dnp ing pulley) ~~ Loosen cninkshaft damp ing puliey bolts-and then disassemble the damping pulley assanb See Figure 6 2-8 D Bassemble the water pump, pulley housing cover assembly and inspection covef®) Disassemble the water pump assembly and seal ring 8 Disassemble the Crankshaft Damper Pu liey I Check Repair and replace relevant parts if the water pump has heavy wom Replace whole water pump assanb Wy if follow ing any touble appeared, @) Water pump body has crack (2) Coolant leaks fium water seal (3) Anti—fretion bearing has abnomal jumpi Figue 6 9 Disassemble the W alter ness or abnomal noise Pump Pulley Housing Cover () Water pump inpelkrhas crack or comupt fe Te ES It PA a A) ll is SB 284 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 6 COOLING SYSTEM Figue6—2—10 Assanble the W ater Pump, Pulley Housing Cover Assmb ly Figure 6—2—11 Assanble the Crinkshaft Damper Pulley Air conditioner compressor and power steering pump transmission belt Z Alternator and fan pulley ‘oansmission belt ** Assembling Assamble the waler pump pulley housing cover as smb ly and inspection covet) () Assemble the O —seal ring into © — seal sing gtooye of water punp body. (2 Assemble he water pump assanbly and then tighten fixed bolts © prescribed tone shown as Figure 6—2-12 ©) Tighten tomue br fixed bolts of water pump 20 N+ m£5 Nem Assemble the crankshaft damp ing pulley) Assanbe the crankshaft damp ing pulley and then tighten fixed bolts of pulley t prescribed ‘prque, AX Tighten tormue for fixed bolts of crinkshaft damping pulley 210 Ne m£15 Nem { T j : [ y YW Attention Fix the’ fywhee! The gear for avoi ding crankshaft tuming when tighten fixed bolts of damping pulley. Assanb the altemator transn ission bel@ Assanbb the power seering pump and A/C can pressor tunsn ission be (D Check the wom or damaged of the tansnis sion belt Replace it if necessary Check the tension of the transn ission belt Adjust it if necessary. (2 Press the middle part of the belt with 98 N forces to check its tension, Transmission belt deflection Figue 6—2—12 Assemble the Seah Transmission Belt fe TES 1 A A) i is SBR Great Wal Banding internal Combustion Engine Marfactving Company Linitee 22SMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanbke the cooling fan assemb hi Odinal install water pump pulley and fan assem bly on water pump and tighten the locking nuts b pre scribed bique See Figure 6—2—13, ®&) Tighten tomue br locking nuts SN-m Figure 6—2—13 Assemble the Fan Assan bly Assanbke the fan cowl) Assanbke the fan cow! and overflow tank hose See Figure 6—2—14 =14 Assamble the Fan Cow! (Only for reference) Figure 6 Canty out flowing tasks after assembling please (D Connect the grounding cable of batter. See Figuie 6—2—-15, (2) Fill coolant into cooling system. (3) Startengine and check if cooling system leaks coolant or not Figure 6—2—15 Connect the G rund ing Cable of Battery Only fr ReferencedCHAPTER 6 COOLING SYSTEM 6.3 Bal Parts Repair Water Pump Water pump Water pump: packing ring. Pulley housing cover assembly ‘Water pump belt Assembling sequence Assembling sequence is reverse to disassembling sequence. Disassembling sequence 1 Set-screw 2) Pan center flange & Water pump impeller D Water seal assembly Oil ring © Bearing assembly D Water pump, pulley housing cover assembly TT Disasgan one Te Tey and pressure bar Figure 6—3—2 Center Flange Diwssenble the Fan LURESUUNUCHRECCOSHRUEORECENCW Fie 6—3—3 Heating W ater Punp Bedy ST AGSSMp he SSGTATS HW aT PD | ' : | +*| Disassenb ling Disassemble the set—serew1) Disassemble the fin center flange) Squeeze the fan center flange using bench piess See Figure 6—3—2, the water pump mpe lle) the water seal assanb h Disassemble the oil ringS) Disassemble the bearing assembly () Heating water pump body inside hot water Disassemble D isassemb le (OC ~90C ). See Figure 6-3-3,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (2) Squeeze the waler pump inpelles waler seal assembly and bearing assembly using bench piss and Pressure bar See Figue 6—3—4 VY Caution Do not use hammer fr disassembling water pump impeller othenise will damage it Disassemble the waler pump, pulley housing cover assembly?) Figue 6—3—4 Disassmb ke the Water Pump Inpelles W alerSeal and Bearing Check and Repair Adjust mpairand replace relevant pasts if the wa ter pump has heavy wom or damaged, See F igure 6 —3 W ater pump bearing assenb iy Check the noise damaged and other ineorwet cond i tions See Figure 6-3-8, Figure 673-5 , Cheek Water Punp Bearing. ssamb)y mm } \ ( ' ) \ *** Reassamb ling_' ok 3 oe Reassanble the water pump, pulley housng cover assembly) Reassamble the bearing assembly) (1D Squeeze he bearing assambly inlo water pump ee body, See Figure 6—3—8 q (2) Align te bearing setserew to the sotscrew Hs hole of water pump body. r (3) Fix the bearing assembly using setscrew. Fue 6-3-6 Assmbk the Waver Pump Bearing Reassanble the oil ring) Reassamble the water seal assambly) (1) Daub thin liquid sealant on outside ring of ae re \ water seal assamb be E SS \. (2) Assemble the water seal assanbk. See Fig ve S ur 6—3—7. Figure 0-3-7 Assamble the W ater Seal A ssamb ly 2s GRERRAEN MEA Za ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 6 COOLING SYSTEM Figure 6-3-8 Measure the D isunce Frm Water Pump Impeller Buke t Water Pump Body End Face wo —_ Fiain'6 3-9 Mggsuiy|the D isunce Be ween Pay Matching Suite and Rear Cover Matching Surtice \o_ 4 Figure 6—3—10 Assembke the Fan Cemier Flange Set-serew —@ o Figure 6—3—11 Assemble the Setscrew Reassamble the water pump inpelk® () Assamble the water pump impeller by bench press, (2) Measure he distance fiom water punp impel ler bulge to water pump body end face See Figure 6— 3—8 Ensure the size of water pump impeller bulge please Size 4) ofwater pump impeller bulge 26 mm Reassamble the fan center fangd2) Measure the distance between fan matching sur face and rear covermatch ing surface See Figure 6-3 —9. Fan center distance Standard Vv ‘A tlen tion: (D Assemble the fin center flmge and water pump inpeller on water pump shaft by press and forbidden disassemble and assanble he fan center flange and wa ter pump impeller again Othemvisa replace whole wa fer punp assembly please The 2" disassonbling and assamb ling of fan center flange and water pump inpel lerwill damage the water pump when engine operation as well as heavy ovetheating (2) If the force to press the fan center flange and walter pump impeller is less han 1960 N, replace whole waler pump assembly please (3) Do not knock the bearing into water punp body by hammer or sin ikir bo} often ise w ill damage the bearing Disassemble the set—screwl) QREABNNERBTA 2. GreatMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 6.3.2 Themostat Disassanb ling Sequence @ Connecting socket @ Upper housing of themostat ® Spacer of themostat Connecting @ Themostat Upper hiusie ~” socket oF thermostat yy Smacer of Assamb ling Sequence B@Thennostat NS, Aneumostat Assambling sequence is reverse to disassembling sequence +] Disassenb ling Preparation (D Disconnect the gmunding cable of battery (2) Dmin coolant frm mdiator and engine Figue 6—3—12 Disassmbling and \V Waming Cookint is poismous and must be stied Assan bling Sequence for Themostat inside original container Fotbidden peop e i contact it Disassemble the connecting socke (2) Disassemble the upper housing of themosta®) Loosen fixed bolts and then d isassamb le the upper housing of themostat and mdiator hose b.. y— \D isassemble-the spacer of themostaf) @ \_/ / Disassemble themdstaél) JP) Check and Repair (D Immerge themostat assamby into the neutral waterwithout convsive See Figure 6—3—14 (® Phe a wood bbck at the bottm of container Do not direct heating themostat See Figure 6—3—14 Figue 63-18 Suucture of Themosiat (@ Heating water gmdually and incessant chum the water to Etwater tenpemtre is acconlant —— Confim the main valve of themostat unlocks Thermometer at prescribed temperature Unlocking tanpenture of thermostat valve 82°C +2 — Confim the 2" vale of themostat unlocks campletely at prescribed temperature, Fully unlocking tanperatue of themosiat valve 95°C — Fully unbeking stroke of hemos t valve> 8mm, Repair or place relevant parts if you find that Fiawo=B—IW! JOneaL THeMoNEE themostat has heavy wom or damaged. 280 (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 6 COOLING SYSTEM 815 Assemble Themostat ** Assembling Assanbk themosta@) Assanbke the spacer of themos@) Assanbke the upper housing of hemosta@) Assmble the upper housing of themostat and lighten fixed bolts to prescribed iomjue See Figure 6— 3-15. 2X Tighten torque for fixed bolts of upper hous ing of themostat 19N+m Fire 6—3—16 Disassemble the Water Supp ly Tank Hl ose of Rada tor Figue 6—3—17 Disassombling and Assembling Sequence fr Radia tor Figure 6 =18 Disassmble the Radiator Assanbk the connecting socke() Cary out Blowing tasks after assembling please () Connect the grounding cab ke of battery (® Fill egulr coolant to prescribed capacity or each prescribed symbol (3) Sturtengine and check if cooling systam leaks coolant or not 633 Radiator Disassembling Sequence Q) Water supply tank.hose of mdjator Rhdiawr hose, |, \ —~ @ Gobler>— as @ Radiator assembly Assamb ling Sequence Assembling sequence is reverse to disassembling sequence ** Disassenb ling Prepamtion (D Disconnect the gmund ing cable of batten: (2) Loosen dmin screw and drain coolant fiom cooling system of enghe, Disassanble the water supply tank hose of radiate) Disassemble the water supp ly tank hose of rad iator frm mdiator See Figur 6—3—16, Disassemble the radiator hosé2) Disassemble the hoses at both top and bottm of ndiator fom the engine See Figure 6—3—17, Disassemble the coolets) Disassamble the cooler fim mdiator and place at one side See Figure 6—3—18 fe TE EE A A) Bl is SB ‘Great Wal Baoding lterral Combustion Engine Marefectunng Company Limited = 291MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Disassemble the Radiator Figure 6—3—19 Asvembly (Only for Reference? Figure §—3—20_ Measure the Unlocking. Piesaim of Presa Valve of Rad iator Cover, ck the Core of y for Reference) Figue6—3—22 Check the Leakage of Coolant ooo GDREREABM NEAR ZA ret Wong ner Combustion Ege Mnetecting Cn Disassemble the mdiator assamb lia) Upward hold out the mdiator assembly w ith hose, VY Caution Forbidden he mditor core is semped by fin blade 8) Check and Repair Check the Cover of Radiator () Measure the unbcking pressure of pressure valve by radiator cover tester See Figure 6 —3 —20. Unlocking pressure of pressure valve of rid iator cover 88—118 kPa Rephce the mdiator cover if unlocking pressure of pressure valve exceeds standard value (2) Measure the unlocking pressure of vacuum valve at the center of mdiator cover valve seat Unlocking pressure of vacuum valve 12 8~17. 0 kPa ( | ' | : —~ Clean-or ‘rephee the_rad iator‘eaver if the vacuum valve cannotmove snoothly due t mst or dust Check the Core of Radiator () The defomation of radiator will decrease the radiation function overheating the cooling systen. Cor wel radiator but do not damage its basa (2) Remove the dust or other mpurily on radiator cor, W ash Radiator Wash the mdiator inside and coolant passage by water or neutm! washing Fully nmove all watemark and scale Cheek the Leakage of Coolant Press the pressure air (pressure 196, 9 KPa) no radiator inside fiom radiator liquid filler by radiator cover testerand check the kakage of coolant of cooling system, See Figure 6 —3 —22. LinedCHAPTER 6 COOLING SYSTEM Figure 6—3—23 Assemble the Rad ilo ssembly Figure 6—3—24 Assanble the Radiator Hose” ply lor Reference) Figure 6—3~—25 Assemble the W ater Supp | Tank Hose of Radiator (Only for Reference) Figure 6—3—26 Connect the G rund ing Cable of Battery *# Assembling Assanbke the radiator assembly4) () Place damping mbber padsat tyo sides of m diator bottan. (2) Assambke the mdialor assembly with hose See Figure 6—3—23 V Cautio: Foibidden he mdiator cow is semped by fan bade Assanbke the coole®) Assambk the cooler on rad lator Assanbke the mdiator hosé2) Connect both niet and outlet hoses of radiator on the engine Assahtb the|water supply tank hose of rad Roel) ~~ PilLregular_codlaint to-rad ia tor fille? jugular’ pas and MAX symbol of radiator water supp ly tank Cany out blowing tasks afler assembling please () Connect the ground ing cab k of battery (2 Stat the engine and heating it (3) Check the coolant level position of he en gine, (@ Check if cooling sysiem leaks coolant or notMAIVTENANCE MANU Air conditioner compressor and power steering pump transmission belt Alternator and Jan pulley trasmission bolt Figue 6—4—1 Adjustment of Transmission Belt Figupe 6-472 j Check she Tension Deane of the Tmingn sin Bett Locking bolts Figure 6—4—3 Adjust Allemator Transm ission Belt Figure 6—4—4 Adjust Paver Steering Punp and A/C Canpressor Tansn ission Belt 294 AL OF GW2.8TC TURBO “DIESEL ENGINE 64 Adjusment of Transm ission Belt 6.4. 1 Check and Repair (D Check the wom or damaged status of the tans mission belt rephce it ifnecessary See Figure 6—4—1, (2) Check the tension degree of the transmission belt adjust it if necessary. (3) Press belt wih force of 98 N at its medium part by hand and check each belts deflection See Fig ure 6 —4—2, Stundard deflection of trnsn ission belt ‘Tension degree when adjust Altemator and fan pulley uansn ission belt Air conditioner compres sor tansn ission bell Power steering pump transn ission be It 8~12mm 6.4.2 BeltTension Adjusment Acitemator and Pan Pulley T rursrission Belt (1) Loosen the Jock ing bolts of a jie mator rest and then adjust belt s tension degre using adjusting bolt of adjusting phite See Figure 6—4—2 (2) Tighten fixed bolts to prescribed mmue EA Tighten torque draltemator fixed bolts Ne mi3 Nem Al Tighten torque Dr adjusting plate fixed bolts 20N+ mt5 Nem Power Steering Pump and A /C Canpressor Trans mission Belt Adjust belts tension degree using adjusting bolt of power steering pump, ‘Tighten the locking nuts of adjusting bolls after ad disment EA) Tighten torque fr lock ing nuts 28N+ m fe Te ES It PA a A) ll is SB ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 7 LUBRICATION SYSTEM CHAPTER 7 LUBRICATION SYSTEM 71 Summary GW 2 8TC turbo—diesel engine adop is compound lubrication system consisted of bot pressure syst librication and splash systan lubrication Lubrication systan of diesel engine includes oil sump, oil stmines oil pump, oil files oil cooley main oil line of cylinder block oil pressure sen sor and oilmananeter ete Places using pressure system lubrication by diesel engine include turbocharger main bearing connecting md bearing camshaft bearing weker shaf} wcker and valve adjusting screw ete Battery | [Warning ith Oil filter and cooler assembly | Filteftement ifr — Piston] [fling gear] [Camshan] [acum +H on ne] ise van cooling | | beating = pam ! 5 shat Oil over, Baten vag ’ » [Connecting] + [rod beseing | FFT) fitch] - 7 L _ P= | Rooke it ene j Rausing | I ois Oil filter ge ¥ BE Oil samp Fue 711 Lubreation Sysier- of GW2 STC Tuibo—D eset Engine Turbocharger adopts pressure systam lubrication, Turbocharger rs i i Its fimction is » ensure ‘that the wir and bearhg can obtain enough lubricating and cooling under nomal op eration The lubrication cycling line of tuibocharer ‘brication comes fim main oil line of diesel engine cylin der block through inkt pipe entering into tibocharer %, ’ ” \, -oitintetnize then flows back to ofl sump via oil retum pipe tubo— diesel engine increases piston — cooling system, oil in Lubrication Lubiation Jects piston tp for cooling piston thrughmain Ine jet {Uf ottetmepe ike. Places using splash systan lubrication by diesel en gine inclde piston piston ring piston pin canshaft and oil pump gearete RERMAMMASSRAA (Great el and interralConbstin Engine Compa Lites 2 Lubrication of Tusbocharer Figure 7MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Water inlet hose ut Oil cooler SN Waterutlet hose il filler Figure 7—2—1 Disassembling and Assanbling Sequence 0 ilFilter Disassemble the O il Filter Figue7—2—3 Check Saby VaWe 2s GRESEAEN NEAR ZE ret Wong ner Combustion Ege Mnetecting Cn 72 Repair in the Vehicle 721 Oil Filter Disassamb ling Sequence ) Water inlet/outlet hoses of oil filler ) Oil filter @® Pixed bolt of oil cooler }) Oil cooker Assembling Sequence Assanb ling sequence is reverse to disassembling sequence &) Disassembling Preparation (D Disconnect the grounding cable of battery (2) Dmin coolant canpletely fiam cooling sys tem, (3) Place a container under oil filter for avoiding overflow lubrication \V Waming Avoid scalded by hot oil appmpri Yate treat od oilland pro eet enviroment” h ~ — Disassmble the water inlet/autlet hoses of oi fille) Disassemble the water inlet hose and walter outlet hose of oil filter Disassemble the oil filte2) Disassamble the oil filter using filter spanner See Figure 7-2-2. Filter spanner 5—8840 —0200 —0. Disassemble the fixed bolt of oi] coole®) Disassemble the oil coole®) Check () Check safely valve Install an oil manancter at ofl line near oil filler Start the engine to check the unlock ing pres sure of safety valve Unlocking pressure of safety valve 422~461 kPa LinedCHAPTER 7 LUBRICATION SYSTEM ‘Input compressive aie (19.60 KPa) check 0 il Cooler Rubber seal ring FimarZ Figue7—2—6 Assanble the Oil Filler Ekment Figue 7-2-7 Assmble the Water Hoses of 0 il Cooker (2) Check oil cooler Cheek the water conduit leakage of oil cooler —— Plug one end of the water conduit of oil cooler —— hmeee the oil cooler into water See Fig ure 7—2—4, Input compressive air with 19. 60kPa pressure fem another end of the water conduit of oil cooler If there is air bubble mise t water level water conduit has leakage ies) Assanbling Assanbk the oil coolef) Install O—seal ring on oil filter and assemble the oil cooler Assanbk the fixed bolt of oil coolefs) Tighten the fixed bolts of oil cooker to prescribed tomue ®J Tighten tomque fr fixed bolts of oil cooler 20.N m+5 Nem Arssanb k-theoil filte®), { | } : ( a — Y Caution Sp ual ail filter elament is one tine using part ibidden repeating use (1) Daub thin oil on O — seal ring of oil filter See Figure 7-2-@ @ Screw the oil filter ekment into oil filter seat by hand until its seal surface contacting with O — seal ring (3) Tighten the oil filter elanent tightly using fil ter spanner and tum it3/4 cycles clockwise please Assamble the waler inlet/outlet hoses of oil filte€l) Connect the water inlethose and water outlet hose of oil filter See Figure 7-2-7. Canty out ®llow ing tasks after assembling please (D Connect the grounding cab ke of battery (2) Fill coolant into cooling system. (3) Start the engine and check if oil leaks or not fiom the oil filterMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 7.22 OilPunp Disassembling sequence Oil return hose of vacuum pump. 2011 rum pine of turbocharger Engine brackets ‘@Reinforecments and rubber pads Assembling sequenee 6 2 5) Oil sump assembly Assembling sequence is reverse to disassembling sequence. Boil pun aasenbty Fue 7=2=8 Disisen bling and Assmb ling Sequence Brow Panp 2s QRESETEN AEA Za ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 7 LUBRICATION SYSTEM Oil hose D Ficue7—2—9 Dimssnble the Oil Hose of Vacuum Pum p Figum7 210, Disussanble the il Retum Pine of Tubocharser 1 Disassemble the kets Pigue 7—2 Engine Br Figue 7—2—12 Disassemble the Ahm num Alloy O11 Sump ) Disassembling Prepaw tion (2) Disconnect the grounding cable of battery (2) Lift the vebicle (3) Drain oil completely from lubrication sys tan. YY Waming Avoid scalded by hot oil appropri ate treat old oil and pmiect environment VY Attention Use new washer please if install oil dmin serew, EX Tighten torque Or oil drain screw 83N- mis Nem Disassemble the oil retum hose of vacuum puns) () Disassamble the oll hosed) tiem oil sump. See Figure 7-2-9 (2) Disassemble the oil hose@ fxm cylinder block, Disassemble-the oil retim pipe of wiboehawete) Loosdn vo hexagon head boltitnits. from oil, metim pipe wekinent flange of-turbochaerand disassemble the oil retum pipe See Figure 7—2—10. Disassemble the engine bmckets3) Loosen engine brckets bolts and disassanble the left/right bmcket of the engine See F gure 7—2—11. Disassemble the reinforeaments and rubber pad@) () Disassemble the exiaustmanifold brackets (D Disassemble the rein eanents (3) Take out mbber pads Disassemble the oil sump assenb hi) (D Lift the engine Or around 50 mm. (2) Disassemble the oil sump fiun cylinder b lock, See Figure 7—2—12, Disassemble the oil pump assanb bi) Disassemble the oil pump frm cylinder blockMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figure 7-213 Assemble the Oil Punp #4) Assembling Assanbke the oil pump assembly@) (D Daub oil on O —seal ring of oil pipe and in stall this O —seal ring into its gwove of cylinder block. (2) Install the oil pump assamb ¥ with oil pipe on cylinder block and tighten fixed bolts to preserbed tomue See Figure 7—2—13. ®) Tighten tomue fr fixed bolts of oil sump 20 N+ mt5 Nem Figure 7—2—14 Daub Sealnton the Valu lied’ Aas) Figue7—2—15 Assanble the Alum inun Alby Oil Sump and Gasket ptiona) Pigue7—2-16 Assanble the Aluminum Alby Oil Sump and Front/Rear Gaskets 300 (3) Tighten sleeve nuts io prescribed tomue EA Tighten torque fr sleeve nuts 20N- m+5 N- m Y Attention Do not tighten the sleeve mut at con necior to tight Assanbke the oil sump_assamb hi) vy \ CD-Daub reganmiended liquid-sedlant-or eqhiva “Gent on “the vaulted areas boh-of 9" ‘Bearing’ housing ‘and of timing pulley housing as well 3 he giove See Figure 7—2-14. (2) Insert the rear lip of seal gasket into 5" groove, (@) Ensure the lip of seal gasket lightly contact the groove, (@) Assamble the oil sump on cylinder block, (9) Tighten fixed bolts of oil sump to prescribed torque See Figure 7—2—15 and Figure 7—2—16, 2) Tighten torque Sr fixed bolts of oil samp 20N* m5 Nem fe Te ES It PA a A) ll is SB ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 7 LUBRICATION SYSTEM Assanbke the reinforcements and rubber pad) () Assemble the mbber pads (2) Assemble the reinforcements and tighten fixed bolls to prescribed torque See Figure 7—2—17. 2X Tighten torque for cylinder block side bolts of engine 37N- m+5 N= m @X) Tighten tomue Sr clutch housing side bolis Figue7—2—17 Asxmble the 78N- mis Nem Reinforements and RubberPads (3) Assemble the exhaustmanifold bracket Assanbk the engine brackets) Install the left and right bmickets of engine and lighten fixed bolts of bracket lo prescribed wrque See Figure 7-218 @Q) Tighten tomue for Oxed bolts of engine bracket 40 Ne mi5 Nem Figure 72-48, Assemble the . . tind Bidcktds vo) \Assanbe the oil iemm'p pe of turbocharge) » t (1) Jnstall he flange washer of oit eum pine can necior of-titbochargér on turbochargey—and then“use ‘wo volt units to fix oil retun pipe wekiment of tutbochaier on the turbocharger (2 Connect one end of oil retum pipe of turbo chargerw ith the oil retum pipe weldment of trbocharg eg connect another end with oil ret pipe weldment of tubocharer and Lightly clip then by two snallmetal strip spring hoops See Figure 7—2—19. =X Tighten tomue for fixed bolls of oil eum Fiawe7—2-19 Assenble heOUReum PPE Assanbk the oil retum hose of vacuum pump) Connect oil hose on oil sump and cylinder block. See Figure 7—2—20. Carry out Dlowing tasks after assembling please () Connect the gmunding cab k of battery, (2 Fill coolant into cooling system. ie () Fill oil into lubrication system, Fieue 7-220 Assamble the 0 illose (4) Start the engine and check the leakage of b of Vacum Pump brication system and cooling system. GR TES ik 7 aD is FSB Great Wa Banding itera Combustion Engine Manfactuing Conperytiniteg 3.01MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 7.23 OilSunp Assenbly ® Left reinforcement Disassembling sequence @ Oil hose of vacuum pump Engine brackets ‘Reinforcements and rubber pads Oil sump Assembling sequence Assembling sequence is reverse to disassembling sequence. Pane 7=2=21 Disisanb Ing and Assen bing Sequence Bro TSump AsaMbIy fe Te ES It PA a A) ll is SB 302 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 7 LUBRICATION SYSTEM \ oy k Oithose D] soy a" Oe ° 7 Oil hose @ ) Disassembling Preparation (2) Disconnect the grounding cable of battery (2) Lift the vebicle (3) Drain oil completely from lubrication sys tan. YY Waming Avoid scalded by hot oil appropri ate teat used oil and protect enviroment VY Attention Use new washer please if install oil Figure 7-222 of Vacuum Pump Fieue 7-228 \D inissahble the fe Brackets | Figure 7—2—24 Disassemble the Reinforeaments and Rubber Pads D isassemb le the 0 il Hose drain screw, EX Tighten torque Or oil drain screw 83N- mis Nem Disassemble the oil hose of vacuum pump) () Disassemble the oll hose) fem ofl sump. See Figure 7—2—22 (2) Disassemble the oil hose2) from cylinder b lock, Disassemble the engine bruckets) Loosen engine 'bnickets bolts and, disigsanble the ‘left/right meket of the ehging Sed F igure 7 23) Disassemble the reinforcements and rubber pad) () Disassemble the exhaustmanifold brackets (2) Disassanble he renfreanents See Figure 7 —2-24, (3) Take out wbber pads Figure 7-225 Disassemble the oil sump assenb hil) (D Lift the engine Or around 50 mm. (2) Disassemble the oil sump fiun cylinder b lock, See Figure 7—2—25, Disussanble the O il SumpMAIVTENANCE MANUAL OF 26 Daub Sealanton the Vaulied Areas Fieure 7-2 27 —Assemble-the 0 iL Sump. and Gasket (Opting) eure 7, 28 Assanble the Aluminum Alby 0 il Sump and Front/Rear Gaskets GW2.87TG TURBO “DIESEL ENGINE ** Assembling Assanbk the oil sump assembly (D Daub recanmended liquid sealant or equiva kent on the vaulted areas boh of 5" bearing housing and of tin ing pulley housing aswell as fhe gove See Figue 7—2—26. (2) Insert the rear lip of seal gasket into 5" groove, (3) Ensue the lip of seal gasket tightly contac L the groove, (4) Assanble the oil sump on cylinder block See Figure 7—2—27. | , (S)_Tighten_fixed bolts of oilsump to prescribed torque See F gure 7—2—28. @&) Tighten torque fr fixed bolts of oil sump 20N* mt5 Nem Assanbk the reinforcements and bber pads) () Assemble the mbber pads (2 Assemble the winforeaments and tighten fixed bolts to prescribed tomue See Figure 7-2 —29. EX Tighten tre for cylinder block side bolts & fon, of engine Ne m+5N*m EX Tighten torque dreluteh housing side bolts Figure 7—2 9 Assemble the 78Ne mt5 N+ m Reinforcements and Rubber Pads 304 fe Te ES It PA a A) ll is SB ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 7 LUBRICATION SYSTEM Pigue 7=2—30 Assemble the Lett and Right Brackets of Engine oithose D Bure 72/91 | Assan bie 0 illfose of Vdewum Pump Figure 7—2—32 Connect the G round ing Cable of Battery Assanbk the engine backe®) Install the left and right brackets of enging and tighton fixed bolts of bricket to prescribed tomue See Figure 7—2—30. A) Tighten toque for fixed bolts of leftand right brackets of engine 40 Ne mi5 Nem Assanbke the oil hose of vacuum punpil) Connect oil hose on oil sump and cylinder block, See F gure 7—2—31. Cany out ®liow ing tasks after assembling please (D Connect the gwunding cable of battery. See Figure 7—2— (2 Fill coolant in cooling systm, (3) Fill oil into lubrication system, (4 Start the engine and check the leakage of b drication system, QREABNNERBRA GreatMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 7.3 Repair Single Part ot 731 Oil Filter Oil cooler Oil inlet Oil filter Oil onllet seat unit Seal ring Fier __| element Figue7—3—1 Check Oil Filter ® Check Oil Cooler a Check the water conduit leakage of ofl coolee (>) = \Phug one end of the-wa ter conduit of oil cooler Inmeé the oil cooler into water’ See Figure 7—3 —2 Input Canpressive air witr 12 GOKPa pres sue fem another end of the water conduit of oil cooler If there is airbubbk mise to water evel water conduit has leakage fey? Figure 7-3-2 Check Oil Cooler 7.3.2 OilPump ** Disassenb le Disassemble the oil pump assanbly Disassemble the oil pipe Disassemble the stm iner Disassemble the pump cover Disassemble the driven fear and bushing Disassanble the driving gear Disassemble the driven shaftCHAPTER 7 LUBRICATION SYSTEM Figure 7-3-4 Disassemble the Pinisn Pin Figue 7—3—5 Measure the Clearance Between Upper Teeth of Gear end Inner Wall of Housing Fiue 7—3—6 Measure the Clearance Bebveen Gear and Pump Cover Disassemble the pinion () File pinion stop pin rivet (2 Strike out pinion stop pin using hanmer and stick See Figure 7-3-4. (3) Disassemble the pinion Disassemble the oil pump body PB) Check and Repair It is necessary to adjust repair and replace the parts if you find heavy wom or damaged during chee king Housing and Gear Rephce oil punp assmbly if you find Olbwing one case (1) Bushing of driven gear shaft has heavy wom or damaged (2 Upper teeth of gear has heavy wom or dan aged. Clearance Between UpperTeeth of G ear and Inner Wall of Housing | CY Messi the clepiance betveen upper teeth, af gear and~inner wall of houSing-using- inspection’ gage. See Figure 7-3-8 ~ ~ (2) Replace gear or housing if measured clear ance beween upper teeth of gear and inner wall of hous ing exceeds the preserbed limit Clearance beween upper teeth of gear and inner wall of housing Standard Linit Clearance Between Gearand Pump Cover (D Measure the clearance between pump cover and gear using inspection gage See F igure 7—3—6 (2) Replace housing if measured clearince be ween pump cover and gear exceeds the prescribed lm it Clearance between pump cover and gear Standand Linit 0. 06 mm’ 0. 15 mm QREABNNERBZA .., Great al ard tral ands xine Mnf Conga intelMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Cleamnce Between Driving Shaft and Oil Pump Body (D Measure extemal diameter of driving shaft u sing screw micrmeter See Figure 7—3—7. (2) Measure the bore of pump body using mi enmeter (% Rep kee oil pump assembly ifmeasured clear ance between driving shaft and oil punp body exceeds the prescribed lim it Cleamnce between driving shaft and oil pump body Fie 7-3-7 Measure Hxtemal D imeter of D riving Shaft Standard Linit 8 0. 04 mm’ 0. 20 mm Clearance Between D riven Shaft and Bushing (D Measure extemal diameter of driven shaft u sing screw micrmeter (2) Measure the bor of bushing using bor mi ing ermmeter oe (3) Replace bushing if measured clearince be & ® tween driven shaft and bushing exceeds the prescribed limit TMNT Ed Mean ban Sie Clearance between.driven shaft and bushing ding! Bush ing’ | ( Siaiddrd, ; { Linit room Ti ** Reassanbling Reassanble the ofl pump body Reassamble the pinion Reassanble the pinion pin () Instill new tansnissin shaft an oil punp body. (2) Install pinion on driving shaft Figure 7—3—9 Assenble he Gear (3) Bore one Smm hob using drill through pin ion and tansnission shaft fam this hole (4) Insert pinion pin int the hole and rivet it Reassamble the driven shaft Reassmble the driving gear Reassanble the driven gear and bushing Reassanb le the pump cover Reassamble the strainer Assanbk the stiainer assembly and tighten fixed boltof strainer assan bly to prescribed tomue. @\) Tighten tomue for fixed bolt of stainer as sembly 16Nem Figure 7—3—10 Assemble the Oil Pump os QRERMMANAE AMAA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 7 LUBRICATION SYSTEM Figue7—3—11 Assanble the Oil Pipe Figure 7—3—12 Assamble the Oil Pump Assmbly Reassamble the Oil Pipe (1) Install wo seal rings on lover part of oil pipe unit (2 Install the connector of oil pipe unit into the correspond ing screw of oil p pe assanb yy and use open mouth spanner tighten then, VV Attention: Do not tighten the nut at connector too tight Reassamble the Oil Pump Assembly () Daub oil inckided molybdenum on both driv en gear of oil pump and transmission gear of can shaft (2) Tighten fixed bolt of oil pump to prescribed torque 2A Tighten torque for fixed bolt of stm iner as sambly 20.N*mi5 Nem. ; | : { y Techn kal rjuiement install oiTpunp, — (D Oilpump should operate flexible smooth and without blocked after assamb ling (2) Leakage of contacting surfice between pump body and pump cover is not pem itted (3) Unlocking pressure of relief valve is 0. 61 ~ 0. 76 MPa (4) Pemit the adjustment of unlocking pressure of relief valve ty add shin within relief valve cor. (5) Tighten tomue for four fastening bolts of oil pump cover is20N+m +5Nem.MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CHAPTER 8 TURBOCHARGING SYSTEM Figure 8— Figure 8—1—2 Identification of Unit Stuctue of Turbocharger 81 Summary GW2, STC tutbo—d lesel engine adopts exhaust gases, turbocharger The exhaust gases turbo is installed with the sane shaftofair compressor this exhaust gases tur bo is driven by the exhaust gas fiom the diesel engine and also drives can pressor for compressing the air fiom air filter suction so that increases the air density en tered into cylindes enlarges alr capacity and increases fuel supply of high — pressure oil pump accordingly. Therefore the output power of the diesel engine increa seg the ftiel consumption decreased and m inin izes the diesel eng ine operation noise, Turbocharging system consists of intake /exhaust systans and exhaust guses uubochawer ele The inter nal structure of turbocharger consists of tuibo impeller compressor inpeller and axial bearing Bearing housing supports these parts. The extemal of wibocharger con sists of-eamp ressorhou sing ait in ake opening and tar bo housing ait exhaust opeiting Turbochawer works at very high speed-and ‘an Demure ‘The materials of its parts are choleels and these parts arm manufietures by extremely pre process The repair of turbocharger requites very carefil and professional If its performance decreased, you should check your diese! engine has toubleAvom or not If the diese! engine doesn thas obvbus uouble or wom, the wibochargermaybe has prob lan, Identification of Unit Nameplate of turbocharger showsm anufictire date and other important infomation required when repair fe TE ES Tit PA A ol ies SB 310 ‘Great Wal Baoding iteral Combustion Engie Maufactung Cong FyCHAPTER 8 TURBOCHARGING SYSTEM 82 Repair in the Vehicle Oil inlet pipe of turbocharger Oil return pipe of turbocharger Exhaust elbow Connecting hose of air inlet © Turbochamer Assembling sequence Assembling sequence is reverse (0 disassembling sequence. Fea §=2=1Disusvenb Ing und Assen bling Sequence br Twibockaging Systmn fe TE EE A A) Bl is SB ‘reat Wal Baoding Itrral Combustion Engine Marafecunng Comparyimted = 31 1MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE **) Disassenble Disassemble the oil inlet pipe of tuibocha wet) Loosen two M12 bolls of the connector beween oil inlet hole of usbochasger and oil inkt pipe of wxbo chames and tke cutoil inlet pipe of wrbocharger and two copper washers See Figure 8—2—2 Figue 8—2—2 Disassambke the Oil Inkt Pipe of Tuibocharger Disassemble the oil retum pipe of tibocharge®2) Take out oil retim hose fixed hoop of oil retum pipe wekiment of turbocharger and oil setum pipe flange weld ment and take cutoil rum pipe See Figure 8—2—2 Piguee 8723, D-igassamh le the 0 il Remm, Pine of Tu wbogha ser ' \ | ‘ D iseshomb le the exhaust ethos) ~ Loosen four fastening bolts to install exhaust elbow on turbocharger and then take out extaust elbow and washer unit See Figure 8—2—4, Figure 8-2-4 Disassanble she Exhaust E how Disassamble the connecting hose of air ink) Loosen two ends hoops of connecting hose of air inlet and then take out comnecting hose of air inkt See Figuw 8—2—5, Fie 8—2—5 Disassemble the Connecting Mose of A ir Inlet 2 QQRERMABM SAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 8 Figure 8-2-6 Disassemble the Turbocharger Figure, Figue 8—2—8 Assemble the Connecting Hose of Air Inlet Fige8—2—-9 Assemble he Exhaust E bow RBOCHARGING SYSTEM Disassemble the tubocha gets) Loosen thive fastening bolls of turbochager and then disassanble the trbochawer and turbo intake washer u nit See Figue 8—2—6. ** Assembling Assanbke the turbocharge) Place urbo intake washer unil on the exhaustmani fold instill wubocharer assanbly on the exhaust mani fold and then tighten and fix thre bolts See Figure 8—2 2 QI Tighten tomue for fixed bolts of tubocharger 25N+mt5 Nem Agsahb k the connecting hose of dir inleéi) Connect wo end $.of connecting hose.of air inlet with air inet pipe and wibocharger air outlet opening respectively. C lip two ends of connecting hose of air in ket by hoop tightly, See Figue 8-2-8, Assanbk the exhaust elbow3) Install the washer unit and exhaust elbow of turbo chargeron the turbocharger and then tightly fix them by four bolt units See Figure 8 —2—9, 2A Tighten tomue for fixed bolts of tubochaiger exhaust elbow 20N* m45 NemMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Assanbk the oil retum p pe of wrbocharge®) Connect to ends of oil 1etim pipe of urbocha wer with oil retum pipe wekdment of turbochamer and oil tum pipe flange of turbochamer respectively. Clip two ends by tvo snallmetal strip spring hoops tightly. See F gure 8—2—10, Assanbk the oil inlet pipe of tutbocha etl Place copperwashers on tvo ends of oil inlet pipe of tubochawer and one end have wo cooper washers Fix Fiae8—2—10 Assmble heOilReum be ends ofoil inlet pipe of urbochargerw ith oi inket hole Phe of Tuibocharger of tuibocharger and oi inlet pipe connector of turbocharger by bolts respectively See Figure 8—2—1L QQ Tighten tomue for fixed bolts of oil tum pipe of uubochaiger 50 N+ mis Nem & 3 > Check and Repair Turbocharger belongs exact high — speed ma Pigue$—2—1—Assamble-the OiHnet) —-chinery, itsmaxinum speed. is 160, 000 rdnin-ormor Pine of Tu tbogha ser ‘Tighes ffomally Iw ‘speed'-is betw gen-mu lt 10) fhpu, “sand s,and hundreds thousands rt.in— ‘therefore do hot freew ill disassanble the turbocharger unless Mecessiiy status “When iis ttor opesttes inflexible due to too much dust or accumulative caibon or engine performance goes to the bad, you can cary out sinple clean and wash under the condition that do not disassemble the turbocharger canpletes De tailed methods are as follow ing () Clean dust and oil dust on the surface of wtbocha wer (2) Disassemble the tribocharger frm engine and forbidden cary upward the turbocharger by push ind as handle (3) You should disassemble the air tion valve regu kitor device (4) Disassanble the compressor housing twrbo housing and the connectors between oi] tm pipe and coolant p ipe (5) Clean and wash the surfaces of canpressor housing tuibo housing and two impellers ©) Inject proper quantity clean cleanout liquid and tum impeller at the sane tine until it op erates Fexible (7 Assemble the turbocharger and install iton diesel engine W hen installing the tibochawg es mp hee all sealparts connects with the ttbochargerat he same tine and fill clean lubrication oil into ofl inlet opening to pre— lubricating introducing pipe at first and then disassemble the defla YV Caution Forbidden inpact he impeller during the course for disassemble assemble and clean Avash the wubochaxer Ifthe inpeller has been impacted forbkden use the blade after cor rected again Cleanout liquid can be kemsene gasoline or high quality diesel oil The necessary adjus} repair or rep lace should be mplanented if you find the turbocharger has been damaged or has excessive wom, ata (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 8 TURBOGHARGING SYSTEM Fie 8-3-1 Check the Working Status of ExhaustGasesM auth Pigue 8-342 Check tie W hb Situs of Tuibocharger Figure 83-3 Measure the Inpeller ShaftAxial Clearance & 43 1 Check the W orking Status of Ex haust Gases Mouth (D Disassanble the hose between exhaust gases mouth and air inlet pipe (2) Connectmananeter (3) When fore 0, 088 MPa pressure at the ex haust gases mouth, check that the drawbar begins to move or not See Figure 8 YY Attention The pressure cannot be larger than 0, 01 MPa during this kind check 8.3.2 Check the W orking Status of Turbocharzer Check if the required pressure tomove contol md for 2mm is within folloy ing limit or not W orking pressure of contol md deme ETSI Please contactwith the specialmaintenance station of “Great W all Baoding Intemal Canbustion Engine yManufieture Company/Limited” for them din-tepa ir and! “maintenance of tu rbocha wee ’ ~~ Foliewing are mportmt slandate-va ues for Mpel ler shat axial ckearance and bearing clearance ony for reference 833 Measure the Inpeller Shaft Axial Clearance Measure the inpeller shaft axial clearance by mi crameteg see Figure 8—3—3 Altemant fes 0. 12 NG. 3kg0 pressure on the impeller end of camp ressor and the inpeller end of uiba Inpeller shaft axial clearance Standard 0. 06~0. 09 mm Linit 6. 11mmMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 834 Measure the RotorAxialC learance When checking you can fix themagnetisn seat at exhaustmouth of wibo housing and let the centesinal —meter touching w ith turbo wtor shaft end fice and then pull or push the turbo rotpr along axial direction The measured difference is the axial clearance Rotor of new tuibocharger Axial clearance 0 10mm Use Imit 0 25mm Figure 8—3—4 Check and Messi the Turbocharger ‘ us Disassemble the assembly and wplace wom parts if the rotor axial clearance of turbocharger exceeds use linit 83 5 Measure the Impeller Shaft and piece Bearing Clearance Measure the impeller shaft and bearing clearance by micrmeter See Figure 8—3—5 eZ : Impeller shaft axial and bearing cleumnce x Funda 7 bint y i spp 0.0 201 Emm] (21 5'mas out Figue 83 — and Bearing C leamnee Measure the impeller Shaft 83 6 Measure the Rotor Rad ial Clear ance When checking depress the campressor rotor by hand along mdial direction and then measure them in imum ckarance between compressor rotor and compres sor housing by feeler gage M ininun clearance 010mm Figure 8-3-6 Check and Measae the Turbocharger Rephie the [ating bearhg if he clearance is mal ker than this vane, Forbidden freewill replace new wibochager if you haven tdetem ined and rmoved the cause for danaging the turbocharger os QRERMMEMA SAR ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER OE aR SYSTEM CHAPTER 9 EGR SYSTEM 9,1 Summary GW 2 8TC turbo—diesel engine adopts EGR ekectric contol systen and its whole mission meets Eur III standa rk EGR sysiem is a system © cont! modem engine exhaust gases recycle (EGR systam). Ex haust gases recycle system will introduce a little of engine exhaust gases inlo cylinder and mix with fiesh air lo reduce anit pollitingmatier It decreases canbustion peak temper ture though decrea sing combustion speed so that duce NOx anission W ithin BGR systen, the EGR ratio has been exact adjusted in acconlance wit different opem tion statuses of the engine Following the change of engine load, the intteduced exhaust gases inside cylinder also should be changed correspondingly so that he EGR systm alvays can split the d iffer ence between excelient exhaust contml and exellent engine paver If the introduced exhaust gases is oo less engine power will decrease snoke will increase lagely and engine will has loud noise so that the emission of the engine cannotmeet anission standart Ther for thew is alvays an oplinal EGR ratio (alo bebveen exhuus! gases reeyele mass and livsh airmas br every different working staius of the engine (load, speed and waler tenperature and so on EGR system of GW 2, 8TC tibo—diese] engine has been installed EGR cooler this cooler is cool the exhaust gases entering in cylinder so that to decrease engine intake tmpemtre improve NOx anission ducing effect and decwase CO. and. HC. an jssion, Air filer / ‘Vacuum regulator wy Air regulator input Cooling water Vacuum Source temperature Signal Air flow rate sensor signal EGR valve — Engine speed signal Recycle exhaust gases Foot pedal signal Exhaust ‘waste gases —— Air intake ° Feuie S=T=1 Skeich Of BGR Eketic Conte Sys fe TE EE A A) Bl is SB Great Wal Banding ital ambustn Engine Marfactving Company Linteg «317MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Rephce following parts timely accor ing to the re quinment of manufacturer and specifications if EGR valve vacuum reguhtor and EGR cooler have been dan aged, ‘Tolerance Campensation () EGR VaWe Position Sensor EGR valve position sensor is installed at EGR valvg see Figure 3—1—3 It is used measure the actual opening degwee of EGR valve in ower to cany its Figure 9-1-2 Assamb ly D awing of Doint for closed loop contolof EGR valve actual open EGR Valve Assenbly ing degree When initializing measure hemasxinum and min imum vollages when EGR valve at the stats of full open and fill close respectivel: The measured voltage tolerance using different valves will campensated by EGR valve Therefore among the batch preduction all EGR valves will have the same opening degree at the same speed and bad. Tolemnce campensation will be automatically carried though for every 50 hours or by manual though computer (reposition) function, ( Vacuum Regulator Vacuum sgubitor locales betveen vacuum pindue ver Cor vacuum received and EGR ye: ‘Tiuse ¥ eleg Figne 9 —1—3—Assemb b-D mw ing of BORValve Assan bly \numagnetie coil to! contr! the open ihe dearee of bypass valve and that bypass valve can control he environ mental air flow rate to EGR valve so that the vacuun degree acted on BGR valve film can reach the antici pant value The electrmagnetic coil is driven by PWM signal The pulse width for each cycle can change within 0% and 95%. Cycle frequency is 250 Hz echnical panmeters of vacmum regulator 9-1-4 As fee! Average] Peak | Short circuit Fie 9-1-4 Assamb iy Diwing of Yaatod Vacuum Regulator Vmod = Vsup Averge| Peak | Short circuit Inod (ma) 700 | 1, 200 7, 000 Nomalwork omalwork ing atom base range Voluge of pover Maximum W) ) Minimum W)_ supply (WV sup) 14.5 10 Cunent of pover = Maxinum (mA) | M inum mA) supply (without 60 50 Figue 9-1-5 Assembly D wing of oad) sup) Vacuum Regulator oe QQRERMREM SARE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 9 EGR SYSTEM 9,2 Repair in the Vehicle Disassembling sequence @ Engine hamess EGR cooler EGR valve @ Vacuum regulator sequence Assembling sequence is reverse to disassembling sequence, Figure J=2=1 Disissan bing and Assanb Ing Sequence OF EGR Sysian REKNA MM SRRAA (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANUAL OF GW2.8TC TURBO DIESEL ENGINE 2 Disassemble the Engine Hames Figue 9 /**) Assembling Disassemble the engine hames¢1) Pull out he connector betveen vacuum regulator and engine hamess See Figuie 9—2—2. Disassemble the EGR coole@) Loosen wo snail metal strip hoops on water inlet pipe jpintof HGR valve and water outkt pipe joint of cooling water pipe weldnent @ Loosen wo snail metal strip hoops on water outlet pipe joint of EGR valve and water inket pipe joint of cooling water pipe weldment ve (3) Disassemble wo bolt units fixed on EGR Air tet cooler exhaust pipe and take out EGR cooler gasket (4) Disassanble two bolt units fixed on BGR . = cagler intake pipe and takeout EGR cooler gasket Figum 0 7278, \D issn le te EGR Cooler (3) Pisasserble wo-bolts fixed on’ exhalistmdni) Figure 9— Disassmb le the BGR Valve Disassemble she Figure 9-2-5 Vacuum Regulator 320 “oid/dnd-take out HGR cooler intake pipe and gasket’ ~ (6) Disassanble wo bolts fixed on EGR valve and take oat EGR cooler exhaust pipe and gasket Disassmble the EGR valve) Disassemble the connecting hose beween EGR valve and vacuum regulator and disassamble the hexa gon socket round head screw by hexagon socket spanner and then ake oulHGR vale See Figure 9—2—4, Disassemble the vacuum regulatof) Disassemble the vacuum hose to connect vacuum regulator and vacuum pump vacuum hard pipe D isas semble the fastening bolls of vacuum regulator fem. its bmeket and then take out vacuum regulator See Figure 9-2-5. fe Te ES It PA a A) ll is SB ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 9 EGR SYSTEM Figie 9-2-6 Assemble the Vacuum Regulsior Fige9—2—9 Assmble the Engine Hames *# Assembling Assanbk the vacuum regula bff) Fix vacuum regulator bracket on intake manifold by two bolt units (M8 x30), and then fix damping pads and vacuum regulator on vacuum regulator bracket by two bolt units (M6 X25) and wo hexagon flange nuts VV Attention Two pipe joints of vacuum regulator cannot be connected incorrect Assanbke the EGR valve) Place EGR seal ring on intake manifold fix EGR valve assembly on intake manifold by hexagon socket yound head screw (w ith spring washed . QQ Tighten tomue for hexagon socket round head screw 20N+ mt5 Nem Assanbk the EGR coole(2) (1)_Place’ seal.ring on EGR yalve at fist then, fiv the EGR dooler exhayst pige on EGR valve by, two bolt unvits (MBX 25) — = = = (2) Fix one end of EGR cooler and EGR cooler seal ring on EGR cooler exhaust pipe by two bolt units (M8 X22), butno not tightly tighten than, () Fix intake pipe of EGR coolerand EGR cool er seal ring on EGR cooler exhaustmanifld by wo bolt units M8 X22), but no not tightly tighten than. (4) Pix another end of EGR cooler and EGR cool er seal ring on EGR cooler intake pipe by wo bolt u nits but no not tightly tighten them. (5) Adjust EGR cooler and EGR cooler intake pipe position align every bolt hole and tightly tighten all still loose bolts Tighten torque for fixed bolts of EGR cooler intake /exhaust pipes 20N+ m+5 Nem Assanbk the engine hames¢)) Insert the engine hamess into the connector of vac uum regulator See Figur 9—2—9, RECROOMSERRA Company (Great aang teal onbstin Engin Mneactring Company LitesMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE CHAPTER 10 ELECTRIC SYSTEM 10.1 Battery 101.1 Battery W hen you urgent need to use dry—charge battery, you can use it after supplying the campoun ded electrolyte into the battery and rest for30m nutes Butgenenlhs the battery should be charged fr3~5 hours batteries all have been charged ford hours before kave factom Perfomance Parmeters of Battery Parameters Model of bate 6—QA—8 Single cell battery number 6 Rated volinge (VY 12 “Rated capacity (AH. 20 discharge mie) 80 Hewitofekctmyte bevel higher tan phe mm) 10-15 Danission ofbattey mm) (XW XH) 300 170 X 220 2 and Table 1 8 Bkeetelyte’specite syuviy /(e 7am") See Table FOI Table 10-1 —2 P pctlivte- Specie ravity-@@ /an'> “fh Different’ ~— Areas and at Different Tanperature Elective speciiic gravity of tll charged baller’ al 13 Clinate eonditions Cenviimental tanperalu > W inter ‘Summer A eas with winter tmperature lower than —40T 3 La Aras wih winter tmpemure higher than —40C 129 125 ‘Aris with wher tmpemtre higher than —30C 18 12 Aris wih wher tmpemur higher than —20C Lar Lad Awa wih wher tnpeuture higher han —0C 1 aa 12d Tabke 10—-1—3 Correct of kclolyte Taenpem ture and Specific G ravily Measure ekctolye impemureC +5) a0 IS 0 —15 ] 30] —45 Reading correct of gravineter +002) +001 0 a1) —a 02} —0 03} —0, o4 1Q 12 Electrolyte Canpound 10. 1, 2.1 Electrolyte Campound Method (1) Electolyte of lead—aci storage battery Is compounded by pure water and oil of vitriol the electrolyte density of vehicle starter battery is 1. 280 g/an’ 40. 005 g/an’ (250) oo QQRERMMEM EAR ZE ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 10. ELEGTRIG SYSTEM (2) The container for eectolyte compound should be acid — resistant and heat— resistant vitre ous enamel aquarium, material container or wood container with lead — liner Workers must wear protective clothing and use protective appliance when compound electolyta (3) Clean and wash the vessel by pure waler before canpound elec toy te 4) When compound electmlyts pure water should be filled int» the contiiner at first and then fill the oil of vitriol into pure water slay and continuous mix wund it Forbidden filling pure water into oil of vitriol tb avoid splashing and buming Conversion formule €25=dt+0. 0007 (t—25) Among the mula d25=25C clectwlyte density Electwiyte density when tanperature is § 0. 0007: lanperaure coefficient t actualmeasured electolye tmperture Table 10 —4 Shows the Pmportion of Pure W ater (or Distilled W ated and V itrio! ih the Container Ekctolyte Volume mip be Mass mtio be Electrolyte Vokme ratio be Mass mtio be specific smvity | teen pure water| tween pure water| specific enivity — tveen pure water} tween pure water (g/an’), 200 | ‘or distilled wa | (or distilled wa (g/an’), 200 (or distilled wa | (or distilled wa ted and viitol | teD end vitriol ted and viirol | to end wil 19 CoE TET 7 Tit eT R84 T 7 T OT COT TOT 113 7287 1 a T 18h 7 Lad @6R4 12% roa] 7% Tis Tey ier aeons 1.16 5.701 i 280: 1 r Low 17 HT CET TT Lis 2981 La 2 60:1 Lak 1.19 46% 1 1. 30 2477 1 34 7 1.20 4381 2: NOE TE TASS TET TACO WT NT HE PTS STG OT PUTS PTT TBS ATT 101.22 Pill Electrolyte () Exhaust bolt the vent cap on battery boltmust be penetrated there are gasket and seal paper under ex haust bol} and the gasket and seal paper must be taken out after fill electolyte (2 The tapemus of electoly must be cooled under30C and then you can fill it into battery (3) Fill campounded electmolyte into every single divider and the electwlyte level of plastic housing bat ‘tery should be the same wit outside housing symbol “MAX.” and the electrolyte level of rubber container battery should be higher 10~15 mm than separator Figure 10-11 Cheek Battery (@) Tighten the exhaust boll of he battery to a Elective Level vol leakage GQRERMN BIAS RAG Great el Bard interal Conbstin Engine MarfactvingConpayyLintee = 323MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 101.3 Battery Charge 10, & 1 Charge Equipment VY Caution Batiew chaigemust use DC power supp bx @) Rectifier Rectifiers in common use are solid rectifier (cupnm oxide rectifier selnim rectifier and sili con rectified, inflitor rectifier (tungsten kmp rectifiep and mercury rectifier Generally the input AC voltage is 110V or220V; the nam inal output vollage is 6V, 12V, and 24V, Solid rectifier is easy to use and do not need in chaige of and is used universally (2) Silicon contplled charger Silicon contiolled charges power supply is 220V AC and changes to DC afer silicon con twlled rectifier it charges the battery fiem output end DC output voltage is 0~220V and current is 0~40A. 10.3 2 Detecting Instument Sinilarw ith daily maintenance the battery charge needs detecting instument and necessary fools such as densinetes themanetey voltage meter and anpermeter and so on 10, 1. & 3 Battery Chawe (1) Preparation —— Cheek if the electolyte or pure water acconis with specifications or not —— Open the exhaust bolt of batter, —— Fill ekecuolyte or pure water lo preserbed level (2) Charge connecting Connect the positive pole of chawerwith positive pole of batters negative of chargerw ith nega tive of battery and forbidden reversal connecting The charge frmost batteries can be detem ined aceord ng-to he paver of chager—The-connecting for charge must be tigh th: (8) (Charge modes: C} | ; ( ' Genemlly, the charge modes thive following thiee' kinds “constant cuirent charge constant volt age charge and quick charge ~ ~ ~ ~ ~ Constant current charge includes early charge additional charge cammon charge and ba knced charge —— Early charge early charge is the first charge before use the non—d y—chaige batien: Af ter filleketolyte into the non—dry—charge battey; rest orl ~6 hours the battery can be charged only when the tmpemtie decreased bebw 35C. For first chawe curent is 0, 07C20A, you can re duce half of the current and continuous to chaige when chawing single divider vollage is 2 4V. —— Additional charge fr the diy—charge battery stored for longer tine or has bad perfom ance or the battery after full chamed but stp to use for around one month The supply charging cur rent is. 1C20A and charging for5 hours or detem ines the charging tine acco! ing to storage period. Common charge thismeans the battery to be charged has used after firstchawe ‘The first stage of common charge for vehicle batlery adopted the current is 0. 1C20A, you can mduce hall of the current and continuous to charge for about10 hours when has charged for $~12 hours and the singk divider voltage is over2 4V. Usually the charging capacity is 1. 5 tinesmore than dischar ging capacity, or you should charge | 3~1, 5 tines of mted capacity. Balunced chaige fully chawge the battery using common chawge then chaige the batteyy using current 0. 035C20A. Stop charge for 1 hourwhen battery rises even air bubble and tmper ture increases such—and—such r3~4 tines Single battery can produce a btofair bubble and finish cha me when battery voltage and clectmlyte temperature alll trend to stable — Constant voltage charge constant voltage charge means that he battery is charged with thick —and—thin voltage Charging current is larger at the beginning and then decreases gmdual ly usually the chaige voltage of constant vollage charge is 2, 3~-2,4 V. During this charge little fe Te ES It PA a A) ll is SB 324 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 10. ELEGTRIG SYSTEM constant vollage charge is aways used gaswill produce and litte water is consumption Therefore frmaintenance — fiee lead—acil siomge batter. — Quick charge quick charge adopts large current for pulse charge and also use short— tine dischawe intemittent charge method charge battery Quick charge use 1~2 tines C20A hige current charging Special quick charger finishes quick charge @) Estimation symbol for filll charged battery A lot of air bubb le produced w ithin battery single divides measured single body voltage of bat ter is 2, 6~2 8 V and do not change formore than 2 hours measured clectwWyte specific gravity reaches to 1, 280 g/em’ £0. 01 g/am’ (25) and do not change formor than 2 hours () Atention for charging Fob iden he tempemtire of electwlyte exceeds 45°C , or lapse measure shouk be adopted Geduce charging current or stop charge or cooling it inside water basin), good ventilation and for biden fire (6) Trouble diagnosis for lead—acid storage battery The usually detecting and diagnosis methods for touble of lead —acid stomge batlery are shown as Table LO—1 Table 10—1— Specific graviy Esiination 5, Table 10—1—6 and Table 10—1—7 respectively. Measurement of Specific G ravity Raney >1 300 Too Wgher ekctol® strength con centutio, incorrect filling Adhust specific erviy use deion water F250 =F 280 Excellent T2507 220 psifiicient came | ; Nia tonal Horse 1220~1 100< ‘Oven ischare 160 lower siengih concentration or ult possibiy Recheck alter chawe Specific gravity diflerence of ever single divider > 0. 04 ormore Maybe single divider battery fut Recheck after charge Table 10—1—6 Measument of Valtge Voluise Estimation Raney S12 ov Nomal 2 5~11 av Tnsu ficient chase Additonal change <1 BV Ovenlischarge or inner ull possibly Recheck alter charge Table 10—1—7 Measurenent of Capacity Volaneter shows Estimation Ranedy Wie aa OT Green area Nomal Yelby awa Rediange Additonal chaze Red ares Fully dischane Recheck alter additional chargeMAIVTENANCE MANUAL O OF GW2.8TC TLNBO “DIESEL ENGINE Figue 10—1—2 Measure the Specific Gravity of Electrolyte | Ballers 2—G lass ube 3—E lament of gnvinetey 4—Rubber ube 5—Rubber ball 6—Electmbyte Figure 10—1—3 Check the Ballory Using Charge D ischanze—Fork 1 —Volmetey 2—Resisignee 3 —Feeler of discharge forks 4 Battery 10. 1.4 Detect the Capacity of Battery () Measure the Specific G mvity of E eetolyte by Gravineter Because the specific gravity of electwlyte will in crease or decrease when the battery is charged or dis charged respectively therefore the capacity of battery can be estinated in accordance with its specific gravity of electrolyle Experiential know ledge told that when the specific gravity of electmlyte decreases each 0. 01 g/an®, this corresponds w the battery discharged 6% . Thus if you know the specific gmvity of electrolyte of fully charged battery, you can wughly estimate the bat ery discharged degree in accordance with measured specific gravity of electrolyte Forexunpla the specif kc gravity of electrolyte of fii lly charged batiery is 1. 28, now the measured value is 1. 20; thismeans the battery has discharged 48% . (2) Measure Single Divider Battery Voluge U sing Tigh —Resolving PowerD ischarge ~Meter Hight reso Wing power dischae—meier is called as discharge fork. it consists of one3.V DC_volmeter and one charge resistince When measuring if you tightly press to fork tips on positive /negative tem inal posts of single divider battery for seconds and observe the end vollage the batlery can keep under laige charge discharging condition, you thus can estinate exactly the discharging degree of the battery and the starting ab ili & For different high — resolving power discharwe — metes you should rad the voltage and curent in ac conlance with different specifications of the manufactur ers Genemlks for the battery with good technical sia tus the single divider voluge should be lamer than 1 5 V and can keep stably for5 seconds If the vollge decreases mpidly within 5 seconds ora single divider battery voltage is 0.1 V lower than other single divider balleries thismeans this battery has uouble and should be repairedCHAPTER 10. ELEGTRIG SYSTEM 10,2 Starting System 1021 Summary (Starting Systan Starting system consists of battery sturtes starting switch, ignition lock starting rly and so =1 shows their connection on Pigure 10 — Starting relay | Contacting points Ss. fer 8 WF 50" Terminal ae aad / § L 0% s “seminal “| ~—- = = \\ yea © © Pinion eluteh Suetion eail Figue 10=2=1_ suring System @ Stuter Starting sysien adoptsmagnetic force type deceler ating starter its shaftalso is used as pinion shaft Con lacting points of magnetic Gree switch will close when starting switch closes so thal amatuw begins to oper ate At the sane tine attracting movable in core and pinion is pushed by divider md forwarl io mesh with ring gear Then ring gear opemles to suit the engine When engine started and starting switch disconnected the movab iron core backtracks and pinion cames a way fm rhg gear so that the amature stop to mn When engine speed is higher than pinion pinion is i Seer dla. thus the amature has not be driven Figue 10-2MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE (3) Starting Loop lols i ese tes : : a 3 TIO pod ‘Stiction ceil Keeping coil Magnetic foree switch Figure 10 Engine Starting Loop 10.22 Repair in the Vehicle Disassanb ling Sequence D tem inal tem inal Ground ing cable fem inal Starter assan bly Isolation plate (excluding cold area Assanb ling Sequence Assanbling sequence is reverse to disassembling sequence. Figue 10-2—4 Disassembling and Assembling Sequence for Sturter A ssemb ly oo QRERMABMA SARE ZA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 10. ELEGTRIG SYSTEM | Disassenbling Preparation Disconnect ground ing cable of battery Disassemble the “50” tem nai) Disassemble the “30” tem ina) Disassamble the ground ing cab le tem inal) Disassemble the starter assamb ly) Disassemble the isolation plate (exc hid ing cold ar o® #4) Assembling Assanb ke the isolation plate Cexcliding cold ae Assanbk the starter assanb hé Tighten fixed bolts and nuts of starter to prescribed torque, Q) Tighten toque fr fixed bolts and nuts of siar ter 81N-+m _-.\ A’ssantb.e the. grouihd ings cable tem ina \_ | /Ceanbet'giound ing cdble tem ital, Assanbk the “30” tem inaf) Connect wire connector Assanbk the “50” tem inafl) Connect the grounding cable teminal of battery with the wire tem inal of starting sv iteh and then tight en fixed nuts to preserbed tomue QJ Tighten torque fr fixed nuts 9N-m 5 Connect G mund ing Cable of Battery Figure 10 Connect the battery cable See Figure 10 —2—5,MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 10.2.3 RepairSingle Part Disassembling sequence @Lead-wire "Yoke housing ‘Carbon brush and carbon brush stand ®Armature @Driving end housiiig | ©F ree wheel device: i — @Return-spring ~— @Steel ball Small idling gear Keeper 3 Roller {Magnetic force switch Reassembling sequence Reassembling sequence is reverse (o disassembling sequence. Figue 10=2=6 Disissanb ling and Assamb #*) Disassembling Disassemble the lead —w indi) Disassamble the lead —wire frm magnetic force switch See Figure 10 —2—7. 7 Disassemble the ead —W ie fe Te ES It PA a A) ll is SB 330 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company Lied Figure 10CHAPTER 0 ELEGTRIC SYSTEM Figur 10—2—8 Disassemble the Thiough Bolt fiom Yoke Figue 40-29 Disussenble the Yoke from Magnetic Fowpe/Siriteh Figur 10—2—10 Disassemble the Catbon Brush and Carbon Brush Stand Figue 10—2—11 Disassemble the Free W heel Device Disassemble the hugh bol@) Disassemble the thiugh bolt fam yoke See Fig ure 10 —2—8. Disassemble the yoke assembly) Disassemble the yoke fim magnetic fre switch See F gure 10 —2—9 Disassemble the yoke housingd) Dibussemble tie carbon busi arid: carhon, Bish ‘StandSy — ~ Disassemble (pull ow8 the catbon brush and car bon brush stand fm amature by need nose pliers See F gure 10 —2—10. the amaturé@) the driving end housing?) D isassemb le D isassamb le Disassemble the free whee! devicdii) Disassemble the fire wheel device fam housing See F igure 10 —2—11.MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figie 10—2~12 Disassemble the Reum Spring o!M agnetic Force Switch Feu 10-213, Digssanble the Sel Ball of Free Wiheeh Device Pigue 10—2—14 Disussenble the Snall ling Gear Fleur 10—2—15 Disassemble the Keeper Disassemble the rtm springd) Disassemble the retum spring fom magnetic force switch See Figure 10 —2—12, Disassamble the steel! bali) Disassemble the steel ball frm free wheel device, See Figure 10-213, ‘J bastenble the $rlall iting lai ~~ Disasiemble-the shell idling gear fam Housing See Figure 10 -2—-14, Disassemble the keepedif Disassemble the keeper fium housing 10-215. See Figure Disassamble the wlle si} Disassamble the magnetic force switcldf ooo QQRERMREMA SAM ZA ret Wat mera Conbstin Eng Manta pg amp iedCHAPTER 10. ELEGTRIG SYSTEM Check and Repair It is necessary Io adjust repair and replace the parts if you find heavy wom or danaged during checking Amaure Check the mdial jumpiness of commutator Re place it if its mdial jump ines exceeds preseribed lin it (see Figure 10 —2—16). Rad ial jmpiness of commutator Figur 102-16 Check the Rad ial Jumpiness of Conmutator Ou'put power Standard Limit 28 Ww 0. 02 mm 0 05mm Insite ; a Check if the mica piece wom or not ieee Depth ofmica piece Correct IT Output paver Standard Linit 2.8 kW 0. 70 mm 0. 20 mm Incorrect Figure 102-17 | Check, the’M ica Piece \ 7 \_) Cheek the extemal diimeter of clmmutator See Fig sare 10-218 ~— = — Extemal diameter of conmutator Ou put power Standard sw 5, 00 mm | Figure 10—2—18 Check the Extema! Dianeter of Canmutator Test for Short Circuit of Amature Place the amature at the short circuit coil tester © test it short or not see Figure 10 —2—19, Use saw blade contacting iron core of the amature when slov iy tum it by hand. ‘The short circuit amature will Jet saw blade vibration and the iron core will absorb it toa If the saw blade is absorbed or vibrates replace the ar mature due to it is short cireuit Figure 192-19 Test For Short Ciwuit ofAmamreMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE G wounding Test of A mature Use one detecting needle of multineter touching with cammutator piece and another one touching with amature in com See Figwe 10—2—20, Result should ‘be open circuit If there is close circuit thismeans the amature is gmunding replace amature please i Yi Figure 10—2—20 Grounding Test ofA mature Chose Ciruit Test of Amature Use two detecting needles of multineter touching with two commutator pieces see Figure 10 —2 —21. Result should be close cireuitatany point Replace the amature if there is open circuit please Riguie 10-2721 Close Cireuit Test ofA many If ( ECM CS _l Yoke G wounding Test ofM agne tie Field W inding Use one detecting need of multineter touching with magnetic field wind ing end wire or carbon bush and another one touching with outside surfice of yoke See Figure 10—2—22. Result should be open cireuit If there is close circuit this means the magnetic field wind ing is grounding rep lace yoke assamb ly please. Fue 10—2—22 Gaunding Test of Magnetic Field Winding Close C iruit Test of Magnetic Fiekd W nding Use one detecting neede of multineter touching with the lead —wire of “C” tem inal and another one touch ing with carbon bush See Figur 10 —2— 23, Result should be close circuit If there is open cireuit replace yoke assembly please Figue 10-223 Close Cireult Test of Magnetic Field W inding asa (TE EC I BE a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 10 ELECTRIC SYSTEM Figure 10—2—24 Measure the Length of Carbon Brush Figur 10-2225 insilatign Test of Cixbon/ mush’S tind Figure 10—2—26 Check Pree W heel Device 2 Figue 10 Cheek Bearing Carbon Brush and Carbon Bnush Stand Measure he length of caibon brush replace it if its wom exceeds prescribed lin it Length of carbon brush Output pover Standard Limit 2.8 kW 14, 5 mm 10 mm Insulation Test of Carbon B msh Stand Use multineter for insulation test of carbon brush sland, See Figure 10—2—25, Use one detecting nee dle ofmultimeter touching w ith carbon bush sland plate and another one touching with positive of carbon brash stand Result should be open circuit ( MOV CS _l FreeW heel Device — Check if the teeth of pinion wom or danaged, Place it if it is damaged See Figure 10—2—26. The running of pinion clockwise should be snooth But the pinion should be beked if tum it counterclock wise re Bearing Check if the bearing wom or damaged, replace it if there is noise during its opemtion See Figure 10 —2 27,MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Idling gear Fie 102-28 Assanbke the Kling Gear and Housing Figure 10—2—29 Pull Foree Test Figure 10—2—20 Keeping Test cs QRERMMBNA SARE ZA ret Wong ner Combustion Ege Mnetecting Cn #4) Reassanb ling Reassanb ling sequence is yerse Wo disassembling sequence Follow ing itens should be noted when ras sembling — Masnetic foie switch —— Idling gear — Chiteh assembly —— Housing (1) Install clutch assembly on magnetic force sw iteh, (2 Install dling gear and housing See Figure 10 —2—28, YY Attention Do not drget to install stee! ball and spring before install chitch on magnetic force switch At first install wlleron idling gear befor this Magnetic Force Switch Tanponuy cohnect masnetic free" swith’ between chiich and housing ahd carly 601 follow ing tests /Bvesy test should be finished within 3~5 seconds (D Pull fore test Connect the negative tem inal of the battery with M teminal When current is given fium positive temi na] of battery to “50” teminal pinion should shift (2) Keeping test DisconnectM teminal lead —wire pinion shoud continuous keep shifting status LinedCHAPTER 10. ELEGTRIG SYSTEM (3) Relum test Connect the negative teminal of the battery with both “50” teminal and housing and connect the posi tive teminal of the battewy with M teminal pinion should shift at this tme When disconnect the lead — wire of “50” teminal pinion should retum to the posi tion before shift mmed iately. Figure 10—2—31 Reum Test (@ Curent Connect as shown as Figure 10—2—32, Connect the positive tem inal of the battery with positive of an permetes negative tem inal of the battery with hous ing negative of anpereneter with both “30” tem inal “50” terminal and then measure the current Current Standard 120A or less OV attention ( Fey e 84 Meraute-Cumeht , (D-Batlery must be used-after-fill charged! (2 The wife should be thick Because hige cur rent will pass itMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 10.3 Charging Systan 10.31 Summary Charging system adopts integrated circuitwhole adjuster ype charging device, itsmain campo nents are connected following the sketch of Figure 10 1. Adjuster isa solid circuit The adjust erand the carbon brush stand assembly inside the genemior are ussanbled on war end cover Genemtor do not require specialmaintenance such as voltage adjusment The rectifier connect ed with stator coil has nine diodes so that lo convert AC vollage into DC voltage, DC vollage after commuted is fed to the output tem hal of the generator r 7 Rotor Integrated Carbon “HEU adjuster Stator brush Roller bearing NN Roller bearing Oil seal WW ay AN at ‘Through bole ‘Vacuum ~ | puny Paley. (py | Front cover Ship ing = __> Rear cover Fgue TT 1 Siichie ofGenemmr 10.3 2 Diagnosis Camprehensive D iagnosis in Vehicle Charging alm ing lamp shows the working status of chawing systan, When switch the starting switch to “close” position the akming lamp will light Afer starting the engine, imp put out thismeans the charging system is at nomal working status shows abnomal if he alaming If the alaming lanp this means that the battery charge maybe insufficient chawe or over charea you should inplenent follow ing check and diagnosis on charging system tinely (1) nplenent apparent checking on engine transmission belt and w ire connectors (2) At the condition the engine stopped switch the starting switch “close” position and ob serve the alam ing lamp. If the alam ing mp does not light 4 neet “L” tem inal to gwunding —— Ifthe alaming lamp lights rpairor replace the generator sco QRERMMENA SARA ret Wa ating mera Conbstin Eng Manfactring Crary Linked ssemble the wire connector fim engine and conCHAPTER 10 ELEGTRIC SYSTEM Changing circu its Battery Starting switch ACC ‘ON Engine ‘Charging relay Generator “St exminal - 7 "W" terminal Gael == “UP terminal 1G" terminal tachometer [4 Tochaning oa fo charging signal Fare 10=5=2= Charen C ieuirar nen = = Resistance Baulery + _ Charging csistanee t alarming lamp Resistanoe = Jenition switch ON Generator terminal + jen Pngine qi 580. tachometer + mA Ra Charging relay “1G” terminal Figaie 1=S=3— Charging System Checks Venice GR TES ik 7 aD is FSB ig ner Conbstin agin Marfan Company Great el Bande ime = 339MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 10.3.3 Repair in the Vehicle Disassembling sequence @) Power steering pump and A/C compressor transmission belt ® AJC compressor assembly © Oil hose © Alternator transmission belt @ Power stecring pump assembly @ Altemator fixed bolts @ Altemator assembly Assembling sequence Assembling sequence is reverse to disassembling sequence. Figure 10=3—=4—Disassamb Ing and Assen bling Sequence for Bngwe fe Te ES It PA a A) ll is SB 340 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTER 10 ELECTRIC SYSTEM Figure 10—3—5 Disconnect G munding Cable of Battery Fire! 1036 Disassemble the A vx is | Figure 10—3—7 Disassemble the A temato} Trunan ission Belt Figure 103-8 Disassemble the Pover Swerhg Pump Assenbly Generator **) Disassembling Preparation Disconnect ground ing cab le of batter. 10-3—-§ See Figure Disassamble the power steering pump and A /C can pressor trinsm ission bel€l) Loosen the adjusting bolts of power steering pump. and disassanble the tansn ission belt Disassemble the A /C conpwssor assanb h2) (D Disassemble the cluteh wite connector (2) Disassamb ke the fixed bolt of A C camp ressor and take outa /C canpiessor assanbly See Piguie 10 -3-6 Disassemble the wie conneco@) (1) Disassemble the “L", “S", “W” and “EB” tem inals. (2) Disassemble the “B" tem inal D Bagsemble the vacuum hosedy , —_D.Bassemble the vacuum Hose fiom eng iné vacuum pump. Disassemble the oil hosé®) () Disassemble the oil hose fron oil sump. (2) Disassemble the oil hose fiom cylinder block Disassemble the allemator transn ission be I@) (@) Loosen fixed bolt of adjusting plate (2 Disassemble the adjusting bolt (3) Loosen fixed bolt of allemator and then disas samble the transmission belt See Figure 10—3—7, Disassemble the power steering pump assenb ly?) (1D Loosen adjusting bolt and then disassamb le the pawer steering pump transmission belt (2) Disassamble the fixed bolt of power steering pump and lake out power sieering pump assenbk. See Figue 10—3-&MAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Figur 10-3—9 Disissemble he A liemator A ssemb ly Locking bolts 10 Agsambi the A emator Pieuye 10 Figure 13-11 Assemble the Power Steering Pump Assen bly Disassemble the altemalor fixed boll) Disassemble the altemator assem b Q) Disassamble the altemator assanbly fem the en gine See Fgue 10—3—9, *) Assanbling Assanbk the altemator assamblyg Assanbk the altemator assemb —3-10, See Figure 10 Assanble the altemator fixed bolts®) Temponnry assanble the altemator fixed bolts Assanbk the power steering pump assanb 7) () Assamble the power steering pump assanbly and tighten the fixed bolt to prescribed rue See Fig ure 10-31, ®J Tighten true for fixed bolt of power seer hg punp 20 N+ m45 Nem ( (2) Connect pil inlet hose of power steering pump and tigh ty fixed by clip. — ae be Assambk the altemator transn ission bel) (@ Assenbk the altemator transmission belt and adjust the belis tension (2 Press the middle part of the belt with 98 N forees to check its tension Transmission belt deflection of a ltemator 8~10 mm ‘Transmission bell of power steering pump: Transmission belt of alternator (3) Assanble the fixed bolt of altemator and tighten he fixed bolt to prescribed tomue @Q) Tighten tomue fr fixed bolt of generitor 25N+ m+3 Nem FA Tighten toxwe br fixed bolt of adjusting pte 12 Check Transm ission BeltTension Figure 10-3 a. QRERMAEM SAR Za ret Wong ner Combustion Ege Mnetecting Cn 20 Ne m£5 Nem LinedCHAPTER 10 ELECTRIC SYSTEM Figue 103-14 Assonble he A/C Compressor Assonbly Fir cara vies ind pow seengnanpammsaen tet) ‘Alternator and Jan pulley transmission belt Figure 10—3-15 Assemble the Power Steering Pump ad A.C Cunpressor Transn sion Belt Pigue 103-16 Connect the G runding Cable of Battery (fr Reference) Assanb k the oil ho: () Install oil hos: ure 10 —3—13, (2 Instlloilhosdi) on oil sump. on cylinder block See Fig Assanbk the vacuum hosé) Assamble the vacuum hose on engine vacuum pump. Assanbke the wire connect) Connect “L”, “S”, “W”, tem inal “G" teminals and “pe Assanbke the A C cam pressor assanb l¥2) (D Assemble the A AC compressor assembly and tighten the fixed bolt to prescribed tore See Figure 10 — a Tighten ‘omue Or fixed bolt of AC campres sor 20N-mt5 Nem (2) Connect the wire connector of magnetic force switch. ( | } ( Ky Assanb k the power steering pump and A/C can Dressor transmission be Iti) ~ - (1) Assenble the A C compressor transmission belt and adjust the belts tension See Figure 10 —3— 15, (2 Press the middle part of the belt with 98 N forces to check tansn ission belt tension ‘Trunsn ission belt deflection 8~12 mm (3) Tighten the lock ing nut of id ler to prescribed torque, al Tighten torque br locking nut of Her 27 Nem onnect he ground ing ¢ ure 10 —3—16, a oeMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 10.34 RepairSingle Part Disassembling sequence @ Vacuum punp @ Lead—wie @ Thiugh bolt @ Rotorand fiont cover assembly Strand rear coverassonbly @ Rowr @ Rearbearing @ Tem inal bolt and nut ® Rearcover fi Sulor Bf Diode HF Integmied circuit adjuster assembly 4 Cusbon bush stind Reassambling sequence Reassambling sequence Is reverse 1 disassembling sequence Figie 10=3=17 Dissanbling and Assanb ing Sequence Or Engine fe Te ES It PA a A) ll is SB 344 ‘Great Wal BeodingIterral Combustion Engine Manfecturing Company LiedCHAPTE: 10 ELECTRIC SYSTEM Figure 10-318 Disassanble the Vacuum Pump Figure 10-3 —19 _Disassam ble the Gente ia ior 20 Disassanble the RowrofGeneraor — e = eees Ge Figure 10—3—21 Disassemble the Genemior | Disassenbling Disassemble the vacuum puny) (D Overspill the liquid fram outlet (2 Disassemble the fixed bolt of vacuum pump. See Fur 10—3—18, Holt centml phe and disas semble vacuum pump horizontally along axial direction of tor Disassemble the lead —w int) Disassemble the though bol@) Disassemble the rlor and front cover assemblya) Disassemble the statorand mar cover assambl¥5) Insert screwdriver into the clearance beween fiont cover and stator imn core and disass@mble this assan, bly See Figure 10—-3—19. YY Attention Do not damage stator inn core when use screwdriver When the assanbly cannot be disas sambled fix war cover and slowly knock the end of shaft by plastic -hanmee D butgdtnbr hd mbm) L ~ Chump the tor by pliers disassamble pulley nut @, and then take out pulle¥2), fan@), front cover) and roto). See Figure 10-3 —20. Disassemble the ar bearing?) Disassamble the teminal bolt and nu@) Disassemble the war cove () Disassemble the nut co connect “B” tem inal and diode keeper (2 Separate statorand rear cover Note the posi tion of insulation washer so hat ensure it can assan ble ‘p its original position Disassemble the siatoi Disassemble the dicd ij Melt the soldering tin on stator coil and diode and disconnect diode fim stator Clamp lead—w ire u sing needle nose pliers for avoiding heat diode when melting the soHering tin RECN MM SRRAA (Great aang teal onbstin Engin Mneactring Company LitesMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE ‘Terminal bolt y erminal plate Figure 10—3 Disassemble the Inlegralial Circuil Adjuster Worn limit Disussan ble the Carbon B nish Stind a a ye ag Pigue 10—3-24 Disassemble the Rowr Slip R ing Maltimncter Slip ring 3-25 Check ifThere is Close Circuit Among Slip R ings as QQRERMABM EAM ZE ret Wa ating mera Conbstin Eng Manfactring Crary Linked Figue 10 Disassemble the integrated circuit adjuster assem be Melt the soldering tin on bracket p hte of integrat ed citeuit adjuster and disconnect diode fia integrat ed ciruit adjuster And then remove nut Disassemble the carbon brush stand (@ Disconnect the bolt and melt the soldering tin on integrated cireuit adjuster (® Do notdisconnect the bolt unless rep hee car bon brush or capacitance (3) Assembling sequence is reverse to disassamb ling sequence, Check and Repair It is necessary ib repair or place the parts if you find heavy.wom or danaged during checking ( | } La Rotor ! (D” Check” if the surface of itor slip ring has been polluted and has rough place Polishing it using 500° ~600" sand paper if there is mugh place (2) Measuse itor slip ring diameter Replace it if the diameter exceeds prescribed limit See Figure 10 3-24 Dimeter of mor slip rhg (3) Check if there is close cireuit among rotor ip rings (see Figure 10 —3—25). Replace nay one if there is open circultCHAPTER 10 ELECTRIC SYSTEM Multimeter Slip ring Figur 1-326 Check if There is Close Circuit Between Slip Ring and Rotor lion Core or Between Slip Ring and RowrShatt Clip ring A. Roller bearing Splines ” Figure (0¥3 420 /Cheek Rear} Roller Bearing Mut rotor Leud-wire Figue 10 Multimeter Figuie 113-29 Check StaiprCoil (4) Check if there is close circuit beween slip ring and lor in core or between slip ring and rolor shaft See Figure 10 —3 —26 Rephce wtor assembly if there is close cireuit Rear Roller Bearing (D Check if wller bearing can mun smooth and without noise Repke new roller bearing if the roller bearing cannot run snooth or wit noise (2 When install the wlerbearng the clip ring should be pressed inlowith bearing inner ring and the clip ring faces splines end See Figure 10-3 —27. Distance ) fr pressing the wller bearing r Standard, (* 8 mn Stator Coil — 7 — 7 () Check if there is close circuit anong every phase, See Figure 10 —3—28. Replace the stator if there is open circuit (2) Check if there Is close circuit between stator coiland iron core See Figure 10—3—29. Repke the coil if there is cbse cinuitMAIVTENANCE MANUAL OF GW2.8TG ‘TURBO DIESEL ENGINE Multimeter Figure 1-330 Check if There is Close Circuit Between Tem nals U, ¥; W mean the load=wire terminals ‘of stator el yoy a Ty dae Diode () Check if them is close cireuit among temi nals (forexample BAT and U). See Figure 10-3 — 30. If here is close cireuit the diode is good Rep hee the diode if there is open ciruit (2) Test with reverse pole If there is open cir cuit the diode is good Replace the diode tmely if there is close circuit at any point (3) Secondary diode hasnt tem inal therefre close cireuil test usually is mplanented between wo ends of diode, Diode negative end “— check ing Connecting end Detecting need 4 ofmultineter eee Positive end . Positive end Open eireuit UVW, Negative end | Close cireuit => Battery Current direetion Fine ig8-7'3n/ Check Diode Figure 10 —3—32 Check Caiben Brush ue C0008 jen 12010 7 3000 .S0V) Battery (12V*2) Figue 10—3—33 Check Integmied CiruitAdjuster Diode positive end “+” checking Connecting end E (negative end “—" diode) Detecting need ofmultineter | Positive end |, Negative end p i Close circu it” Positive end, [1 “Negative end | Open cireult Carbon Brush Measure the length of carbon brush. See Figure 10 “3-22, Length (L) of carbon brush Standard Lint 20 mm 6mm Thee Sa tansverse Tie on the brush means use jimit Integrated Circuit Adjuster Testing instuments are required Figure 10 —3 — 33 shows the connecting instu mentand inplanent flkwing measurment please V, is the volige at BATI —stndart TTS Ves he wolage at = Standard Linit 2V orless QV ormor aus QRERMMBM SARA ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER 10. ELEGTRIG SYSTEM Disconnect “S” tem inal and test it Vy is the vollage al BAT! —BAT2 Standard 20 ~26 V (D Use variab eb sistance and measure the volt age atE—F when change the sistance fm ze grad ually ‘Then check if the voltage increases fium 2V to 10 ~1BV. Repke the adjuster if voltage is discontinuous at discretionary point () Vj is the measured voltage between the mid dle tap varhble resistance and “E” tem inal when do not change the resistance 14.9V Standard voltage at20C 8 ) 14,0 Rephce the adjuster if the measured voluge is de wep RSS parture with standard \u eRe Figure 10 —3 — 34 shows the connecting instu mentand inplement follow ing measurement please ——— Use-vatiab lo-resistance Rv and measure the roll P|) \ ain TS | vq ltige [bepween| “8” teminal and fE* tem Ral when “he tease the msistance Ry gradually. “Cheek if the volt age increases fim less 2V to the mange of 10 ~13V. Battery (12V%2) Replace the adjuster if the voltage is changeless —— Do not change the resistance and measure the voltage between the middle tap variable resistance at CI ” Figure 10334 Check Integmted and “2” tem inal Ciruitadjusier Standard voluge at20C 8 ) 145~169V Replice the adjuster if the measured voltuge is de parture with standard Vacuum Pump 1) Check Check the wom damaged or otherabnomal status of vacuum pump housing blade and one—way valve Rotor Disassemble the Vacuum Punp Disassembling of central plate blade and rotor ime 10—3—35 Check and Disassemble See Figure 10 —3 —35, Vacuum PumpMAIVTENANCE MANU Ficur 10—3—36 Measure the Bore oft ousing Acad Bend Feu 103-37) Cliegk Qfe—W uy Valve Figure 10—3—38 Assenble the Vacuum Pump Figue 10—3—39 Assemble the Carbon Bush Stand Assembly 350 fee te DA a is ret Wong ner Combustion Ege Mnetecting Cn AL OF GW2.8TC TURBO “DIESEL ENGINE Housing Measure the bore of housing rpkee it if the measured bore is departure with standard See Figuie 10 —3 36. Bore 4) of housing Standard 57. 0~57. 1mm Bhde Measure the length of blade @) Standard 4, 42. 0 mm Check One—W ay Valve (2) Slight press “B” end of one —way valve by screwdriver and check if the valve can work smoothly or not (2 Input compressive air at 98~490 kPa inw “A” end of one—way valve and check if the valve leaks or not See Figure 10-3 —37. ‘|| BA Reassanble the Vacuum Pump * (Dy Locatetor at-central plate” and trousing at the case that the spline is upwarl Align the holes of central plate and tor (2 Install blade into rotor gmove See F igure 10 —3—38, YY Attention: The chan frend of bade should be upward (3) Instill the cental phite and O —seal ring *) Reassanbling Reassamble the carbon brush stand Reassamble the integrated cimuit adjuster assan bhi () Use carbon bush stand Srhold carbon brush and melt ead—w ire See Figuie 10—3—39, ER Z ol a LinedCHAPTER 10 ELECTRIC SYSTEM Connecting plate (2) Place integmted cimuit adjuster on catbon bush stand and press bolt inside Isolation tube and connecting plate should be installed when pressing bolt inside See Figure 10—3—40. Figure 1-340 Assemble Integrated Circuit Adjuster A ssenb ly Reassamble the dioddi Connect tem inal using fixed rivet at plac) and melt the tem inal at placd2). See Figuie 10—3—41, Rigyre 10 3-d) \/Assen ble Diode Figure 10—3—42 Assamble Stator \) Reasdemt le the staid \ ~~ Chimp diode lead wie using meéd le imose plies and finish this tisk as quick as possible when melt the connecting lead —w ire between stator coil and diode for avoid ing the heat transfer to diode Reassamble the rar covet) Reassanble the tem inal bolt and nu®) Reassanble the rear bearing?) Reassamble the wto® Use coppemlate encasing the pliers mouth and then ckmp rotor tightly by pliers Tighten pulley nuts lo prescribed torque ®\ Tighten tomue Br pulley fixed nuts 90 Nem Figure 10—3—43 Assanble RorMAIVTENANCE MANU AL OF GW2.8TC TURBO “DIESEL ENGINE Reassamble the statorand rar cover assemb Reassamble the wtor and front cover assanb Reassmble the through bol) (D For centering aligment insert a leader through the hoks of front cover and rear cover flange and then in stall thmugh bolt (2 Tighten though bolt to prescribed wre See Peur 10-344, Tighten lorjue for tough bolt of generator Figue 10—3—44 Reassemble Tighten tomue Figure 10—3—45 Reassembe the Vacuum Pump 35N-m Reassamble the lead —winé3) Reassanble the vacuum pung) (1) Install the housing on genemor by thre bolls Fill in oil (about5mD though filler mouth and then check if the generator pulley can opemte smoothly ornot @ tomjue ighton fixed bolt of vacuum pump tp prescribed = = = SNe i 7 Fill in oil Cabout5 mD through fillermouth and then check if the generator pulley can operate smooth ly or not Lubrication oil (oib: grade C1—4,CHAPTER 11 EXHAUSTING SYSTEM CHAPTER 11 EXHAUSTING SYSTEM 11,1) Summary \Y Attention Exhausting systm assembly must has enough distance apart flan vehicle under body to prevent the overheating of base plate boliam and the damaging for passenger body heat insu lation and decomtive materials When check or replace exhausting syst assanbly please ensure that the exhausting systan as sanbly must has enough distance apart fmm all places of vehicle underbody i prevent the ove heating of base plate bottm and the damaging for passenger body heat insulation and decomtive materials Check whok exhausting systan, nearby bodywork exterior and rear body cover fr ensuring if there is bmken, damaged parts lose or dislocation as well as the damaged caused by disjoined dint eyelet loose connection or other reasons leaking exhaust gases into rear body or passenger body. There maybe same prob len within these areas fiultmust be rmoved immed iately. ‘The detailed stmicture of exhausting system depends upon the vehicle type the structure of the vehicle and then adopt pertinence measures, you find rear body has dust orwater Any you shoull know Fee T—SREU OT EXMAUSINE SYSIM CONF WOT ETAT 11.2 Repair in the Vehicle The cause of knock ing and vibrating noise of exhausting systan usually are thal parts have not been cent! aligned, W hen adjust exhausting system, loosen all bolts and nuts until all parts have been centml aligned at first and then tighten all bolts and nuts fram fmnt to rar B] lens to Inspected (1) Check the joint if there is loose or damaged, especially if there is exhausting Pakage (2) Check the grip and mbber if there is disfigurement cmck ordanaged (8) Ghee the cabnremrhant meulition vis ‘any pareedanaped orearane will aed wie position of activatoy imp laent repair or replacanent timely pleasa (4) Check if them is concave or damaged, aswell as eyelet or crack caused by cornup tion. GR TES ik 7 aD is FSB ‘Great Wa Banding itera Combustion Engine Marfactving Company Lintee = 353MAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE 1.3 Front Exhaust Pipe Disassembling sequence DFixed nut of front exhaust pipe @ Fixed bolt for installing bracket of front exhaust pipe @ Fixed bolt and nut of front exhaust pipe @ Front exhaust pipe ©Mutiler Assembling sequence © Exhaust tail pipe Assembling sequence is reverse to disassembling sequence. Pigue = D isassemb ling and Assanbling Sequence for Pmnt Exhaust pipe **| Disassanbling Preparation D isconnect ground ing cable of battery. Disassemble the fixed nut of font exhaust pipd) Disassemble wo fixed nuts fim the connecting Place between intake manifold and front exhaust pipe 7 See Figure 11-3 —2 Fron: exhaust pipe Disassemble the fixed bolt for installing bracket of front exhaust pipé2) Disassemble the fixed boll and nutof font exhaust Figure 11—3—2 Disconnect Fixed Nut pips) of Front Exhaust Pipe asa (FE EC I ME a SO ret Wa ating mera Conbstin Eng Manfactring Crary LinkedCHAPTER EXHAUSTING SYSTEM Figure 11-33 Disassemble and Assemble the Mufler Exhaust tal pipe Figur 11—3—4 Disassemble and Assemble the Exhaust Tail Pipe a! wr = \ Installing bracket Front exhaust pipe Figure 11—3—5 Assamble Both the Fixed Nut of Front Exhaust Pipe and Fixed Bolt of Installing Bracket Disassemble the finnt exhaust p ing) Disassemble the front exhaust pipe and pul away nearby, See Figure 11 —3—2. Disassemble the muffle) Disassemble the fixed bolt for hoop and then d isas semble themuffler See Figure 11—3—3 Disassanble the exhaust tail pip) Loosen the fixed bolt for hoop and then disassen ble the exhaust tail pipe See Figure 11-34, *¢ Assanbling Assanbk the exhaust til p ip Assanbk the muffle) Assanbk the fiont exhaust pipe) Install the fiont exhaust pipe on the exhaustmani fold. See Figure 11—3—5 Assanbk the-fixed bolt and nut.of fiont. exhaust, (Pe ' Ce AV " Tighten the fixed bolt and nu tof finn t exhaust pipe ‘To prsefibed brjue See Figure 11—3—5, ~ |) Tighten torque dr fixed bolt and nut of font exhaust pipe 50 Nem Assanbke fhe fixed boll for instilling bracket of front exhaust pipe) Tighten the fixed bolt for installing bracket of fiont exhaust pipe to prescribed torque See Figuie 11—3—5, EX Tighten tomue for fixed bolt for installing bricket of fiont exhaust pipe 40 N+ m Assanble the fixed nut of front exhaust pipél) Tighten the fixed nut of front exhaust pipe to pre scribed pique See Figure 11—3 —5, Tighten wmue wr fixed nut of front exhaust pipeMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE out Bliow ing works a fier assam bling () Connect ground ing cable of battery See Fig ur 11 —3—6. (2) Starting the engine to check air leakage at each connecting position after assembled all parts and ensure that the assanbly is correct Figure 11—3—6 Connect the G rund ing Cable of Battery Gir Reference)APPEM DIN. APPEMD IX Canmon Metric Unit Conversion Table of Engine Engneering unit Tegalmetnc unit lien Code nane Name Symbol Nane ‘Symbol Lb | Kibmewr ten Kilometer in Meter m Meter m Length Centineter om Centineter a Millimeter om Millimeter om Micon um M icron am S ‘Square meter m Square meter m Ara Square centimeter om Square centneter gy’ Squaremillimewr | mm Square millinetr pyyn Vv Cubic meter m Cubic meter m Cubic centineter on) Cuble centimeter | gn’ ee Cubiem illneter mn K ilo litre KL (kb Lite La Lite Lay M illilitre mL m) eA tee a Tor, tT ‘W'e tht & igram kg! ) K dlogrwm Tbe: | Ginn e nm ag NS ANS Fore Kibgrm fre kat Newtn N kg ikgf=9, 81N 8 Tkge m/s=1N Pressure P K igram /square kef/an® Pascal Pa centmete Nt =1Pa Ikef/or’ =9 81% 10° An Moment M | Kibgnm five kgm | Newtnmeter Nem meter lkgf+ m=9 81N+ m Wonk A K ilgram foes kgfin Jou le J meter Kilowetthour |W +h IN+ m=1J kgf m=9 81d Gabe Q | Kib calorie eal TW © = Oxia 1iJ= 1000 3 Ikeal=4 187 kJ Power N | Metic hone paver | PS Wat w K ilowatt AW IN* m/s=1d/s=1WMAIVPENANCE MANUAL OF GW2.8T6 TURBO DIESEL ENGINE Continue) Engheerng unt Tegalmetric unit Item Code name Nane Simbol Nane Sim bol Tanpe t Centigrade e Kelvin K mire Fehrenheit Centignde c TC =1K 1 =0 556K Voltage u_— | Kibvolt kv Volt v Volt v Current 1 Ampere A Ampere A M ili pee mA Speed of ® Revolution im inure | rain Revolution per | rfmin rotation minute Revolution /second | r/s Irfnin= (60) 5 Speed V | Meter/seeand m/s Meter per second | m/s Spec if g G iam forse & PS h | Gam per gxW sb fiel pavers hour kilow att hour cons mption “Tine t Hourth) a [Hour hb , Minute é in mooi) -M inate mh Serond (9 ‘slvee) [] Second’ af / Power ny "| Paséal ' Pat s ~—|"Pascutsécund” — = = vise ity Poise P IP=0 1 Pas s Ikgf sin’ =9 IPAs s Khnenaie Stokes St Square meter per viscit ity Squarmeterper | m/s second second Centisioke est

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