MA NTENANCE MANDAL OF GW 2, 8TC TURBO —D IESEL ENG INE Edited by Research and Development Center of Great W all Baoding Intemal Canbustion Engine M anufac turing Company Lim ited GreatW all Baod ing Intemal Combustion Engine Manufacturing Canpany Lin itedMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, BRIEF NTRODUCTION The main technical pammeters troubleshooting maintenance dis mounting adjusment repairand 0 on of GW 2, 8TC turbo—diesel engine are detailed introduced in thismanual It can be used as working basis for fhe maintenance workers and repaimen of the tubo—diesel engine MANTENANCE MANUAL OF GW 2. 8TC TURBO —D IESEL ENG NE Edited by Research and DevelomentCenter of G rat W all Baoding intemal Combustion Engine Manufacturing Com pany Lin ited Books Editoria| Deparment of Auttmobila Chinese Acadeny of AgricultumIM achinery Sciences (CAAMS) (Add | Bebhatan Deshengnen Wai BEUING® Post cade 100083) Tel 86—10—GIS82616 + E-mail qetb}@ 163 am Copy Editor GaoHai English Trnsltoe W ei Deshi Drawn and writen by Books Editorial Deparment of Autmab il CAAMS FomatDesiner Xu Limyin + CoverDesimer Yu Suying ComputerCampositins Luo jan + Computer D whe Huang Q isheng Printed in Beijing Ded i Press ook siae 880mm x 128mm 1/16 + Paper weauinek 23° W ‘The 1s Fallon, Nowh 2007 Beling » The Ist Publisied, March 2007 Betine CAAMS—1034—92/G + 346—QC —07 ~03—600, 00 | QFRBSwASM BSE ZaMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, PREFACE GW 2, 8TC turbo—diesel engine is a product developed based upon the GW 2, 8TDI turbo—diesel engine Apart frm Sliw ing chamcteristic such as lower noise better econo my starting quickly at lov temperatura excellent perfomance both at high and at low speeds lightweight campact and high reliability this type turbo—d ese! engine also has mor powerfull efficiency and achieve the standard of Euro III an ission GW 2, 8TC turbo—diesel engine adopts CRS 2. 0 high—pressure fue! rail fuel supply system fam BOSCH Canpany ofGemany. This fuel supply system consists of various sen sors ECU, various actators and connecting hamess The fuel supplying pressure of the system is 145 MPa and BOSCH EDC16C39 type electric control unit (ECU) will autamati cally control the fuel— supplying course Apart fan direct contolling relevant actuators within fuel supply system, ECU also contiols other systems work ing course such as EGR system, air-conditioner system, electric fan system and so forth concemed the operation of diese engine GW 2, 8TC turbo—diesel engine mainly used on light tucks pick—up, SUV, can mercial vehicla light bus and themechanisn w ith diesel engine as power GW 2, 8TC turbo—diesel engine is a power—mechanism with modem advanced tech nology and complex stuctur. Therefore more strict requirments for the coordinate anong materials \technobgies and the various assortative parts are needed,_and mow higher levels of operation maintenance and |repair ate also needed correspond ingly] BMA NTENANCE MANUAL OF GW 2 8TC TURBO —D IESEL ENG INE#fis a campre hensive manual for diesel engine maintenance and it collects follow ing contents such as the main technical parmeters disassembly, assenbbs adjusment detecting troubleshooting and soon of GW 2, 8TC wibo—diesel engine Read thismanual carefully and mplenentev ery reguktions in this manual strictly so as to you could eam about trouble diagnosis trou bleshooting maintenance and repairmethods of diesel engine to ensure that the engine after maintenance can be at op tinal work ing status and arrive ideal index of pover and econany. Sane contents concemed with vehicle and mechanica | chassis or the parts offered by ve hicle factory and mach ine manufacturing enterprise in the process of maintenance, pair and tioubleshooting ad the maintenance manual of assanbled vehicle and machine please For your life and property safety, you must strictly read and mplanent the safety part in this manual while using and operating this turbo—diesel engine. Inportant safety items must be observed strictly. Ifyou do not observe than, may cause your lit injured orengine damaged and even very dangerous In this manual “waming” means the danger thatmay damage human—body “caution” means the danger thatmay damage the enging and “at tention” used tomean the mportnt infomation but without danger Follow ing the requirement and changing of the market GW 2 8TC ttbo—diesel en gine will also be improved continuously. Please notice that the inprved operation and ma intenance content will be added and corrected in republished manual Please understand that we would keep the changing right on aspects of diesel engine supply mnge equipment and technology. U sets cannot require others accom! ing to the dat illusttions and explanation in thismanual The changing of diesel engine supply range REKM AMM eA EL) Banting interralConbuston Engine Manuactring CompanyMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, equipmentand technology is without notice In order to mprve our products and perfect the operation and maintenance technolo gies we hope our users and readers could reflect your op inions about the quality perfym ance and stricture of GW 2, 8TC tibo—diesel engine as welll as its operation, maintenance and repair experience to us Our address ig GreatW all Baoding Intemal Combustion En gine Manufacturing Campany Limited, Develomment Zone D ingxing County, Hebei Prov ince China Post coda 072650. Because thismanual deals with comprehensive content and the ed iting tine is lin ited, there 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 direct or indi rect responsbility for the loss caused by using this manual G watW all Baod ing Intemal Canbustion Engine Manufacturing Con pany Linited es tab lishes special repair stations passin. U sers can handy consultwith and gain service after sale frm the station for yourmaintenance trouble orwhen you need techn icalma intenance troubleshooting repair or replace parts. W ithout pem ission of G rat W all Baoding Intemal Canbustion Engine Manufacturing Company Limited, anybody cannot copy and republish thismanual in any for G reatW all Baod ing Intemal Combustion Engine Manufacturing Campany Limited would reserve all right about copyright wgukkted in law, keeping changing right and explaining right All right reserved, GreatW all Baod ing Intemal Cambustion Engine M anu fae tring Company Linvited June 16, 2006 WV GS REEMA Bi Bis Fe? aMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, CHAPTER 1 TECHNICAL INFORMATION OF THE DIESEL ENG INE The Camponent of the D iese| Engine- 1 1 1 1 1 1 1 1 1 l 1 2 1 1 1 1 1 3 4 i 1 1 1 1 1 1 5 6 1 1 ae ee Re aoneen 6 6 1 1 1 1 1 6 1 Ne er ease 9 The V iew of the Diesel Engine «+--+ Characteristic Curve of the Diesel Engine CONTENTS Cylinder Head and Cylinder Block Crank and Connecting—Rod Mechanism ValveMechanisn and Intake /Exhaust Systan Turbo—Cha rging System +++ Fuel Supply System Lubrication Systan Cooling System sss seers Starting Equ ipment EGR Systan FrontV iew of the Diese Engine Rear V iew of the Diesel Engine- Left View of the Diesel Engine - Right View of the Diesel Engine +++ Vertical V iew of the Diese] Engine ‘Techn ical Parameters and Specifications ofthe D jese | Engine *++++of+ yest rte 1 Maintenance Standard Technica! Parm eters of the Engine -- Tightening Tonue of Main Tighten Parts of the Engine Main Adjusting Data of the Engine s+sssssseesseeseeeeseesteeeeeeeneenane eee The Range of Various Tanperature and Pressure of the Engine Main Fittings Specifications of the Engine Main Parts Specifications of Fuel Supply System of the Engine s++++++++++ Main Parts Fitting Clearance and W ear Limits of the Engine Techn fea Mita arionampetcesrsreetreartsrsneetecsmeceerssessrernesramecrstemeenseerecetey 1 eeaaaae Technica! Maintenance Period Technica! Maintenance Contents 1 Daily Technical Maintenance-+ +--+ The FirstG mde Techn ica 1M aintenance The Second G mde Technica Maintenance The Third G rade Technical Maintenance ++ Season Technical Maintenance ++-+++++++++e++serseresrons ceseeseesanenen cee Technica! Maintenance of Air Filter 3.1 Maintenance of Oil Bath AirFilterW ith Inertia Steel W ire V illus Pilon nent 3 2 Maintenance of Air FilterW ith Paper FilterE lament « Technica! Maintenance of Fue! Supply System + 4.1. TechnicalMaintenance of Fuel Filter s+++++s+sssseseesseseseeeesen eee 4 2 Dminage of the Fuel Systan - Technica! Maintenance of Lubricating Systan Ge TE te IN PA A is SB Zl Great Wall Baoding Internal Combustion Engine Mansfacturing Company Limited NNN oN NN a) a) a a) a) a @) @) @) (@) @) «@) @) ) «s) (6) @ (8) «9, (a) ap ap a2) a2) a3) a3) as) an an aa) as) ep ap ep 22) 22) 23) 23) (23) (23) a) (25)MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 16 5 1 Choose Lubricating 0 il 25) 1 6 5 2 Oil LevelM easure ses seeeesesreeeceersseesereee ceeetseeresseecesterrereeers (25) 1 6 5.3. Replace OX Oil and Use New Oil 2) 1654 Technical Maintenance of Oil Filter - + 26) 166 Technical Maintenance of Cooling Systan ++ + @D 167 TechnicalMaintenance During Storage - 28) 16 8 Attention Points forTechnical Maintenance (28) 1-7 Running— In of Diesel Engine vss eeeeesseee 8) 17 1 Preparations Before Running— In - 8) 172 Running—in + 29 17 3. Attention Points During Running— In s+s+s+ssessscsssersesseeeseesseeessessees (29) 174 TechnicalMaintenance A fter Running In 29) 175 Attention Points forNew Vehicle Operation 30) 1 8 Maintenance Treatment vss tsssseeeeeseeennsees BD 1 8 1 Model Symbol BD 182 AirFilter BD 1 8.3. Lubricating System sess sere eee + G2) 184 Fuel System » (33) 1.84.1 Rephcing Process - @3) 1.84.2 Dminage Process of Fuel Filter @3) 1,8 4.3 Air Remove Pucess for Fuel Filter -+++++ teseeeeeeeseeseesees (3d) 185 Cooling Systan @4) 1, & 5.1 CookntLevel + GA) 1\8, 5/2) Cheek of Cooling Systems *+4++y soe sofort enn BB) 1. 815.8 | Check of RadiatorG uae + G5) 1-8 54 “Testing of The mostat Action + 5) 1.8.6 Transm ission Belt erssss+0sserseeereee eee sree (36) 1.861 Altemator Transm ission Belt - en 1. & 6 2 AirConditioner Canpressor and PowerSteering Pump Tansn ission Beltervessseessseeessssescessessteseeserssseeessseescansssessresersnsesssneesses (37) 1.87 Diesel Engine Control en 1.87% 1 Check Kling Speed + 6D 1.8 % 2 Adjusment of Valve C earance sss vss cernesenneerens (38) 1,8 7% 3 Measumment of Canpression Pressure (39) 1.8.8 Fast Starting System - 40) 1.9 Tightening Torque sssesessesessssecsersesconensees eeneneteeneteereee een) 1.9.1 Valve Bonnet Unit Cylinder Head, and Rocker Shaft Stand ap 1.9.2 CylinderBiock Assembly - 42) 1 Crnkshaft Main Bearing Housing Connecting Rod Cover Damping Pulley A ssamb ly Flywhee] 0 il Sump v++sereerresseseeseeeeeeceeseseeneereer ces (43) 1.9.4 PulleyChambes Camshaft Tim ing Pulley Transition W hee! Unit Tensioner Unit Timing Pulley, Camshatt0 il Sealing Seat - aa) L Cooling System (Fan, WaterPump Pulley W aterPump Pulley Chamber CoverA ssmb ly Themostat housing) 45) 1.9.6 Lubricating Systm ( il Filtey O il Pump, Injection Pipe W eldment and OilSump) sserseessereseesesensen see ssscsneeseessnesssssveessnesseesseneeseee (46) IntakeM anifol, ExhaustManifold Exhaust Tube - an Electric Systm Gener StarterAssamb¥ and Preheating Plug) 48) VL @eECURUMNEGR ZS Grea al Beedig internal Conbustion Eine Manfactring Company Lined xMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 1.9.9 Fuel Systm (igh Pressure Fuel Pump and H igh—Low Pressure Fuel Pipe Assamb b) (49) 1.9.10 Exhaust Recycle Systan ++ (50) 1.9.11 Sound Insulation Board Assambly and C btch Assembly GD 1.9.12 Turbocharger A ssanb ly (2) 1.9.13 Diesel Engine Support Assembly (3) 1.10 Special Tools and Instumen (4) CHAPTER 2. TROUBLE DIAGNOSIS AND TROUBLESHOOTNG (56) 21 Troubleshooting: (56) 2.1.1 Diesel Engine Cannot be Started GD 2.1.2 Diesel Engine Starts Difficulty at Lov Tanperature (58) 2.1.3 Diesel Engine W ith Insufficient Output Power (58) 2.1.4 Diesel Engine Has Too Much Fuel Consumption (60) 2.1.5 Diesel Engine Running W ith Unusua Noise (60) 2.1.6 Diesel Engine Has AbnomalNoise 6D 2.1.7 Diesel Engine Exhausts Gas with Unusual Cob (61) 2.1.8 Diesel Engine Lubricating Syston Has H igher 0 ilConsumption and Low Pressure (3) 2.1.9 Diesel Engine Cooling System Has A bnomal Cooling Temper ture and Lack Liquid (4) 2.1.10 Diesel Engine Tutbo—Charging Systm Trouble - (65) 2.1. 11. Diesel Engine Fuel System Trouble (66) 2.1,12\ Diesel Engine W obbles at idling (68) 2.1. 13° Diesel Engine W olks atH igh Idling ~ (69) 2. 1.14~ Starter Cah Not Run Starts Powerless and W ith Noise 69 2.1.15 StarterW orks ButD iese| Engine Cannot be Running ao 2.1.16 Diesel Engine Can be Running ButCannot be Ignition to Start- oan) 2.1.17 Fast Starting Syston Fau lt Causes D ifficult Starting - ap 2.1.18 Diesel Engine Flameout ButCan be Started Again (72) 2.1.19 Generator Runs W ithout Output Insufficient Charge and Too Large Chauging Current (73) 2.1.20 Battery Capacity is Insufficient Starts Difficultly Self—D ischarges Excessively -- (73) 22 Trouble D agnosis (75) 2.2.1 Trouble Diagnosis Or Starting System - (75) 2.2.2 Trouble Diagnosis or Turbo Charging System (78) 2.2.3 Trouble Diagnosis r0 il Leakage of Tuibocha wer: (80) CIAPTER 3 MECHAN CAL SYSTEM (83) Al CylinderHead -- (83) & 2 Rocker Shaft Assen bly- a (89) 33 Vale Spring Valve Stan OilSeal Valve Guide Push Rod (92) 34 Camshaft and Tappet 00) &5 Crankshaft 108) 3.6 Piston and Connecting Rod A ssanbly 24) &7 OilPump Assembly (132) &8 Cylinder Block (136) QRWANAsawza GreatMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, CHAPTER 4 GW 2, 8TC TURBO —D IESEL ENG INE 4 4. 4 4 4 4 4. 4, 4 4. 4 4 4 4 4 4. 4 4 4. 4, CHAPTER 5 . FUEL SYSTEM, ~ 5 a CHAPTER 6 COOLING SYSTEM 6 1 2 3 4 5 6 7 8 9 10 rn 12 13 14 15 16 17 18 19 20 1 1 Summary + Engine Assembly Engine Bracket Intake Manifold ExhaustM an ifold Valve ChamberCap Rocker Shaft Assan bly Vale 0 il Sealing R ing and Valve Spring Cylinder Head Assembly and Gasket Tining Pulley Oil Filter Assan bly F whee! and Front Bearing of Transmission 1% Shaft Oil Pump A ssamb ly Oil Sump Assanbly Canshaft and Tappet Piston and Connecting Rod Assembly Front 0 il Seal R ing of C mnkshatt + Rear Oil Seal R ing of Crankshaft ~ Crankshaft and Main Bearing Cylinder Block Assembly ++ Summary ++ 1 \ High >Pyessure Fuel Pump » 2 Fuel Filter and Fuel—W aterSeparator + 3 Injecbr H igh Pressure Fuel Rail 5 Sensor 1 1 1 1 1 5.1 Hull Effect Phase Senso: 5.2 Heat—Fim Type A irflow Rate Sensor I. 5. 3 Engine Speed Sensor - 3 L 5. 4 Cooknt Temperature Sensor 5 PotentimeterType Foot Pedal Position Sensor + .6 Electric Contwol Unit (BCU) .7 Engine Hamess Repair in the Vehicle - 1 Fuel Filter Assembly Filter Ekment of Fuel Filter Injector--- H igh —Pressure Fuel Pump Assembly Fuel Tank -* Fuel Liquid Level Indicator Election Accelerator Pedal « ween no Summary «+MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, WaterPump Themostat Radiator 4 Antifreeze Repair in the Vehicle - Parts Repair 3.1 WaterPump 3.2 Themostat 3.3 Radiabr Adjustment of Transm ission Belt~ 4.1 Check and Repair 4,2 Belt Tension Adjustment -- ReNe a PPegagwen CHAPTER 7 LUBRICATION SYSTEM - 71) Summary + 7.2 Repair in the Vehicle - 21 OilFilter 2.2 OilPump 3 Oil Sump Assanb ly Repair Single Part 3.1 Oil Filter 3.2 OilPump 7. 7. 7. 7 3 7. 7. CHAPTER 8\, TURBOCHARG NG SYSTEM & 1 \ Summary ++ 82 “Repair in the Vehicle ~ & 3 Check and Repair 8.3.1 Check the W orking Status of Exhaust GasesM ou th 2) Check the W orking Status of Turbocharge: 3 Measure the Impeller Shaft A xial C learance 4 5 Measure the Rotor Axial Clearance -- Measure the Impeller Shaft and Bearing C learane 6 Measure the Rotor Radial Clearance CHAPTER 9 EGR SYSTEM 1 Summary + 92 Repair in the Vehicle + CHAPTER 10 ELECTRIC SYSTEM 10.1 Battery oa 10.1.1 Battery 10. 1.2 Electrolyte Canpound 10. 1.3 Battery Charge 10. 1.4 Detect the Capacity of Battery 10.2 Starting System 10.21 Summary 10.22 Repair in the Vehicle 10.23 Repair Single Part -- (280) (280) (280) 281) (282) (287) (287) (290) an) (294) (294) (294) (295) (295) (296) (296) (298) (302) 306) (306) (306) (310), (310) BID B14) (315) 315) B15) (316) 316) 316) BID BID 319) (322) (322) (322) (322) (324) (326) 327) 327) (328) (330)MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE 10.3 Charging Systan- (338) 10.31 Summary (338) 10.32 Diagnosis (338) 10.33 Repair in the Vehicle (340) 10.34 Repair Single Part « (344) CHAPTER 11 EXHAUST'NG SYSTEM (353) HW. 1) Summarys 11, 2. Repair in the Vehicle 11. 3 Font Exhaust Pipe (354) APPEMD IX fe TE KK Mit 0 Bt A BIS SOR AS Greta acing tral Conbstin Engin Mandfacting Company inedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE CHAPTER 1 TECHNICAL INFORMATION OF THE DIESEL ENG INE 1 1 The Canponent of the D iesel Engine Diesel engine is a kind of camplicated machine that can transforn themal energy intomechani cal energy. Although there are various types of diesel engine that have different stucture in detwil ‘hey all inchide follovingmechanisn and systems 11 1 Cylinder Head and Cylinder B lock The function of cylinder is 0 close the upper side of cylinder and foms the cambustion chanber with the upper site of cylinder and the tp of piston There are intake valves exhaust valves am wckers and injectors mounted on the cylinder head Thee 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 are a lot ofmechanisn and systmsmounted on the cylinder b bck 1 1 2 Crank and Connecting—Rod Mechanisn The crank and connecting— rod mechanisn can transit the recip wcating motion of the piston in ‘he cylinder into the rotational of the crankshaft ie itcan transit the pushing force on the piston by-bu med gas into tational torque of the crankshaft it can-also tansit-the wtationalmotion of the crankshaft into thé eeiprocating motion off the piston) i/e/ it trnsit-the mtational /wigue of the crankshaft into, he push ing /foree to the piston” so that it can make ‘he dieséliengine achieving cycle of operation with output by crankshaft The crank and connecting md mechanisn is mainly formed by such camponents as pistons connecting mds crankshaf’ flywheel ete 113 Valve Mechanisn and Intake /Exhaust Systen The function of the valve mechanism and intake /exhaust system is to open and close intuke valves and exhaust valves in tine guarantees more fresh and clean air could be absorbed into cylin der in time so that exhaust gas could be pushed out of cylinder in time asmore as possible The systam is mainly fomed by intake and exhaust valves tans ission mechanisn (such as drive gears cam shaft tappets push mds mcker shat? am wcker®, air cleaner and intake /exhaust ports In the air intake /exhaust systan, the EGR valve is equipped which being used to re—cyck fhe exhaust gas in this way the NOx can be contlled efficiently. 114 Turbo—Charging Systan The function of turbocharging systan is to use the energy of exhaust gas to compress the air cam ing fram air filter trough the tuibocharges and then send the campressed air into the cylinder Although the volime 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 fuel in Jected into the cylinder can be bumed campleteh; and then the output of the engine will be in creased. Usually turbocharger consists of air in ake /exhaust systan and exhaust— gas turb ine— char ging systan etcMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 1.1.5 FuelSupply System The function of fuel supply system is to inject fuel into chanber regularly at fixed ting fixed quantity and fixed pressure according © the working condition of the diesel engine so that providing favomble cond ition for ensuring the diesel fuel could bum campletely At the same tine the fuel supply will be adjusted autanatically by electric control unit (ECU) according to the load of diese! engine ensuring the speed of the diesel engine constantly. The fuel supply system mainly consists of fuel unk fitel filles transfer pump high—pressure fielpump, injectors high—pressure fuel mil high— low pressure fuel pipe various sensors ECU, various actuators connecting hamess ete 116° Lubrication Systan While diesel engine working the surface of crank and connecting md mechanisn and other moving parts w ill occur friction and create wear So the function of lubrication syste is lubricating moving parts surface reducing friction resistance and wear and tak ing off the heat ofmoving parts cleaning friction surface and seal the surfice The lubrication systan mainly inchides oil stminer oil pump oil filter oil mdiator ete 1 1 7 Cooling Systen The function of cooling system is to take off the heat fm the hot parts while the diese! engine working keeping the tempemture of diesel engine at nomal state Cooling systen mainly consists of water tank (mdiaiod, waterpump, themostat fan ete 11 8 Starting Equipment The function of the starting equ inment is to, tum the, diesel engine by outsite force fram” sti to nini ig) state/‘The) starting equipmentmainly inclidés starter battery (and other equipments 119 EGR Systan BGR system (i e¢ ExhaustGas Recirculation System) inducts suitab le quantity exhaust gas into intake manifold form ixing with fresh air to reduce exhaust enission contam ination NOx The dilute fresh air decreases the cambustion peak tempemture so that reducing the exhaust NOx Itmainy consists of EGR valve assambly EGR cooley vacuum regulator etc Asmentined above cylinder block cylinder head, crank and connecting — 1d mechanism, valvemechanisn and fuel supply systam opemted together direct camplete the work ing cycle of diesel engine and transit themal ene1y into mechanical energy. The technical cond ition of these cam ponents w ill directly affect the perfomance of diesel engine A Ithough the lubricating systan and cooling systan do not direct camplete working cyck of the diesel engine they are the necessary fac tors that could make diesel engine working for longer tine Moreoves the starting equipment pm vides the initiative condition © make the diesel engine munning fiom static stateCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 2. The V iew of the D iesel Engine 1 2 1 Front View of the Diesel Engine Figure 1—2—1 shows the font view ofGW 2, 8TC tusbo—diesel engine sm Figure 1-2-1 Front V jaw of GW 2. 8TC Tutbo—D ese! Engine 1—Damped pulley 2—Generiog 3—W ater pump pulley 4— Inspection cover 5—O il sump (Aum inun alloy) 781MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE 1 2 2 Rear iew of the Diesel Engine Figure 1—2—2 shows the rear view of GW 2, 8TC tibo—diese| engine Figue 1-2-2 RearV iew of GW2 8TC Turbo—D iese! Engine 1 —Cooling water conduit wekiment 2—EGR cooler 3—Cylinder head 4—0 il filter 5—Oil cooke 6—Cluteh assembly GRE ES It a iS SR Sl 4 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 23 Left View of the Diesel Engine Figure 1 —2—3 shows the left view of GW 2. 8TC turbo—diesel engine, Figure 1-2-3 Left View of GW 2, 8TC Tutbo—D iesel Engine I —High presse fuel pump, 2—High pressure fue! rail (cammon mid Intake manifoke 4—High pressure oil pipe 5—EGR valve assamb ly 6 —O il dipstick subassemblyMAINTENANCE MANUAL OF GW2.8TC TURD DIESEL ENGINE 124 RightV iew of the Diesel Engine Figure 1—2—4 shows the right view ofGW 2. 8TC tutbo—diesel engine 552 | Figure 1-2-4 Right V iew ofGW2. STC Tutho—D iese| Engine 1 Oil inlet pipe of usbocharges 2—Turbocha ger assenbh: 3—Camp essor holes 4—W ater inlet p ipa 5—Oil tum pipe of vacuum pump, 6—Oil retm pipe of turbocha wer GRE ES It a iS SR Sl 6 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER | 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—Diesel Engine | —Generioy 2—Intake connecting hose 3—Turbocharger assambly_ 4 —Exhaust elbow 5—EGR cooks 6—EGR valveMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 1 3. Characteristic Curve of the D iesel Engine Figurel —3—1 shows the overall pover test curve of GW 2. 8TC turbo—diesel engine w0 280 70- 260 g s é 3 S a 2 3 a 3 1000 1500 2000, 2300 3000 3500 in (eimin) Figure! 3-1 Overall Paver Test Curve of GW 2. 8TC Turbo—Diesel Engine ¢ —Fuel consumption rate (g/IWW + 1); G —Fuel consumption (kg/h): P —Effective power (kW ): Me —E fective tomue N+ m)CHAPTER I TECHNICAL INFORMATION OF THE DIESEL ENGINE 1.4 Technical Parameters and Specifications of the D iese! Engine 14 1 Technical Parameters of the Engine Main technical parmeters of GW 2, 8TC tuibo—diesel engine are shown as Table 1 —4—1. Table 1—4—1 Main Technical Parmeters of GW 2. 8TC Turbo—D iesel Engine Tren Unit Technical paemeters Model Gw2, sTc Inline 4—stroke water cooling electric controled ‘Type of engine high pressure fel conmon mild irect injection, tur bocharging Type of combustion chamber Quadrangle with shrinkage periphery and © ype Cylinder number a Cylinder bore mm 93 Piston stioke mm 102 ‘Campression ratio 2st Total displacement L 2771 Firing onier. i— 3— 1— Rated pawer/speed RW rn 7) +3 R600 Max Tonjue /speed Ne mm 225 £5 1600 ~2600 M in. fuel consump tion rate g/kWeh = 218 Idle speed rim in 800430 Max no— load speed r/min 4200 Max explosive pressure MPa 12205 May evans empenne c <700 Lubrication way Pressure and splash can pound lub rica tion Oil capacity (sump capacity) L 5.6 (When wash or replace oil filted Oil pressure of main oil passage kPa = 100 at idle > 441 at 2000r/m in Cooling Forced cycle water cooling Netweight kg = 240MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, The oil and coolant used by GW 2, 8TC turbo —diesel engine are shown as Table 1 —4—2, Table 1—4—2 Specifications and Technical Parmeters of O il and Coolant Used by GW 2, 8TC Tuibo—Diesel Engine Tan Technical paumetens ; 3) | © light diesel oil (choose —10" or —20°, —35" light diesel oil in winted Gride of fuel oil (accom ing t GB 252-2000) Gude of oi Choose class APICI—4 lubricant (oid accom ing to environmental temperature Cooknt Antifieeze and anti— mst cooknt The main parts technical parameters of electrical system of GW 2. 8TC tibo—diesel engine are shown as Table 1—4 —3, Table 1—4—3 Main Parts Technical Panmeters of E kectrical System of GW 2, 8TC Tuibo—Diesel Engine Tem Unie Technical pasmetes Model 12V 90A (with vacuum pump and inner regulatop Nam inal voltuge Vv 12 Rated current A 30 ng vo bee f Rated speed rin | & 000 GenemtorW oncing speed rimin | 900~11, 000 Rotating direction Clockwise (see fion fiont t rea Pole Negative pole ground ing Working style Continuous rated style Regulating voluge of y ate regulator Working style Continuous rited style Working speed rin | 10, 000 Vacuum| pump | Max vacuum degiwe kPa | 90.7 aes Hime Brvecuum s Amiving tine of 66, 7kPa<35 (1, 000 rnin) Model T2V 2.8 RW Voltige Vv 2 Sturter Power output RW zs Rotting direction Choekwise (see from the direction of the small zea’ Baten | Rated volmee Vv 12 AS i a Sl 2 al ir 10 Great al Bzdingnteral Cousin Ege ManufacturingCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 14 2. Tightening Tomue ofMain Tighten Parts of the Engine Tightening tomue ofmain tighten parts of GW 2. 8TC turbo—diese! engine are shown as Table 1-4-4, Table 1—4—4 Tightening Torque of Main Tighten Parts of GW 2, 8TC Tuibo—Diesel Engine ne n Tishiening brque a Tihienne onque Name of tighten part panel Name of tighten part ele cc oaatett (onl ey ees ene 100~120 | Bolts of crankshaft pulley tional wheel tightener Bolts of camshaft tining pulley 1843 Bolts of flywheel 120~130 Bols orhih prssue Gelpump| igz3 | Bols of nkctwromprswrsheet| 24 ~80 Nuts connecting high pressure Bolts ofmain bearing housing 170 ~180 fuel pipe end and high pres sure fel rail end Nuts of connecting md 80 ~90 Bolts of valve adjusment 15~21 Bolts of high pressure fuel pump Bolts of EGR cooler air outlet 65~75 2045 pulley isu pipe 0 Nuts connecting; the high pres sure filel|p pe end and injec tor| 25 29 Bolly of Aitborhiargér oi] is um 192 ee Pipe we lament Nuts connecting high pressure fuel pipe end and high pres 25~29 Bolts of themostat lower housing 2045 sure pump end Bolts of eylinder head 100 ~105 Bolis of themostat upper housing 2045 14 3 Main Adjusting Data of the Engine 1431 Valve Timing Intake valve opens at 24° BTDC (crankshaft w ming angle) Intake valve closes at 55° ABDC (crankshaft tuming angk) ; ‘xhaust valve opens at 54° BBDC (crankshaft tm ing angle) ; Exhaust valve closes at 26°ATDC (crankshaft tum ing angle). 1432 Valve Clearance Intake valve clearance (cold state): 0. 35mm +0. 05mm; Exhaust valve clearance (cold state): 0. 4mm £0. 05mm. 1433 Max fuel supply pressure of high pressure file! rail. 145 MPa, 1434 Fuel injection oriee 1—3—4—2. 1435 Fuel supply advanced angle ¢ CA BTDC): automatically contwlled by ECUMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 144 The Range of Various Tanpemture and Pressure of the Engine The mnge of various tampemtie and pressure of GW 2, 8TC tibo—diesel engine ar shown as Table 1-4-5. Table 1—4—5 The Range of Various Temperature and Pressure of GW 2, 8TC Tuibo—Diesel Engine Ten Tanpemtre mnge Tem Pressure rinse Coolant outlet tampemture of| +5C i 2 cooling systan” 80C £5C Idling oil pressure 0. IMPa Oil tmpenituve of kbrice ting! <95C Rated whting speed oll pres |) 35) soupy system sure Note @ The coolant tempemure of closed pressing water tank system can be up to 105C. 1 4.5 Main Fittings Specifications of the Engine Man fittings specifications of GW 2, 8TC turbo—diesel engine are shown as Table 1—4—6, Table 1 —4—6 Main Fittings Specifications of GW 2. 8TC Tutbo—D iesel Engine System and components ‘Spec ications ‘Type of oil pump Gearing type Lubrication system ‘Type of oll flier Row inst Iki tion ‘Type of fei filter Rows’ inswllation wih fiel—water sepa mtor BOSCH CPI ype axial 3 nm — pe pumps High pressure fuel Sh Pressul PumP | magnet valve control with gear fuel pump Fuel supply system BOSCH LWR ype maximum fel supply High pressure fie! rail eee Type of jecior CRIZ 0 wpe (orifice wih si hokd GanetCT2 orMiisib Ri TFOSSHM wpe highest Hnke sysem Turbechaaies speed 180000 nimi maximum pressure mito 2 ‘Type of water pump Centrifugal War pimp lifting head | > (3000 rf in) ™ Cooling system ‘Type of themosiat Wax wpe hemostat Silkson olf chich and plstie Bin diwet pint or oe unattached eleetrie fin Preheating plug vollage | 12V Specifications of surier | 12V, 2. SRW Electric system Specifications of altemator | 12V, 1080 W Aliematbr miate direction | Clockwise (see fm the end of crankshaft pulley) 12 (6a Te A Ui 7 a lB 2) Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 1 4 6 Main Parts Specifications of Fuel Supply System of the Engine Man parts spccifications of fuel supply system of GW 2, 8TC turbo—diesel engine are shawn as Table 1—4—7. Table 1—4—7 Main Parts Specifications of Fuel Supply Syst of GW 2 8TC Tutbo—Diesel Engine Part name Model Installation position ‘Spec ification Te PBI ERT Tosca cpus | ROS SPBE Oar an ype pps — Bosca cn ¢ | TSC OF OTRe [NPPROXT TH, ansini ot High pressu fuel mail| Laser—wekied LW) VO SHE OFATRSE | Gi supply presse 145 MPa Bwcuie contol unt | EDCISCI9 inside hemet Woilchg voltage 127 Speed senior DG 6 Upper part of wheel W orking cleanince 0, 2~1, 8 mm housing Ouiside of pulley chan Cam shaft phase sensor) PG & 8 ber cap W orking clearance 0. 2~ 1. 8 mm Rated voltage 5V £0. 15V, rated sistance 2. 5kO +0, 6% for W ater temperature Lowerhousing of themo mi TREW ove NIC ype at 200, mated rer resistance (. 168kO 2% ) for NTC typelat 100 orking voIRge 7. 5V 17. OV, Air flow sensor HEM 6 Air inlet of compressor | flow measuring range 40 kg /n~ 640 kg/h Wh pressure fuel wil Front ofhigh pressure | Resistance bpe ouiput 0. 5V~ pressure sensor fuel mail 4-5V voltage Pedal position sensor | FPM nse cabin Voluge of power supply 5V Top surlice oF evlinder | Keeping constant tempenture 3 Preheating pg Gsk2 ee en EGR valve 7. 00068, 01 Rearpart of nktpie | Vacuum ype W ith manual fie! pump, oil—wa ‘er sepamipy diesel heater (flow Fuel filter BOSCH, Carrer mite 125 L/h), papery filter ele ment particle filtering ratio >15 um 100%, 3~5um 94, 5% 14 7 Main Parts Fitting Clearance and W ear Limits of the Engine Main parts fitting clearance and wear lim its of GW 2, 8TC tuibo—diese] engine are shown as Ta blel—4—8MAINTENANCE MANUAL OF GW2.8TC TURBO —DIESEI ENGINE Table 1—4—8 Main Parts Fitting Clearance and W ear Limits of GW 2, 8TC Tuibo—Diesel Engine Ne ing pars Fi Chamnce or suphis fim) | Wearhe Inis am Valve gue innerhok and : ce ~ 2 y | Wane eve ne Clearan a. 039~0, 071 0.20 Valve guile innerhok and 64 ~0. 096 2 2 | Vale aul ner Clearance a. 064 ~0, 09 0.25 | Rockeram hol and weker Gp cola us a% am shaftd imeter Cylinder liner inner dime ce 0, 055 2 1 Oe ean ain Clearan 0. 037~0. 0 at 5 | Tappethok and tppet out | Cpegrance a. 010~0, 041 0.10 erdimeter e 6 | Tel he grove Releht) Crarance 0. 078~0, 137 0.20 and the 1°" ring height The 2° ring groove he ght 7 whe groove Hele Cea rnce 0. 055~0, 095 O15 and the 24 ring height Oil The gmove het 8 ws eave het and) Clearance 41 025~0. 07 015 oil cup height T 1200-40 1. 50 W\itth of the piston ring S f 9) \ laced insite, 93. mm TI 0600 85 ANB ring’ gaugey Tl 0. 350, 65 1.50 Connecting mod Title end - . 10 | ihe heleuel pkenen| — CHumnce a. 008~0. 020 0.05 11 | Pisbn pin seat hok and Clearance a. 002~0, 015 0.03 piston pin rz | CrBak pip Joumal and con | vist clearance a. 175~0, 290 0.35 necting red big end 13 | Camshaft bearig and cam 7 Cea rance a. 015~0. 085 a2 shaft joumal ug Comshatand oll seat) xi clearance 0. 075~0. 145 0.30 Connecting red big end 15 | bow dimeter and emnk | Clearance a. 029~0, 075 0.10 pin joumal bear i 1g | Mah bearhe bore dimer] Crarance a. 033~0, 079 on and main emnkshaft ju mal 1z_| Thmst cleamnee of enki efearance’ 0.05~0, 20 0.30 shatt 18 | Rotbr of tbochawer Axial clearance 010 <0 3 a fie Tet I 7 A ll i ASR Zl Great al BzedignterralConbustin Engine Manfactring Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 15 Maintenance Standard Diesel engine works nomallymeans that the consumption of fiel and lub ricantmeet original de sign requirement can output design powes opemting smooth and stably without abnomal noise Every exceptional cires concems with fitting status ofmovable fitting parts of the diesel engine. Dur ing the assembling of cach movable fitting parts the technical requirament is very strict parts geo metrical shape fitting clearance surface roughness and cleanness should be up to standart W hen assembling counterparts ensure fixed precision please the most important is the fitting clearance Too smaller clearance will cause operation retarlarce, bigger friction heating and even lock too kawer clearance will cause nois impact difficult for fm ing lubricant oil fin and shorten parts life The utilization tine limit of the diese] engine assembled through strict assembly and running in will be depending upon excellentmaintenance The size and utilization limit ofmain parts are as shown as Table 1—5 —1. Table 1—5—1 The Size and Utilization Limit of Main Parts of GW 2, 8TC Tuibo—Diesel Engine Part name Ten Siandanl Utilization Init | Remark Planeness beween cylinder head <0. 15 0. 20 plane and exhaustman fold mm _— Cylinder | Cylinder head height 31, 95~92 05 = Cannot be head grinded Warp of eylinder head botum phne =0 08 0. 20 Wap of intake manifoH plane S05 20 Five height mm as 0° a 1 J - Installation Vale spring | Pempendicularity mm = i? height is 38 9m Spring stniin N 296 257.9 Vahe stm dimewr | lke vale | 7 946~7. 961 7. 880 a) Exhaust whe 7 921 ~7, 936 7, 850 ‘Clanmce of waive and| Mike valve | 0. 039~0, 071 a 200 eee Exhaust whe 0, 064~0. 096 01 250 Upper end height of vale aude Cian 2 130 = upper plane of cylinder head). mm Vahe and vale aude | Suplis of valve eudemm = Le Tnake valve 179 150 Valve thickness mm Exhaust valve 1. 83 1. 50 Vale seat interfice angle (degree) ® = Vale wat nerice | Rake wave i? 22 ee Exhaust vakel 20 25 Push wd | Canberam = 04MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, (Continued Part name Tan Sandan Talzaton Init] Renate ‘Axil cleamneemm 0 0750. 145 05 Cam heghtmm 202 a, 05 Joa mal diam etermm 78 915 ~A8 975 73. 60 Camshatt Radi imphessmm <0 10 Cam bearing immer dimeteram 50, 000 ~50. 030 30, OF Camshaft phy mim 0, 025~0. 85 0120 Extemal dimetermm 12 9712 99 12 & Tappet Pay wy eween tppet and cylinder _ block tappet hole) mm 0810 a ay un Extemal dimeter of weker shaitmm | 18 98~1 00 18 90 nner diameter of wekermm 19, 01018 030 13,10 Rocker ( assmbly | Phy (beween meker and meker bop aos baw shafd mm Rocker shaft mdial jam piness mm = 02 Phy beween pump bady and gearmm| 0.13 ~0,14 015 Oil\pumip Phy belvéen pump cap aid gearmin|)| p. d240p7 a) 15 ‘Thrust clea fae mm 0-05 ~020 1 30 Crankshaft md BT jump hess mm S005 008 Mai shaft oumaldimeermm 68 917 ~69 982 6 OT Crank pin diametermm 53 915~52, 980 52 90 ‘Cank— shaft Tjneven wear beween main shaft : < 0.05 0. 08 Joumal and crank Joumalmm Clearance between crunk Pe aera la 0, 029~0, 075 0, 100 bearing mm Clearance between man sha®eJoumall 5 y35 9 p79 bio and main bearing mm Piston dimeiermm 92 965~95 024 = npisin| Piston clearance (beween piston Piston piston] Piston clearance (bh Piston and) 9 37 ~0, 055 — pin piston | evlinded mm rng od Tring a 20-0. 40 750 connecting Width of pi nd Mh of piston TT ring 0, 60~0, 85 150 ring mm Oil rhe 0 35~0.65 150CHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE (Continued Part name Tan Standart Unilzation lini) Remark Tring 0. 078~0. 137 = Side clearunce of Ty ring 0. 055 ~0, 095 150 piston ring mm Oil ring 0. 025~0. 075 150 Pision pin dimetermm 30, 995~31. 000 30, 970 ‘Assanbling clearance (between cor enbThg FReRnee Pewee STD Gog. ony os Piston pisin| PeCtinE fod and piston pid mm pin piston | Assenbiing suplis (between piston - ring and and piston pin) mm 0020. 015 not connecting rod Correct of Canbermm =008 a 20 connecting rod mm Twisted mm =005 015 Clearance between pision pin and ~0, 02 5 connecting md bush mm 8. B08 0. 020 0.050 Thrust cleatunce of connecting red mm | 0. 175~0. 290 0 350 Phy beween cmnk pin and comect |) 59) yg bw ing od mm W rap of upper plane of eylinder _ 120 Evligley block mm. $ block Cylinder hoe dismeterhim 98-62 ~92.06 = 1.6 Technical Maintenance During the operation of the diesel engine the technical cond ition of diesel engine will get worse because of parts wom, tigh tener bosing electric equipment joint loosing clearance change and oil deteriomte and so on so that this diesel engine will occur abnomal electrophoresis such as difficult starting powerdecreasing higher oil and fuel consumption, and even then could notwork nomal ly. It isa very importantwork tomaintain the diesel engine temly for cleaning check ing lubrica ting adjusting or rep lacing same parts accom ing to its technica! condition working tine and mun ning miles It is also propitious to your reasonable utilization of your diese] engine \V Attention In onier to keep your diese! engine in good condition avoiding touble, pwlng fhe life ofdiesel enging youmust imp lament technicalmaintenance seriously acconting to thisman ual 1 6 1 Technical Maintenance Period Accom ing to the technical cond ition deterioration degree of different parts of the engine there are 4 gmdes of technicalmaintenance thatmust be takere 1611 Daily technicalmaintenance usually ken after 8 to 10 hours running every day. 1612 The first grade technicalmantenance taken after have worked for 100 hours or run ford, 000 © 5, 000 km. 1613 The second grade technical maintenance taken after have worked for 250 hours or mn for10, 000 w 12, 500 kn, Ga Se tS In Pa A) Is FO ZA Bz era Conbasion Ene Mandacuing Company 7MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 1614 The thirt grade technicalmaintenance taken after have worked for 1, 000 hours or mn fr50, 000 to 100, 000 km, Useralso can do his dec cal status Technicalma intenance period of GW 2. 8TC turbo—diese! engine ar shown as Table 1—6— ion depend ing upon d iese| engine s practi Tab le 1 — ‘The Techn ica IM aintenance Period of GW 2. STC Turbo—D iesel Engine Manenance The fist amie] The scoond sade) The hint mde period ‘echnical technical ‘echnical Remarks Daily technical) maintenance | maintenance | maintenance . maintenance Maintenande. 000 To 000= oO items 5/000 im | 12500 im | 100-000 im Change of Nomally every ou Check oil kvel bane See Chapter 1. 6 4 Change filer element Nomally 5 Oil ater pean See Chapter 1,6, 8 4 Change fiker ekment Nomally Fuel filter even 25,000 30, ObDkmD | SEE Chapter L641 Coolint heck cookunt vet Air filer Clean Change filter elan ent See Chapter 1. 6 3 Loose and danaged a Check. tighten, maintain and wepair ekeciie equim est " cinnectirs Tworkting con Cheek if its operation is in nomal cond ition Four kinds of leak age Checking and nmoving the kakage of oi Notice if the lover part of pulley case leak oid. water gas and electricity Diesel engine appearance Keep clean Valve cleamnce Check and adjust See Chapter 1. 8.7, 2 Loose and damaged of fuel pipe connecting position Check tighten, main n and repair Simining fore and damaged of fin belt} Check tighten, maintin and repair See Chapter 1. 6.6.3 Rad aor Clean ‘Connection of turbocharger Cheek and maintain Fuel—water sepamitor| Check and maintain Injector Check and replace itwhen there is tioub le display Go to professional maintenance sta tion for check ing and repairingCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE (Continued Maintenance ‘The first grade] The second gmdel The thinl grade! peril | techni! | wehniea! | technical Ranusks Daly weil] panmanse | mahtnnse | mabtnanc Maintenance, 4 OOD TO, 000 50, O00 ee 5, 000 km 12, 500 km 100, 000 km Tin ing transmission Checking the appearance of the Bopbcelbel On belt ti ission belt (nomally Br maintenance sta a ansmissiog pe every 80, 000km)| tion for repairing Replace tighte ner and tran siton wheel Tightener and tan depend ing on sition whee! ; Prctical con dition when replacing belt w Check water kakage of overfall ever pump hole Check wire camecting een Electric equinment fecey lee ‘Ventilition system of eee Check and clean ‘Clean cooling ‘Clean cooling system accord ing syste ‘jo. fechnical requirement . Clean carbon “oll di wale WS hein diesel dnaind va crustation, oil path,oil p ipe Pisen Fhe Chesk wom conden ‘Cylinder Check wom condition ‘Connecting — rod i amet Check wom condition Acconing w diese Main shaft bearing Check wom condition engine s working ‘condition Gear Cesk worm conden Thaust plate Check wom condition Air intake and 7 Cheek wom cond ton exhaust valve a or 16 2. Technical Maintenance Contents In onler to ensure the diesel engine can work nomally, you should take technicalma intenance as low ing process during your utilization 16 2.1 Daily TechnicalMa intenance @ Checking diesel oil (fied, coolant (see Figure 1—6—1) and oil (lubricating oiD levels (see Figure 1—6—13), refilling them accord ing to specification if necessary. YY Attention Only the engine stopped, you can correctly check every liquid level Ga Se tS In Pa A) Is FO ZA Bz era Conbasion Ene Mandacuing Company 19MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, Specification for diesel oil (fieD: The specifica tions prescribed by GB 252—2000 are 0° light diesel oil in summes —10" or —20" light diesel oil for south em area in winter (wam area) and —30° or —35" for northem area in winter (cold area). VY Attention Forbidden refilling fel into fuel tank during diese! opemtion Dont filly refilling fuel tank at fervent summer to avoid fue] overflow ing caused by heat expanding or expunge the overflowed fuel oil inmed ittely, (2) Clean the dirt or elect lyte overflowed on the Figurel—6—1 Checking CoolantLevelof batter, keep breathe hok free In nomal condition, Refilling W ater Tank (Only for eierence) 2 Checking Electrolyte Level of Battery Figure 1-6-3 Equipment Every 2 @E hecking Electric Hames Joint battery needs not maintenance But if tampemture is vely high, you should check electiolyte level for same tine Electwlyte should be the level between M in and Mix marked at the side of battery (see Figure 1 —6— 2. If the electrolyte is not insufficiency, you should fill in distilled water V Caution Don t add dinty water and other liquid into the batters othenvise the charging will not be e ough and~its using will be affected If battery, liquid level falls down quick! | you should make it repaired at the maintenance station. V waming The acid liquid of battery is convsive Don t let it splash to your eyes skins and cbthes Using water forwashing ifacid liquid has splashed w your eyes skins and clothes (3) Afr started diesel engine youmust check if there is oil leakage water leakage gas (aid leakage or electricity leakage If ther are “fur leakages’, you must treat it in te ® Checking the status of every accessory devies electric equipment ECU and every hamess joint (see Figure 1—6—3). (5) Afer started diesel engine check if diesel engine works as usual and check metes if the meter damaged, repair it or replace it in tme (6) Keep diesel engine clean there should not be dirt or oil on electric equipment also there should not be othermatter on the radiator (@ Check and tighten the connector between tur bocharger and diesel engine Remove the troubles of oil and gas leakages etc Keep the surface of turbocharger clean TE ES iid 0 Sh a all is FR ial BzedingnteralConbusi on Engine Manuacturng Company LinedCHAPTER | TECHNIC AL |. INFORMATION OF THE DIESEL ENGINE Figure 1—6—4 Checking Transmission Belt Tightness Degree Figure 1—6—5 Grind Valve and Valve Seat CF Lubricating 0- ‘Ty Antifreeze and Battery antirust liquid Figure 1—6—6 Used for Diesel Engine in W inter VV Caution Assemble and clean the air filterevery day if diese! engine working in the environment with heavy dusty Keep air filter in good working cond ition 16 2.2 The FirstG mde TechnicalMa intenance Completing daily technical maintenance. A fter diesel engine have worked fr 100 hours or mun for 4, 000 to 5, 000km, adding maintenance listed below. () Checking electwlyte gmvity or voltage of the battery. (2) Checking and adjusting drive belt deflection, see Figure 1-6 —4, (3) Clean air cleaner (4) Checking the tightness of every bolt and nut 1 6 2.3. The Second Grade Technical Maintenance Canp keting the first grade technical maintenance Afier diese! engine have worked for250 hours or run for 10, 000 to 12, 500m, add ing maintenance listed below (for new diesel or the diesel after the third grade tech nicalmaintenance the first tine © carly out the sec ond grade technical maintenance should be ahead of schedule that after ithave worked for L00 hours or run for 4, 000%to 5, 000 km) () Repkace’ he oil inside oil sup. Replace fel filter elanent Cnomailly after nun for25, 000 to 30, 000km), oil filter elanent and air fil ter element (3) Checking valve cleainee adjusting it ifnec essary. ) Checking the overflow hole of water punp, if there is water leakage fiom overflow hola please replace the water punp (S) Checking the connector of electric equipment and every hamesg bumtwire should be replaced. See Figure 1-6-3, (6) Clean the furring in cooling pipe and radiator (7) Clean crank case ventilation system. 1624 The Thirl Gride Technical Maintenance Atnomal condition apart fan completing the sec ond gride technical maintenance after diesel engine have worked for 1, 000 hours or nun for50, 000 to 100, 000km (nomally for every 80, 000km), replace tin ing transmission belt checking transition wheel and tigh te nex and clean whole cooling systam please Adding fol owing maintenance if necessary acconl ing to practical status Ge TE te IN PA A is SB Zl Great aon Cangany ited neal Conbaston Ene anda 21MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, GB 252-2000 light diese! oil (fuel) 35" light diese! oil =20° light diesel oil 10" Tight diesel oil =O" Tight diesel oil 25% 0G 5ST Environmental temperature for diesel engine Figure 1—6—7 Choose light Diesel 0 il Fue Accord ing to Environmental Tanperature Cle rade esl ening oi (ubricating oi) or be ere poe hy Esaon Male Cop =107 0 10) 20, 30 40 s0'e G14) 32/50 68 | 86 104 122°F Environmental temperature for diesel engine Figure 1—6—8 Choose Lubricating 0 il Accor ing to Environmental Tanperature () Disassemble diesel engine clean carbon oil dirt and farting clean all oil pipe and oil hok, (2) Check forwom of connecting surfaces of valve pushing wd and rocker repair or replace than ifnecessa % (3) Check forwom ofpiston ring cylinder lines connector mall end bearing and big end bearing Re place than if necessary. @) Check forwom of crank bearing and thust () Check forwom of cam driving gear fiont oil sealing and axial clearance of camshaft transition wheel unit and tightener unit (6) Check forwom of intake /exhaust valves and their seats cany out the repair or mbbing (See Figure 1—6—5) and leakage testing Replace than if neces say. @ Checking oil pump, disassembling and chee king easy damaged parts and adjust then, (8) Checking cylinder head gasket and man ifoll gasket replace than if necessary. (D) Checking altemator and startes clean parts and bearings refill lubricating grease checking starter gear for wom check transit equigment Hrmov ing smooth, 1 62 5\ Season Technical Maintenance (It is suggested that befor winter caning every year you shoul replace antifreeze and anti—rust liquid fram cooling systan. (2) When enter into wintes you should choose suitable fuel (diesel oid brand according to enviormental tempemtim see Figure 1-6 —7, (3) When enter into winter you shoul choose suitable libricating oil forwinter see F igure 1 —6-8, ) Change consistence of electrolyte accom ing to different season 16 3. Technical Maintenance ofA ir Filter The function of air filter is to filter the dust and impurity ete in amosphere for avoiding abr sive wom happened to the cylinder hole piston ring and valve air valve and air valve seat Ther fore the air filtermust be provided high filter efficiency Absolutely forbidden GW 2. 8TC turbo—diese! engine without air filler It could easy damage the airflow sensor and the diese! engine cannot operate nomally with damaged airflow sensor Both oil bath air filterw ith inertia stee1wire villus filter element or air filter with paper filter el ement can be used forGW 2. 8TC turbo—diesel engine acconi ing to practical utilization requ iram ent Air filter will not be installed on the engine if it is used for vehicle itwill be selected and installed by vehicle manufacturer The flow of selected air filter should be larger than 450 m’ /h, It is very important b maintain the air filter 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 snoke power falling and early wom of engine (6a Te A Ui 7 a lB 2) Grea al Beedig internal Conbustion Eine Manfactring Company Lined 22CHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 16 3.1 Maintenance of Oil Bath A ir FilterW ith Inertia Stee! W ire V illus Filter Elam 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 steel wire villis filter ekment please The tines of cleaning may be adjusted according to dust density of environment When cleaning fetch the steel wire villus and put it in the petrol for cleaned, then blow it dried by pressing ait Clean oil pool of air filter meantine then fill prpernew oil in it 1632 Maintenance of Air FilterW ith Paper ilter E lament In general for every 4, 000 ~5, 000km running of the vehicle equipped with diese! engine, dust on the shell of air filter should be cleared away and filter elament should be cleaned @) To clean the shell and cover of air filter when technicalmaintenance is taken or air filter element be changed, dust on inner of shell out cover and surface of sealing gasket should be cleared away cleanly (see F igure 1-6 —9) . (2) To clear the filter elanent when the filter elanent 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 elanent by pressed air rotating the filter elenent at the meantime. The pressure of pressed air should less than 490 kPa YY Cautions Dont clear the filter element fem outer to inner by pressed air If so the dustwill go into insite of the filter elament Replace the filter elenent if follow ing-situations happened (D- The filter ¢ lament is polluted’ by charcoal and oil (2) The filter element polluted heavily, dirty can not be easily cleared, (3) The filter elanent warped and damaged. Pique! 6-9 Mahunance ofairPine —W Caution () Air filterwith paper filter elament should not be cleared by oil or water othenwise the dust will be stuck on it easily and filter elaent will be blocked. The engine s power output will be dropped down and heavy smoke exhausted due to the lack of air intake (2) The sealing of connector between air intake pipe and air filter should be often checked If any leak age exit the treatment should be adopted immediately such as rep hee sealing gasketand tighten the connector to avoid abnomal wom of the diese] engine 164 Technical Maintenance of Fuel Supp ly Systen. 1641 Technical Maintenance of Fue! Filter Fuel filler is installed at the lov—pressure fuel pas sage Diesel oil enter ino filler then is pressed through Ge TE te IN PA A is SB Zl Great aon Compan init InteralConbatn Engine Nandactng| Figure 1—6—10 Clean AirFilter Eement 23MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, filter element thus in purity will be cleared away. Diesel oil after filtered will enter into fel transfer pump on high—pressure fuel pump. GW 2 8TC turbo—diese! engine adopts whirl—stye fuel filter Replace the fuel filter after the engine has worked for 500 hours or the vehicle uns for 25, 000 30, 000hn. When low quality diese] oil has been used by the diesel engina the replace period should be ahead of schedule please place the fel filter after the vehicle run fr 10, 000 to 12, 500 kn, The replace method of fuel filter are as following (@ Clear the outside surfice of fuel filter assanb ly thowughly. Grip the fuel intake p 2) Loose and disassan ble the filter element by wrench or proper tools 3) Ensure that the serew connector is tightened on the filter seat and the inner of the filter seat is cleaning @ Lubricating new sealing ring with a seat by hand until you feel the resistance () Tighten the filter elanent by wrench Open fuel passage and check the leakage ) Ranove the air insite the fire! filter le clean fuel Screw the filter elment into the filter 164 2 Dminage of the Fuel Systm Examplify a diesel engine for vehicle here W hen water level inside fue !—water separator rea an ches to the dangerous level the indicator lamp of fuel —water sepamtrwill bright (assanbled on the vehicle panel see Figure 1—6—11). \V Attention During the opefation of the diesel en, ging \the-indicalor kmp ‘of el watet separator b right frevermeans that the water inside fuel—water separ tor shoul be drained out Figure 16-11 IndicatorLamp of Fuel—W ater SeparorW ater Level Water drainage method for fuel—water sepamor (D Stop your vehicle on safety and flat place (2) Open the diesel engine bonnet and puta con tiner (content is about 0. 2 L) under the water drai ning plug pipe end of the fuel—water separator (3) Loosen the dmining pkg in counter clock wise O perme manual fuel— supply pump of fuel—wa ‘er separator up and down by hand to drain off water (see Figure 1—6—12), until fuel fill in the fuel—wa ter separator fully. @) Tighten the draining pg clockw ise after wa ter drained off then press manual fuel— supply punp up and down fr several tines (see Figure 1—6 12). (5) Starting the diesel engine and confim ing no oil leakage atdmining plug and checking the indicator limp of fuel—water separator if it is un—bright at the same time Figure 1—6—12 Fuel Filter 1—Filter elament_ 2—Fuel inlet connections 3—Mama| fie!—supply pump 4—Fuel out let connection 5 — Electric connector 6—D minage p hg fe Se In) 1 a 24 Grea al Beding internal Cousin i iCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE \V Attentior If water need dmined off frequenth; itmeans that the fuel used is not cmply with requirenentor specification W ater exited in fue! tank should be drained off at thema intenance sewice station 165. Technical Maintenance of Lubricating Systan 165 1 Choose Lubricating O il The choice of lubricating oil for the lubrication system of the diesel engine should accor to the envitrmental tempemtire (see Figure 1 —6—8). VV Caution Don t use lubricating oil with different brand or different gmde. 1652 Oil level inside oil sump of diesel engine ismeasured by oil dipstick mounted at the keft side of diesel engine (see Figure | —6—13). Stop the vehicle on level plane and then stop the diesel en ging after oil getting still pull out the dipstick clean the oil on the dipstick by clean cotion— cloth, then re— insert the dipstick into oil sump and pull outdipstick again for checking oil level There are wo holes on the dipstick (see F igure 1—6—13). Oil level shout be not bwer than lower hole because in this case oil level is lover than oil striner so oil pump could not pump oil inw oil port Oil kvel also should be not higher than upper holg because in this case crank may strike oil when crankshaft running there will be lot of oil brme or oil splashing in crank case and cylinder liner more oilmay be bumt in chambes and there will be a lot of carbide on the top of piston and in the chamber piston ring may clogged, diese! engine willmeet same trouble such as exhausting black” srroke>\ causing” oil sea ling leakage~and increasing~oil consumption and so-on. Therefore, apart fram notice the oil pressur you are also needed| to check oil Jeve! before you want drive vehicle go out/or your Vehicle has un for every 300 to 500 kn. il Level Measure VY Attention Check the oil pressure when the diesel engine is running before running your ve hiele and check the oil level at any manent 165 3. Replace OH Oil and Use New Oil After long tine operation there will be impurities ordirt insite oil due to same fuel didn t but eanpletely 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 for same tine (for exan ple vehicle mnning for 12, 500 kn), you should drain outall of the oi fill new oil into oil sump Method for oil rep aeing () Pee the diese! engine or the veh icle on level position Upper hole (2) Running the diese! engine until its oil tem Lower hole perature up to 80C, then stop it (3) Place an oil sump under the diese! engine ramove the oild a inage plug and drain out the used oil () Use new gasket tighten the oildminage plug accord ing to requirment Fill new oil into engine and aaa NCratneo Ten check oil level using the dipstick By D ipstick REEMAM A Misa AS |. Great Wall Baoding Internal Combustion Engine Mansfacturing Company |MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, YY Waming Be careful to prevent ficm scalded by heating oil appropriate dispose the used oil and protect environment If there area lot of mpurities in oil sump you should use 5’ or7 machine oil (light spindle oid ‘b clean lubricating system during engine sunning in forbid using gasoline or coal oil for clean When you need t clan the inside of diesel engine fill5’ or7 machine oil into oil sump to the level between upper hole and lover hole of oil dipstick disassanb le all injectors and tum the crank shaft for2 © 3minutes then drain out allmachine oil quickly. After oil replace Hrevery tme you should mun diesel engine without bad for short tine to en sure that the lubrication systan and other places needed lubrication will get enough oil When you fill oil fram oil inlet of the valve can You should clean the oil inlet filler and forbid ding mpurity and dirt into oil sump. After oil filling tighten the cap filler VV Attention Check oil evel after oil filling for 5 minutes because the oil will flow to oil sump through the push md hole of cylinder head and the side hole of the tappet of cylinder b lock 1654 TechnicalM aintenance of 0 il Filter The whirl—style filter elanent of oil filter should be rep heed when new vehicle have run for manning in for4, 000 km, Then replace whirl— style filter element and oil after driving for every ac cumulative 12, 500 km. See Figure 1 —6—14. Method for filler elanent placing and notice i fens (Put a container under the vil filter to. collect overflow ing oil (2 Disassemble the filter e kmient of of! filter sing special spanner by counter clockw ise (3) Check and clean the oil filter seat so that new oil filter elanent can be assemble into it exactly (@® When assembling apply thin coat oil on the O— ype sealing ring at first (see F igure 1 —6—15), then screw the ekment into the filter seat by hand until you feel resistance Finally screw the element clock Figue 16-14 Disassembling and wise with 34 cites by special spanner Assanbling the O il Filter () Diesel engine can tbe started bere you con fim that there is enough oil in the oil sump. ©) Start engine after the assembling work has be dong check if there is any oil leakage of the oil filter Check oil level using oil dipstick and replenish oil if necessary, VY Caution () Whirl style filter element is one — tine — sing part don t 1 use it Q Whirl—style filter elmentmust be placed regulary acconiing w technical maintenance require ment Figiel—6—15 Replace the Filter Element of Oil Filter fe TE tS Ib 0 A a tS BR Zl 26 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE The oil pressure limited by the pressure regulator of oil filter is 0. 5SMPa +0. 02MPa This valve is properly adjusted bere the diesel engine kaving factory, please do not readjust it at cam mon cond ition, When disassembling and assembling the oil filles please do not damage the mbber— sealing ring othenv ise itmay cause oil leakage Replace the mubber—sealing ring of oil filter if it has been damaged 166 Technical Maintenance of Cooling Systan 1661 While running the diesel engine there must have sufficient antifreeze and antimst (cooland in cooling system to take away heat and ensure the diesel engine coull work nomally. Therefore youmust check coolant level before running yourvehicle fill clean antifeeze and antinst liquids and let its level between the Min and Max inside the radiator refilling water tank (small funk), see Figure 1—6 —16. 16 62 Usually the usage tine limited of lng —effect antifreeze and antirust liquids is 1 to 2 years Replace itwhen its usage limited at tem. When rp cing the antifreeze and antinust liquids you should be accor! ing 1 the requirment and then start the diesel engine and keep rotating for 5 minutes so that the anti fieeze and antinist liquids can fully fill into the cooling system, Then stop the diesel engine and check the lev el ofantifieeze and antinust liquids if not enough, re plenish than again VA tten tion: () Foibidden using untreated hard water such as Figure 1-6—16 Checking Coolant Level tap waterorm ineral water ORT KET EA ETL Ta) (2) Forbidden using low quality antifreeze and antinist liquids don tmix different type antifreeze and antinust liquids to avoid part cormpting (3) For over consumption of antifieeze and anti ust liquils at first you should check their density. If the density of antifreeze and antimst liquids hasn t in creased, thismeans that there is leakage of the cooling system, rmove this leakage and don t mix different type antifeeze and antimust liquids If the density of antifreeze and antimst liquids 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 fieezing point If you are without the method mentioned above, you stould go to the maintenance station for checking 166 3 Checking the tightness degiee of punp Ec een belt Press belt between pump and generatorwith force BLE SIE of 70~80N by hand, the suitable deflection of the belt is7 © 8mm (see Figure 1 —G6—17 and Figure 1-6 — 18). RECN MMA SSRA ‘Great Wall Baoding | Company Limited InteralConbatn Engine Nandactng|MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 16 7 Technical Maintenance During Stor age Diesel engine needs technical maintenance only ac cond ing to its accumulative work ing hours or accumulative driving distances if the stmge tine were less than one month Special protecting steps should not be needed Special techn icalma intenance must be carried out if the stomge tine wer mor than one month The de of requinment see “Chapter 7 Sealing and Unsea ling of the D ese Engine” of this Manual please Figure 1—6—18 Checking and Adjusting the Tighiness Degiee of the Transm ission Belt 1 6 8 Attention Points for TechnicalM aintenance 16 8 1 User should maintain your diesel engine accorl ing to the technicalmaintenance reg ulations by gmde by item and by quality Especially during busy tme forbidden freew ill duce themaintenance items or fieewill delay the maintenance period. 16 8 2 The third grade technicalmaintenance should be carried on in—door for preventing dust into the inner of your diesel engine 1 6 8 3. Same strict or very camp lex maintenance items of your diese! engine should be car ried out by professional technician or take your diesel engine to the special maintenance station of G rat Weil Baoding intemal anbustion Engine M anufacturing-C am pany.L im ited-formaintenance, 1. 7\_Running ~ In of D iese! Engine New orheavy repaired diesel engine (include piston piston ring cylinder liner main bearing and connecting md has been replaced) must be mn— in fim small load to awe load gradually for same tine before nomal operation By this mnning— in process you could cany out earlier chee king adjusting and maintaining and the friction surface of diesel engine parts will fitwell quickly ‘» avoid abnomalwear and danage Experience shows that the working life reliability and econany of the diesel engine mainly depends on running — in at its initial stages 17 1 Preparations Before Running— In 1711 Opertorsmust read this manual carefilly and be familiar with the stucturs per fomance operation maintenance and sevice of the diesel engine 1712 Clean the outside surface of diese! engine 1713 Check the oil level in oil sump. Refill oil to prescribed level accord ing to techn ical requirment if necessary. 1714 Adding bbricating greases every required phees 1715 Check and fill fel and coolant (antifiveze and antinst liquid) . 1716 Check the electolyte— level of battery fillelectrolyte ino battery to regulated level acconl ing to technical requirement 1717 Check the tension of belt 1718 Check electric equipment circuit ECU, sensors and every hamess connectors link than correctly and reliab b. 1719 Set the handle of gearbox at “neutral position 28 (6a Te A Ui 7 a lB 2) Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER | TECHNICAL INFORMATION OF THE DIESEL ENGINE 172° Running—In New diese! engine must be run— in for2, 500km on vehicle accowi ing to running— in regulation (see Tab le 1—7—1) or 50 hours on engine test stand according to rmnning— in regulation Diesel engine afterheavy repaired such as the piston, piston ring main shaftbearing connect ing— md bearing and so on have been rep bced must be mun — in for500km on the vehicle according to Table 1—7 —2 or 10 hours on engine test stand. During mnning— in presses you could further check the assanb ling quality of every part of the diesel engine and camry out further adjustment if nessary Table 1—7—1 Run—In Regulations For New D iesel Engine on Vehicle Mileage of vehicle (an) Vehicle kad Rotating speed of diesel engine (rimin) 0~300 Load five <= 50% mied speed of relevant diesel engine >301~1000 = 50% mated bad | = 50% mied speed of relevant diesel engine >1001~1500 = 75% mied bad | <75% mated speed of relevant diesel engine > 1501 ~2500 Full rated load =Maxinum rated speed of wlevant diesel engine Table 1—7—2 Run—In Regulations For Heavy Repaired D iesel Engine on Vehicle Mileage of vehicle Cm) Vehicle load Rotating speed of diesel engine (rimin) 0~100 Load free 502% mated speed of relevant diesel engine S101 250 = 5 mated kad) |/] 3]4 /1)2]4]s5]6 eles acc] B | on| st |B, | P| Pm | Ww |W Disconnection Closedown Oo ‘Accessory Oo o--o Close Close ° Oo ° oO Start ofo+o | o Oo Ensure that there is open circuit apart from the connection mentioned above ‘Contact-point of magnetic switch ‘melting and cannot move, or return spring broken or damaged Replace starter switeh Replace magnetic switch 222 Troubk Diagnosis for Turbo Charging Systan Trouble diagnosis @) The purpose of trouble d gnosis is to find the trouble position and reason so that to suit the ramedy to the case. @) Do not replace old turbochargerwith new one before solve the pwblem, @) The diagnosis method and procedure of tutbo— diese! engine is the same as other diesel engine @ Trouble diagnosis cannot be carried out for disassanb led wibochargerCHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING. Fault phenam ena Diesel engine with insufficient power Diesel engine exhausts black smoke Diesel engine with insufficient power Diesel engine exhausts blue smoke ‘Turbocharger with loud noise Turbocharger with periodically noise Oil leakage at compressor side Oil leakage at turbine side of turbochargee Trouble diagnosis for tusbo—diese| engine Possible cause Ranedy Air filer diry Replace filter ekment of air filter Compressor air inlet blocked ‘Clean inpurity acconling to practical cond? tion or replace damaged parts ‘Campressor air outlet tube blocked ‘Clean impurity acconling to practical condi tion or replace damaged parts Diesel engine intake blocked ‘Clean impurity inside intake tube Pipe air kakage fim air] filter to cam pressor Repkice seal part accorl ing to prictical con dition or tighten fasten ing part according to prescribed torque Pipe air leakage fitm ‘com pressor to diesel engine Replace seal part according 10 prietical con, dition or tighten fasten ing part accorling to prescribed tomue Jonnt surfice air leakage between diesel engine air inlet pipe and cylinder head Replace gasket according to practical condi tion or tighten fastening part accor prescribed tomjue Diesel engine exhaust pipe blocked ‘Clean mpuriiy inside exhaust pipe Mulfiler or its rear air autlet tube blocked Clean impuriy inside exhaust acconling to Pmetical cand ition or rep lace damaged parts, Jont sirtice air leakage betveen diesel engine exhaust pipe and cylin derhead Replace gasket acconing 1 prctical condi tion or tighten fastening part acconling prescribed tonjue Joint air leakage between ‘turbine inlet tube and diese! engine air outlet Air leakage of tuibine air) outlet pipe Replace gasket acconling 1 practical condi tion or tighten fastening part acconling > prescribed tomue Renove leakage of tuib ine air outlet pipe Turbocharger oil retum pipe blocked Clean impurity acconling to practical condi tion or rephce air outlet pipeMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, (Continued Faulk phenomena side oF wrbosharase wulficient power Trouble diagnosis for tusbo—diese| en: Diesel engine with insufficient power Diesel engine exhausts black smoke Diesel engine exhausts blue smoke Turbocharger with periodically noise ‘Turbocharger with loud noise il leakage at compressor side Diesel engine with Oil leakage at turbi Possible cause Ranedy Breather of diesel engine cemnkcase blocked Clean ipuriy Hside breather diesel engine crunkease Tuibochargerm if — case fom dirtor tar Replace olf and oil Tiler acconting wo pracit cal condition or heavy repairor replace tur bocharger Tneonrect ad justient of high pressure fue! pump) or injector Replace or adjust high pressure fel pump and relevant parts acconling to practical cond ition Inconect diesel engine tin ing Replace danaged paris adjust timing of diesel engine Diesel engire piston-ting orcylinder wom causes: gas scumy Repair diesel engine and “teplace-paris ac conting to practica | condition Inner problan of diesel engine (valve piston) Repair diesel engine acconng t practical cond ition Canpressor impeller or diffuser bide fom dirt Clean find and remove the reason Or un— filter ais replace oil or oil filter Turbocharger damaged Find and remove the reason caused damaged heavy repairor replace turbochawer accom ing to practical cond ition Y Attention The turbochargerwith excellent appearance flexible operating rtor and without blade attrition means that this tuibocharger is at excellent status 2.23 Trouble Diagnosis for O il Leakage of Turbocharger The sealing of tubocharger depends on the air pressure within wo end — cases of turbocharger higher than the air pressure within m id — body oil retum chanber (equal to the pressure inside crank case). Before diagnosis move both the oil inside front inlet pipeline of canpessor housing and the soiled oil on the exhaust pipe before tub ine housing inlet and so on,CHAPTER 2 TROUBLE DIAGNOSIS AND TROUBLESHOOTING. Trouble diagnosis for oil leakage at the end of cam pressor @® Check all exhaust pipes bose or| ‘pwoken @ Check compressor impeller is Yes Clean and repair air inlet system, 1 damaged or not by other object phice tu:bocharger No ® Check turbocharser sha axiall yg, | Remove factors cause clearance in clearance increase or not (compres creasing of tusbochages replace tr sor blde wearw ith housing or nod bocharger No @® Diesel engine idling tme is wo|___Yes _[ Clean iubrcating ofl avoid iling fr long or not (more than 20 m inue) long tine No Yes r replace filter elmer | @ Air filer dirty or not ea Oe eee enone filter No ® Check wibocharger inlet is thot Renove factors cause inet throttle o tle or not tuihocha reer No Yes Tighten pipeline or wp lace broken Pipe \No @ Check tibocharger bub rica Clean-and rmave throttla~reptace lubricating oil oil dmining tbe if @ Check tubricating oil of crankcase is too much or not Suggested testing air inlet negative pressure (for wference <6, etm pipe blocked or not ecessty No ® Check diesel engine crankcase Yes Cieek an war wang mannan breather blocked or not aoe corned by diesel engine) manufiewrer ® Check diesel engine fiult or not Yes | Check and repair using maintenance (piston heavy gas scurm: higher manual provided by diesel engine pressure of crankcase) manufieturer Yes Adjust lubricating oil level inside| cminkcase to correct height 5 kPaMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, oil Trouble diagnosis for oil leakage at the end of turbine ® Check turbocharger shaft axiall Yes _| Remove factors cause clearance in clearance inewase or not (compres | erasing of turbochawes replace tr sor blade wearwith housing or no’ bocharger No ® Diesel engine idling tine is tool __YeS__| Clean tubricating of avoid idling for long or not (more than 20 minute) long tine [No ® Toomuch hubricating oil added in| _Y€S_| Unwanted lubricating oil will be advance bum, do not adopt trea ment No @ Check diese! engine crankcase] ___Yes__] Check and repair using maintenance Een manual provided by diesel engine manufieturer |No Clean and nmove thmttla rep hee Check turbocharger lub ricating oil Yes tim pipe Lnckedeae not lubricating oil oil draining tube if necessary [No ® Check m id—housing has silt or Yes | Maintain tubricatng sysion of diese! not_or hibricating oil coking or not engine replace wibocharger [No 7 5 " @_Check iibricating oll bf ctankegse|—~_Y €s ~~} Agjust oll evel insidé emnkease 10) is too much or not correct height [No @® Check diesel engine fiult or not Yes Check and repair using ma intenance| (piston heavy gas scurgs higher |—————| manual provided by diesel engine pressure of crankcase) manufieturer leakage is a usual phenanenon for turbo —diesel engine if you can find and rmove the phenamena in tine you can avoid turbocharger failure Following instance will cause turbocharger br leaking oil @ pressure Q) 3) @ 6) © DO 8) Blocked air filter or oil inlet pipe of the diesel engine result in kuger air inlet negative Curving or damaged oil retum pipe of turbocharger result in retum oil throttle Accumulated carbon inside oil chamber ofm id—body result in retum oil blocked. Air leakage of the connecting pipe ficm campressor housing outlet to diesel engine intake tube Air leakage of the connector frm volute air inet © exhaust outlet Too longer id ling tine Too higher pressure or oil level insite crankcase crankcase s ventilating flue blocked, Toomuch lower gas scurry of the diesel engine Incorrect leakage diagnosis Sta rt the diesel engine after disassan bling the connecting pipe fam camp ressor housing outlet engine intake tube then observe whether there is oil leakage following the injecting air flow or not fim campressor housing outlet 82 (6a Te A Ui 7 a lB 2) Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER 3. MECHANICAL SYSTEM CHAPTER 3» MECHANICAL SYSTEM 3.1 Cylinder Head Disassembling sequence @ Thermostat system assembly ® Injector assembly ) Preheating plug and its connecting piece @ Rocker shaft and rocker S) Push rod 2 @ Cylinder head Reassembling sequence Reassembling sequence is reverse to disassembling sequence Figue 3=1=1Disisenbling and A ssanb ling Sequence forCylinder Head RECN ABMS Great Wall Baoing | Manufacturing Company Limited Inter Conbastion EngineMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, Figure 3—1— down 2 Disassemble the Holi — n Bolis of Injector Figure 3— =3__Disassemble the Invector Body, Figure 3— P Fac) Figure 3-1-5 84 1-4 Disassemble the reheating Plus Reo ee", Disassemble the Cylinder Head Bolts fe TE tS Ib 0 A a tS Manufactur Great al Beeding internal Combustion Engin V Attention () During disassanbling the parts belong to valve unitmustbe collected together at one place and marked with symbol so that to ensure that these parts could be reassembled to restore their original| position During disassembling injector position must be maiked with symbol and restored original position when reassembling forbidden © wrong position (3) Please camy out the compressive testing and record testing result for one tine before d isassamb ling cylinder head frm the diesel engine and disassembling valve unit (4) Disassembling Disassemble the themostat Disassemble the injector assan bly () Disassemble the hold — down bolts of injec tor See Figure 3—1—2. assemb KD) (2) Disassmbk the injector and hold — down plate together using injector body knockout and sliding hammer—See Figure 3 —1—3. Injector body knockout 5 +8840 —2034—0. Sliding hanmer 5—8840—0019—0. Disassemble the preheating plug and its connect ng piecd3) Disassemble the wcker shaft and rocket) Disassamble the push md5) Disassemble the cylinder head@) Loosen 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 If you do not loosen the cylinder head bolts at a few tines gmdually accord ing to the sequence as well as Just bosen a little at each tina there will have bad impact on lower surface of cylinder head. RZ] fing Company LimitedCHAPTER 3 MECHANICAL SYSTEM Figure 3—1—6 Check Cy! Cylinder H ead Bolts Figure 3-1-9 Check Cylinder Head Clean Up () Cylinder head bolts (2) Cylinder head Carefully clean up all oildirt carbon— smoke and accumulated carbon until it shovsmetal color Forbid den electric metal brush for any gasket and sealing sur face 18) Check and Repair If you find heavy wom or damaged parts during checking it is necessary to adjust repair and rep lace the parts ) Check leakage mst and gas scuny at gasket surface of cylinder head. You shouki find the reason if the cylinder head gasket file Incorrect assan bly. Cylinder head loose or wam. Insufficient tighten torque for cylinder head bolts — Cylinder head block surface warp. (2) Check screw thwad of cylinder head bolts damaged or elongated or not or incorrect tools damage the cylinder head. \W/Cautiok Doub tir eylinder head bolis shou be replaced. (3) Cheek there is erick or not for cylinder head especial at the places of cylinder head valve seat and the outlet (& Check there is mst or not at bottam plane of cylinderhead, arenaceous and loose hol or not inside cylinder head. YY Caution Forbidden weld the cylinder head replace damaged cylinder head immediately (S) Check cylinder head plane and phne degree ofmatch ng surface between intake and exhaust mani folds See Figure 3—1—8 and Figure 3-1-9 These surfices can be cut and grinded. If the plane degree of the surfices is notwithin the prescribed lin it cutand grind these surfaces tomeet technical speci fication Replace than if plane degree exceeded linit too much. Standard Linit Plane warp of cylinder nena) Botan ene 0..05mm | 0, 20mm. Cylinder head height 92mm 91. 55 mm RECKNAM MEST ‘Great Wall Baoding | Company Limited InteralConbatn Engine Nandactng|MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, (6) Measure the warp of thematehing surface be tween exhaustmanifold and cylinder head by miler and inspection gage See Figure 3—1—10. If the measuring value is between prescribed linit and standar, re—grind the matching surface betveen exhaustman ifol and cylinder head please, Replace exhaust manifold if measuring value ex ceeded prescribed lin it Wamp of the matching surface between exhaustmani fold and cylinder head Figure 3—1—10 Measure the Wa Between ExhaustM anifold and Matching Surface 0. 20 mm “t Reassambling Reassambe the cylinder head@) ) Assamble the valve seat Carefillly assanble the accessory @ (its extemal diameter is slightly snaller than the valve seat) at valve sea@). See Figure 3-1 —11. Pia 3-1 £11 | Asianbie the Valve Seat VV Attention The surfice contact with valye seat’ shou ld be accessory § slippery surface Forte the accessory into valve seat graduia lly for its position using bench press3). 'YV Attention Forbidden ovemuch fe of bench press othenvise itwill damage the valve seat re Valve guide installation height measured fiom the side at top pkane of cylinder head is shown as F gure 3 1-12. HeightH (for reference) 13mm Figure 3—1—12 Measure the Upper || 2 ____ Height of Valve Guide YY Attention If valve guide has been disassem bled, the valve and valve guide should be replaced in coup les. (2) Assemble the valve Lay oil on extemal diameter of valve stan bebre valve installation (3) Assemble the spring washer () Assemble the vaWe oil sealing —— Install new oil sealing at valve stm. See Fig Poe 8 18, Figure 3—1—13 Assemble the Vahe —— Use special too] for leading Valve oil sealing Oil Sealing erectos 58840 —2033—0. (6a Te A Ui 7 a lB 2) 86 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER 3 MECHANICAL SYSTEM Figure 3—1—14_ Assamble the Valve Spring Piguip 351=15, Asomble the Vale a rester 16 Tighten Fixed Bolts of Rocker Shaft Figure 3-117 Assanble the Preheating Pg () Assamble 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 be downward See Figure 3—1—14, —— Input canpressive air frum preheating pug of cylinder head into cylinder to fore valve for its posi tion ©) Assemble he valve anester —— Press valve spring its position by spring canpressor See Figure 3—1—15, —— Install valve arrester into spring seat —— Slightly knock around the arrester head to force it for its position by mbber hanmer Valve spring compressor 9—8523 —1423—0 (J 29760). Reassambe the push 1d5) ) Clean the contact surface of rocker shaft seat and cylinder head by white cloth 2) Insert the convexity of eight push ds with a Little of oil into relevant holes at thetop surface of cyl inder head and pee, than™to their position Reassanbke the wcker shaft and wckef) () Pkce the weker assanbly on cylinder head ac conling to comect direction let valve adjusting screws a lign upper end concave of push 1od (2 Tighten the studs and bolts of mcker to pre scribed tomue See Figure 3—1—16. ) Tighten tomue fr stds and bolts 55 N+ mt5N-m YY Attention Studs and bolts should have pkne washers Reassanbke the preheating pg and its connecting pieced) Screw preheating plug into relevant hole of cylin der head, tighten it to prescribed torque using f 1k spanner See Figure 31-17, ) Tighten tomue for preheating plug 20N+ miS Nem QRezsenwnieswza ,, Great Company Limited fl Baoding nerralConbstin Engine NantMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, Injector < En Figure 3—1—18 Install InjectorGasket and O Sealing R ing Reassamble the injector assembly) () Place injector O — sealing ring into the 1st gmove of injector then insert following injectors into wlevant hoks of cylinder 1, 2, 3 and 4 according to the serial number 1, 2 3 and 4 on the injectors (2) Use the open end of injector hol —down plate ‘o clip the injector another end pressed at the cylinder head bolts Place the injector hold—down plate washer into the concave of the cylinder head bolis at first then let the convexity on the injector hol —down plate bot om surface align the concave of injector hoi — down plate washer the washer cannot be tum, now fix the injector hold — down plate using injector tightening bolts During assanbling the concave side of the in Jector hold —down plate 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 axig or let the side of the washer extemal wound with the shortest distance fim round concave center face the rarend of the engine Lay a little of grease on the injector hod —down pkte bottm surface is helpfir] for orientation EA) Tighten tonjue fir injectorhold dawn bolts 27N-mt3N-m Figue 3—1—19 Assemble the Injector Figure 3—1—20 Assemble the Themostat Systm A ssemb ly (3) Forbidden mmoving the dust cap of injector oil inlet YY Attention The nozzle pinhole of injector can not be polluted or damaged when rmove the dust cap of injector oil inlet Reassamb ke the themostat systan assanb lx) Tighten the fixed bolts of themostat system assem bly © prescribed torque See Figue 3—1—20, EX) Tighten torque for fixed bolts of themostat systam assembly 20N+ mi5 NemCHAPTER 3. MECHANICAL SYSTEM 3. 2 Rocker Shaft Assenb ly Disassembling sequence @ Rocker shaft assembly @ Rocker shaft circlip © Rocker @ Rocker shaft seat © Rocker © Rocker shaft spring @ Rocker shaft Reassembling sequence Reassembling sequence is reverse to disassembling sequence. Figure 3=2=1Disassamb Ing and Assanb ling Sequence for Rocker Shait Asanby Ge TE te IN PA A is SB Zl Mancfacturng Company Liited Gyret Nl Bang tral Conbasion Ege 89MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, Figure 3-2-2 Measure the Bore of Rocker Figure 3—2—3 Measure the Extemal Diameter of Rocker Shaft Hok of ‘| D isassanbling Disassamble the rocker shaft assembly) Disassanble the 1wcker shaft circlig®) Disassemble the rocket) Disassamble the meker shaft seatt) Disassanble the wcke) Disassemble the weker shaft sp ring) Disassemble the meker shaff) (®) Check and Repair If you find heavy wom or damaged parts during checking it is necessary to adjust repair and rep lace the parts Check 0 il—Bound F im C learance () Measure the bor of meker using vemier cali perormicrmeter caliper See Figure 3—2—2, Replace the rocker if the measured value exceeded the prescribed lim it Rocker bore Standard Linit 19, 036~19..060 mm, 19, 100 mm (2) Apart from sw ing at cker shaft measure the extemal diameter of meker shaft using screw m iemme ter See Figure 3—2—3 Replace the rcker shaft if the measured value exceeded the prescribed limit Extemal diameter of rocker shaft Standard Linit 18. 98~19. 00 mm 18, 90 mm Check the Oil ocker Fig 3-2-4 Clearance between cker and rocker shaft Standard Linit 0. 06~0. 08 mm 0. 10 mm (3) Check the oil hok of weker as shown as Fig ure 3—2—4, it should not be blcked B bow the oil hole of rocker to be clean using cam pressive air if necessary, A) i is SBR 2 al on Engine Manuacturng Company LinedCHAPTER 3 MECHANICAL SYSTEM Se Fige 3—2—5 CorrectRocker Figue 32-6 Measyre the Radial Jump iness of Rocker Saft ‘Sequence for tighten bolts of rocker shaft Figure 3-2-7 Assanble the Rocker Shaft Figue 3—2—8 Check the Rest Bolts of Rocker Shaft RockerCorrection Check the step—style wont) and nick2) of upper valve stam contacting surface of rocker See Pigure 3— 2-8 Finish upper valve stem contacting surface with slight wom and nick using whetstone please VY Caution Replace the weker inmediately if its upper valve stan contacting surface with serious wom and nick. Check the Radial Jumpiness of Rocker Shaft () Place meker shaft atV —b bck (2) Measure the mdial jumpiness at the middle position of rocker shaft using micrmeter See Figure 3 —2-6 If the mdial jump iness is slight comect the rad ial Jump ness of rocker shaft using bench press Y Caution Replace the reker shaft if tie meas ured value exceeded the prescribed lim it Linit-for dial jumpiness of rocker shaft +) Reassamb ling Reassamb ke the wocker shaft) (Daub a little of oil on weker shaft (Assemble the mcker shaft and rocker rocker shaft spring and rocker shaft rest together at the cylin derhead See Figure 3—2—7. Reassamble the wcker shaft springs) Reassambke the eke) Reassambe the rocker shaft sea) Reassanble the wckef3) Reassanbke the 1cker shaft cirelip) Reassanble the wcker shaft assanb KD) ) Install the mcker shaft assanb ly at the cylin der head. (2) Tighten the mweker shaft seat bolts to pre scribed tomue accord ing to the sequence shown as Fig ure 3-2-8 Tighten torque fr rocker shaft seat bolts 55N- mi5 N-m QRtsnenneswza ,, Great Company Limited fl Baoding nerralConbstin Engine NantMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, 3.3 Valve Spring Valve Stem OilSeal Valve Guide Push Rod Disassembling sequence @ Rocker mechanism assembly @ Valve arrester © Valve spring @ Valve © Valve stem oil seal © Valve guide Reassembling sequence Reassembling sequence is reverse to disassembling sequence. Figure 3=3=1 Disassanb ling and Assanbing Sequence br VaWve Spring Valve Stam OilSeal Vale Guide and Push Rod Ge Se AS In A) 1S FA OR ZA 92 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER 3. MECHANICAL SYSTEM ‘| D isassanbling Disassemble the wckermechai Disassemble the valve arreste®) Use special tools to press valve spring and disas sanbling valve arrester See Figure 3—3—2, Valve spring canpressor 9—8523 —1423—0 (J —29760) . Disassemble the valve spring3) Disassemble the vaivdd) Disassanble the valve stan oil sea®) Figure 3—3—2 Disassemble the Disassemble the valve guid@) Vake A rester Valve guide changer 9—8523—1212—0, ism assem hid) US) Check and Repair If you find heavy wom or damaged parts during checking it is necessary to adjust repair and replace the parts ©) Check Valve Spring VV Attention Check valve spring by eveballing place it if it is damaged or has abnomal wom obviously (1) Measure the fiee he ght of valve spring Measil the five height of valve-spring See Fig uje 83-3-3,| Replace it ifthe height is-lewer than pre seribed Innit Free height of valve spring Figue3—33- Measure Valve Spring, Freel eight, Standard init mm a7. Timm (2) Cheek valve spring pempendicubrity —— Measure valve spring pemendicularity using steel square See Figure 3—3—4, —— Replace valve spring if the measured value exceeded the prescribed limit Limit of valve spring pemend ieu rity Figure 3—3—4 Measure Valve Spring Pemendicularity 17mm iL, ~ @) Check valve spring tension —— Press the valve spring to installing height u sing spring measurer Measure cam pressive spring ten a sion See Figure 3—3—5. 33 —— Replace valve spring if the measured tension is lower than prescribed limit Valve spring tension Installation heght| Standard Linit Fig 3-3-5 Measure Valve 38. 9mm 296. 2N 257. IN ‘Spring Tension RECN AM Maem Dal Great Wall Baoing | Company Limited InteralConbatn Engine Nandactng| 93MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, (S| Check Valve Guide VY Attention Exhaust valve (1) Do not damage valve seat contacting surfice when remove the accumulated carbon on valve head. (2) Carefilly check the scrape 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. Intake valve Figue 3-3-6 Check Valve Check Valve Guide Clearance (1) Measure extemal diameter of valve guide u : sing micrmeter See Figure 3-3-7, Rephice valve and valve guide in couples it if ex temal diameter of valve guide is snaller than prescribed limit Extemal diameter of valve guide ‘endant Linit Tntake valve 7. 946 ~7. 961 mm 7. 880 mm Figure 335 7M pase Valve Guile, Exhaust valve) 7-921 ~7.-936 mm | — 7. S50-mnt Extema| D ameter (2) Measure valve guide bore.using micrometer. (3) Subtrictmeasured valve guide bore fim meas ured extemal diameter of valve guide Replace valve and valve guide in couples if the value after subtacted excee ded the preseribed lin it Valve guide clearance Standart Linit Intake valve | 0. 039~0. 069mm | 0. 200 mm Exhaust valve| 0. 064~0. 096mm | _0. 250 mm Figure 3—3—8 Replace Valve Guide Replace VaWe Guide @) Knock out the valve guide fram one side of a combustion chamber using special tool See Figure 3— 3-8 Valve guide changes 9—8523—1212—0. (2) Daub oil on outside surfice of valve guide Install new valve guide fiam one side of cylinder head upper surfice using special tool and check the height of the valve guide See Figure 3—3—9. Valve guide changer 9—8523—1212—0, Fig 3-3-9 Measure Valve ‘ide Height fe TE tS Ib 0 A a tS BR Zl 94 Grea al Beedig internal Conbustion Eine Manfactring Company LinedCHAPTER 3 MECHANICAL SYSTEM Figure 33-10 Measure Valve Thickness Figure 3—3—11 Measure Valve Shrinkage a Height of valve guide GH): 13 mm V Attention Repkce valve guide and valve i couples if valve guide has been disassanb led. ) Check Valve Check Valve Thickness Measure vaWe thickness See Figure 3-310, VY Attention: Repkce valve guide and valve in couples ifmeasured valve thickness is smaller than pre seribed Im it Valve thickness Linit ‘Standard Intake vaWe 179mm 1. 50 mm Exhaust valve 1. 83mm Check Valve Shrinkage () Install valveD on cylinder head2). See Fig ure 3-31, (2) Measure valve/ shrinkage fiam bottim plang of cylinder head \using depth gage) ‘miler or steel ruler See Figure 3-311. Rephce valve seat ifmeasured valve shrinkage value exceeds preseribed lin it Valve shrinkage ‘Standart Lini Intake vaWe 0 73mm 1. 28 mm Exhaust valve 070mm 1 20mm Check Valve Contacting W ith (1) Check the mughness and planeness of valve contacting surfice The valve s contacting surfice should be snooth, (2) Measure valve contacting width, See Figure 3 3-12, Replace valve seat if measured valve contacting width vale exceeds prescribed limit Valve contacting width tandard Linit Figure 3—3—12 Measure Valve Intake valve 17mm 22mm ‘Contacting W idth Exhaust valve 2.0mm 25mm RECMARMAESRAA Great Wall Baoding Internal Combustion Engine Mansfacturing Company |MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE, Figure 3—3—13 Measure the Contacting Conic Angle of Valve Seat Figure 3-3-4) Disassanble the Valve Seat (8) Check Valve Seat Check the Contacting Conic Angle of Valve Seat at Valve (D Measure the contacting conic angle of valve seat See Figure 3—3—13, (2) Replace valve vahe guile and valve seat at the same tine ifmeasured value exceeds prescribed linit Standani for the contacting conic angle of valve seat at valve 45° Disassemble the Valve Seat (@) Aw weHiing © inside around) of valve seat @. See Figure 3-314. (2) Cooling valve seat fora few minutes this w ill cause valve seat 0 shrink and make it is easy to disas semble (3) Prize the valve seat and let it cames off using screw openef8), Carefirlly operating and do not damage cylinder head). (®- Carefirlly-¢lean-accumulated-catbon-and other, impurity from) the installing hole of valve seat of cylin, derhead. Assanble the Valve Seat () Careft lly install accesso?) (its extemal di ameter slightly mnalier than valve seat) at the valve sea@). See Figure 33-15, Figure 3—3—15 Assmble the Valve Seat ¥/ Attention Smooth surface of accessory should contact with valve seat (2) Use bench press3) gradually forces the acces sory and forces the valve seat to its position See Figure 3-3-1585, Y Attention Forbidden using lage force of the bench press or damage the valve seat