MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES
122
Great Wall Baoding Internal Combustion Engine
Manufacturing Company Limited
Fig. 4-1-7 Removing the fuel injector
assembly
Fig. 4-1-8 Removing the EGR Condenser
Fig. 4-1-9 Removing the air intake manifold
pipe and gasket
Disassembling the fuel injector assembly
⑦
(1) Removing the fuel injector harness plug: Pull out the
harness plug self-locking device, and then remove the
fuel injector harness plug.
(2) Remove the fastening bolts of fuel injector ballast.
See Fig. 4-1-7.
(3) Remove the fuel injector ballast.
(4) Take out the fuel injector assembly from the cylinder
head.
Prompt:
Place the removed fuel injectors carefully
according to the cylinder serial numbers 1, 2, 3 and 4,
and make corresponding marks on these fuel injectors.
Protect them from being contaminated or bumped.
Disassembling the GER condenser air intake pipe,
EGR condenser air outlet pipe and EGR condenser
⑧
(1) Remove the 2 high-temperature resistance hexagon
flange bolts (M8×1.25) connecting the EGR condenser
air intake pipe to exhaust manifold pipe. See Fig.. 4-1-8.
(2) Remove the 2 hexagon flange bolts (M8×20)
connecting the EGR condenser air intake pipe to EGR
condenser.
(3) Remove the 2 hexagon flange bolts (M8×16)
connecting the EGR condenser to EGR condenser air
outlet pipe.
(4) Remove the single-ear stepless clamp connecting
EGR condenser to water inlet pipe. See Fig. 4-1-8.
(5) Remove the hexagon flange bolt (M10×16)
connecting EGR condenser to cylinder head, and take
down the EGR condenser. See Fig. 4-1-8.
Disassembling the air intake manifold pipe
⑨
(1) Remove the 7 hexagon flange bolts (M8×105 &
M8×25) connecting the air intake manifold pipe to
cylinder head. See Fig. 4-1-9.
(2) Take down the air intake manifold pipe and its gasket
from the air intake side of the cylinder head. See Fig.
4-1-9.
Check the air intake manifold pipe gasket. It must be
replaced if there is any damage or deformation.
Fuel injector
assembly
Water outlet pipe
EGR condenser
Exhaust manifold
pipe
Water inlet
pipe
Air intake
pipe
Air intake
manifold pipe
Air outlet
component of EGR
condenser
Air intake
manifold pipe
gasket
