MAINTENANCE MANUAL OF GW4D20/GW4D20B TURBOCHARGED DIESEL ENGINES
236
Great Wall Baoding Internal Combustion Engine
Manufacturing Company Limited
Fig. 5-4-2 Removing the air intake connecting
hose (for reference only)
Fig. 5-4-3 Removing the intercooler connector
Fig. 5-4-4 Removing the air outlet pipe
component of EGR condenser
Removal
Preparation
Disconnect the earthing cable of storage battery.
Removing the air intake connecting hose
①
(1) Loosen the clip connecting the air intake connecting
hose and intercooler connector.
(2) Remove the air intake connecting hose from the
intercooler connector. See Fig. 5-4-2.
Removing the intercooler port
②
(1) Remove the 4 hexagon flange bolts (M6×20)
fastening the intercooler port to air intake manifold pipe.
(2) Remove the intercooler port and throttle gasket from
air intake manifold pipe. See Fig. 5-4-3.
(3) Check the throttle gasket and replace it if there is
any damage or deformation.
Removing the EGR valve and air outlet pipe of EGR
condenser
③
(1) Remove the 2 hexagon flange bolts and 2 hexagon
flange nuts (M8×25, M8×30, M8×1.25) on air outlet pipe
of EGR condenser and EGR condenser. See Fig. 5-4-4.
(2) Remove the 2 hexagon flange bolts (M8×20) on air
outlet pipe of EGR condenser and EGR valve
assembly.
(3) Pull out the plug connecting harness and EGR
valve.
(4) Remove the 2 hexagon flange nuts connecting the
EGR valve and air intake manifold pipe, and then
remove the EGR valve. See Fig. 5-4-4.
Removing the fuel inlet pipe of high-pressure fuel
rail
④
(1) Loosen the fastening bolt on fuel inlet pipe clamp of
high-pressure fuel rail, and then remove the fuel inlet
pipe clamp of high-pressure fuel rail.
(2) Loosen evenly the pipe connector at both ends of
fuel inlet pipe of high-pressure fuel rail, and then
remove the fuel inlet pipe of high-pressure fuel rail. See
Fig. 5-4-5.
Air intake
manifold pipe
Throttle gasket
Intercooler
port
EGR valve
assembly
Air outlet pipe of
EGR condenser
