MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE CHAPTER 5 FUEL SYSTEM 5.1 Summary VV Attention People engaged with the maintenance of fuel supply systan must alvays keep fim ly inmind the following items G) Atany tine when fuel supply system is working battery—ground ing cable should be dis connected exchiding the testing requiring power supply fram batt (2) Always prepare diy— type chanic fire extinguisher (class B) around the operation location please @) Use the sane fuel pipe and spare parts to replace the disassanbled fuel pipe and spare parts ) Release the pressure inside pipeline at first before maintaining any part of the fue! supply systan. (S) Do not repair the fuel supply systan if you haven t wad the manualand check against the dra ings concemed w ith repairing « Figure S=1=1 Pipeline of the Fuet Supply 1 Fuel unk 2—Fuel fit 3—Fuel tim valve 4—Three—way for fuel eum 5—Magnetic valve of high —pressire fie] punp, 6—CPIH high—pwssrm fuel pump: 7—Fuel pump, 8—Pressure sensor of hieh pressure fel mil RPS; 9—High— pressure fuel mil 10—Injece 11 EDC 16039 contml unit GW 2 8TC turbo—diesel engine adopts CRS 2. 0 electric control high— pressure fuel rail ype fuel supply systan developed by Gemany BOSCH Canpany. This fuel supply system mainly consists of various sensors ECU, various actuators and connecting hamess and so on the pressure for fuel 259 REE KC 1 7 WO A 1S (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM supply can be up to 145 MPa and the fue! supply process is autmatically contolled by BOSCH EDC 16C39 electric conto unit (ECU). Apart fem direct contol relevant actuators inside fuel supp y system, it also control other systan s working process concemed with the diesel engine operation such as EGR systm, A/C electric fan ete High— pressure fiel mail type diesel engine mainly consists of sensors ECU, actuators and the connecting hamess to connect than and s on Sensors inchide water tmperatuw sensos engine speed sensox camshaft phase sensor foot pedal position sensos air—flow mie sensoy high—pres sure fiel mil pressure sensor and so on Actuators mainly consists of low — pressure fuel way and high—pressure fiiel way lbw —pressure firel way consists of fuel tanks fie! supply pipe fuel filles fiel pump, and low —pressure area of high — pressure fuel pump, bw —pressure fuelway consists of high— pressure area of high — pressure fel pump. high—pressure fuel rail high— pressure fuel Pipa injector and so on 5. 11 High—Pressure Fuel Pump GW 2 8TC tuibo—diesel engine adopts BOSCH CPIN3 high— pressure fuel punp: thee ram — ype pumps wih 120—degive angle distribution evenly canpress fuel to provide high—pressure fuel to fuel mil the flow rate of high— pressure fuelway is contolled by magnetic valve (fuel inletmeas ure proportion valve) and step —exceed ing valva ECU operate the magnetic valve forcontwlling the fuel flow (high—pressure fuelway) of each mm—type pump see Figure 5—1—2 BOSCH CPIH3 high— pressure fiel pump has gear— type fuel pump Cow —pressure fuel way) . Magnetic valve Foalogllceatt Z Puel inet valve To high-pressure joint of high-pressure titel rail => Ram of fuel pump Many-sided ring Wd \ Sy Pressure control valve Driving shaft with “ Fuel supply fuel way % Throdle Fuel return RECN ARMS ARTA |. (Great Mal andg etal Conbastn Exe NanfactungCangany LintetMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE Low — pressure fuel way provides enough fuel for high—pressure fuel way, the operation of fel pump is to provide enough fire! fr high— pressure fixe way, At vari il suelo Driving | ous woulcing status and different pressure requirment as 5 Pescure | Well as within whole working life the requirment men end tioned above must be meet GW 2 8TC tutbo—diese! engine adopts gear— type pump that incorporated with high—pressure fuel pump as shown as Figure 5—1—3, Main parts are wo rever sal— ming gears and they ar meshing during work ing fuel is sucked into pump body and enpty chanber among gears and pumped to outlet at pressure site The meshing line anong gears ensures excellent seal and prevents fel retam ype Fuel Pump The fuel supply tte of gear—type fie! pump is with ss direct pwportion engine speed The throttle at inlet end or the overflow valve at outlet end linits the fuel supply mite of gear— type fuel pump. Gear—type tel pump ismaintenance free Bere the first starting or the fuel inside tank exhausted cam pletely the air inside fuel unk systan should be ex hausted before the first starting When exhausting air use manual fuel pump to p1ess and provide fueluntil no. air hsidevuel way, Manual-fuel pump.and diesel [filter are /neorporitive manufactred, 5.1.2 Fuel Filter and Fuel—W ater Separator ‘The impurity inside fel will damage high— pressure fuel pump parts fuel outlet valve and injector There fore fuel filter should be installed Fuel filter shou H ial requirment of injection sysiem, or the ss ~ Manual fuel pump Fuel outlet joint meet the spe Fuel inlet joint nomal operation of the fuel supply system and the working lif of relevant unit cannot be ensured Fuel has dissolubility emulsion or free water (for exan ple cooling water for temperature changing), if this water Fuel tank iter — entered injection syst it will cause hole cormd ing element Q Drain serew: —4 Fuel Filter Ge TE te Int Pa A) ll is OR 254 (rst al Bandginerral Combustion Engine Mandactung Compa inet Fig 5—CHAPTER S S) te Papery filter eleinent Housine— Wate collector Drain screw Fuel Filter Fie 5-1-5 5.1.3 Injector Fuel return pipe Pivot disk Ball valve Fuel release hole ‘Needle vale control chamber Puel inlet (a) Fear 5= ~ a ‘Cointeol pistoir Nozzle shaft needle FUEL SYSTEM GW2 8TC turbo—diesel engine equips fre! filter with fuel—water separator this separatorcan drain wa ‘ter fim water collector Folkwing longerusing tine of diesel engine the water level of water collector of the fuel filter will reach to fixed height the autmatic a ming lamp at the panel of cab will be bright driver should dmin out fhe water collector tinely at this tine Loosen the drain screw is to drain, tighten it is w screw tehtly the dmin screw: the directions to loosen and tzhten should be the same direction w ith the bolt Papery ekment of fitel filtermust be replaced tine! Replace it when new vehicle has nun Or4, 000 ~5 000 ~ 30, 000km, and then replace it Hr eve! 004m, High-pressure conection Bearing chamber of needle valve (b) © Injector fe ie te DA A a is BR a... Gest iemlomesin ae ancageogantniel 255MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE GW 2. 8TC turbo—diesel engine adopts BOSCH CRB. 0 injector Injectorwith electric trigger controls the adjusment of injection tine and rte Injector consists of hole nozzle, hydmulic servo system and magnetic valve, Fuel comes frm high—pressure fiel rail and flows to injector through fel way and one fue] release hole conuolled by magnetic valve W hen closed fiiel release hole the hydraulic force acted on the wp of needle valve exceeds the hydraulic fore on bearing of need le valve, therefpre the needle valve will decrease intp valve seat and stop i el injection W hen themagnetic valve of injector is touched off and the fue! rlease hole is opened, the pres sure inside needle conti! chamber will decrease and also the pressure acted on the top of needle valve will decrease Once the pressure decrease to be lower than the free on bearing of need le valve the needle valve will be opened, fielalso will inject into combustion chamber It adopts a set of hydraulic enlarging system; magnetic valve opens the fuel release hole and decrease the pressure of needle contol chamber so that cause the fluctuation pressure difference of rm, and this pressure difference opens the needle valve Moreovey fie] also leaks fim places of needle valve and control ram, and the leaked fielw ill floy tum to fiel tank with retim fuel fm high—pressure fiel pump trough fiel retam pipe & 14 High—Pressure Fuel Rail ODV° ttiah-pressure OV pressure sensor of Tiel sa highepresare tl Tail = = ry Hh a ee | Pine to nestor uc om high-res felral v FgueS=T Tren Pressure Fut ait GW 2 8TC turbo—diesel engine adopts BOSCH LW R2 high— pressure fuel rail High— pressure fuel rail stores high— pressure fuel At the same tme the high — pressure surge caused by fiel supply of high—pressure fuel pump and injection of injector has attenuation in side high—pressure fuel mil cubage so that ensure the injecting pressure for keeping stable value when injector opened. H igh sure fuel rail is equipped the pressure sensor of high— pressure fie] mil formeasuring the pressure of fuel supply. The high— pressure fiel cames fiom high— pressure fuel pump getting into the fuel inlet of high pressure fue! mil Fuel enters into high pressure fuel rail and is distributed to each injec tor through fuel inlet The pressur ismeasured by the pressum sensor of high — pressure fue! mil and is adjusted to required pressure value by BCU and the magnetic valve of high — pressure fuel pump. Thiough flow restrictos high —pressure fuel is pressed to injectos and the flow restrictorcan prevent superfirous fixel into combustion chamber when injector closed inccmple te ly oo QRESEAUN ERR Za (rst al Bandginerral Combustion Engine Mandactung Compa inet ressure fire! rail also has the function of fel distributor H igh— presCHAPTERS PUEL SYSTEM Fuel with pressure is filled with inside high —pressure fuel rail tmelessly. Fuel condensab ili under high— pressure is used to provide pressure storga when fel is sent to injector for injecting frm high —pressure fire! rail even if ther is larger fie! capacity injected the pressure inside high —pressure fue! mil is kept at fixed pressure value p mctically. To inputa voltage frECU in allusion w prescribed fuel pressure the pressure sensor ofh igh — pressure fuel rail should measure the fuel pressure inside high—pressure fuel mil at any manent The pressure sensor of high — pressure fue! wil shou ensure enough precision and respond ing speed, Pressure sensor of high —pressure fel rail consists of ‘liow ing parte (1) Integrated sensor components welded at the pressure devices @) Printing cireuit panel equ ipped with electronic checking loop, (3) Sensor housing equipped with electron ie plug— ype wire Fuel flows to pressure sensor of high—pressure fue! mil through a snall hole at the high—pres sure fuel mil its end is sealed with sensor fin. Fuel with pressure arrives at the sensor fim through one blind hole One sensor component (san iconductor device) switching pressure signal into elec trie signal is installed at this film, the signal produced by sensor is inputted into a checking loop for enlarging collection signal and ECU ‘The working process of pressure sensor of high— pressure fuel mil is as folbwing when fin shape changing the resistance to connect filns also changes The establishment of system pressure causes fim shape changing (about Imm at 150, 000kPa, the changed msistance value will cause the yollage changing thwugh 5V electric bridge Voltage changing range is )~70mV depend ing on using pressure), and is increased 0. 5~4, 5 V by enkawing circuit Precise voltagemeasured val ue is necessary condition for precise working of the systan, W ithin main working mnge the meas ured, precision is around 2% of fuel pressure reading dataIf pressure sensor of high — pressure. fel rail is damaged ECU will start uigent/stop \fimetion 5.1.5 Sensor §.1,5,1 Mull Effect Phase Sensor er of following two Controlled ‘ flo catage m0 circuits direction 4 — Computer Impelier W 1% 2 2 ws @ ch Voltage ~~ Permanent Tenition switch receptive magnet Blade ‘iret 1 yeas TompuTer Window ran? OH Voltage w+ receptive N sa \ Voltage of collector cireuit Arsoninrted Trasnor nce to abo 2V when alin crystal Sich trans str from switch om Weak analog Pn Amplified Cuvoft "Switch on. change to eutaft signals Se signal igi Smith [signal )~ Collector fs trigger ~ Sender Siwiteh transistor Fue 5=1=8 Hull Efiect Phase Sensor RECN AMMAR | = (Great Ml andg etal Combaton Engine NanfactungCangay LinMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE GW 2 8TC turbo—diesel engine adopts PG2, 8 Hull effect phase sensor See Figure 5—1 Hull effect phase sensor adopts Hull efféct principla one steel magnet triggerwheel rotates fol lowing camshaft lull effect integrate circuit is installed between trigger wheel and pemanentmag net and pemanentmagnet produces the magnetic fle peipendicular to Hull canponent Ifone of trigger wheel fingers passes carrying linear— type sensor camponent (san iconductor wated, itchanges the magnetic field intensity pempend ular to Hull component so that the electron driven by voltage along long shaftd irec tion will drift off to the direction perpendicular to current and produce voltage sigal atmV grade wheel put itwith square wave signal Terminal of measuring fomponent Integrate Sensor seat \, 4 Integrate J circuit a SS Sensorfhousing Temperature sensor hn Type A if Rate Sensor dps. D “Ol \ Altemating current sine wave + Voltage SAAAA, | = Voltage | Figure 5—1—10 Operation Princip le of Engine Speed Sensor its amplitude concems the sensor speed relative © trigger he calculating circuit integmted with sensor}ull integrate circuit teats the signal and out 1.5 2 Heat—Fiin Type A irflow Rate Sensor GW2, 8TC turbo — diesel engine adopts BOSCII HFM6 heat~filn type airflow mate sensor Heat—flln type airflow rate sensor is an airmass sensor with gic output To obtain airflow mata middle — installed heating resistance heats sensor filn at sen sorcanponen$ filn s temperature distribution is meas ured by the temperature resistance installed parallel heating resistance The airflow passed sensor changes the fin s tanperatue distribution so that the resistance difference produced between two lanperitire wsistances The resistance difference depends upon the airflow di rection and rip therefore the aiifloy_ mate sensor has, higher requ itanent } ainflew direction-and’ mate, “Air let kmperature sensor can-be installedinside sensor b, b nYeasure air inlet tan pemtie iPhecessary. 5.1.53 Engine Speed Sensor GW 2 8TC wibo—diese! engine adopts DGG speed sensor The instalktion of engine speed sensor is just face to the trigger wheel of steel magnet body and smaller air clearance spaces out than. A soft ima core is inside the sensor and is surrounded by coil and also connects with a pemanentmagnet Magnet field of pemanentmagnet is transfered trigger wheel though soft iron cors the magnet kar ance between trigger wheel and sensor affects the mag net field intensity. The magnet field intensity will stron gerwhen triggerwheel fingers else to sensog the mag net field intensity will weaker when trigger wheel fin gers away fiom the sensor A llemating magnet field w ill produce when trigerwhee! mtates aswell as the mag netic coil will produce one sine inductive voltage the amplitude of altemating voluge will increase ®llow ing the trigger wheel speed (few mV-+ >100V). It is re quired that suitable volluge signal can be produced with in 30 r/min at kast al is BBR Zl 2c QRESEVBMHESEZECHAPTER SPURL SYSTEM 5.1.54 Cooknt Temperature Sensor GW 2. 8TC turbo—diesel engine adopts TF—W water tampemture sensor See Figure 5 —1 11. Sam icon ductormeasuring resistance changed lbw ing tempera ture in installed inside sensor ‘TF—W water tamperature sensor adopts tmperture resistance w ith negative resistance coefficient (NTC). Electron Housing, joint ENTC resistance Fie 5—1—11 Cooknt Tenpemiue Sensor The temperature resistance of coolant tam pemture és sensor is as one part of 5 V voltage distribution c irew it the Wo ends of coolant temperature sensor are connect ed with voltage bearing circuit When the tampemtre sistance of cooknt tempemture sensor changes follow ing tmperatire the voltage of voluge bearing cireuit also changes this voltage is inputted into ECU inter 2 fice module tunsitio cireuit The chamcteristic curve 3 of betveen voliage and current relationship is stored in 2 Temperate | (mB) . { | [Characeristi¢ eve of coolant temperature sensor (MIC) — oO C/U Figue 5—1—12 Coolant Tnpemtare Sensor and Its Characteristic Curve . 1. 5 5 Potentioneter Type Foot Pedal Position Computer Sensor —3v GW2, 8TC turbo — diesel engine adopts FFM po [-}—} VV tentieter type foot pedal position sensor Benchmark Potentimeter type foot pedal position sensor works accor! ing to voltage distribution ciruit principle and sim) computer supplies 5V voltages to sensor circuit Foot Eo pedal is connected with sliding rheostat brash inside ae sensor through steering shaft the voltage betveen biush Lapping iron} SH and ground ing will change when the position of potenti . I «meter type foot pedal position sensor changes and the [+ q 4D vollage bearing circuit inside can puterw ill transfer the vollage into position signal of foot pedal W ork ing prin ciple of foot pedal position sensor is as shown as Figure Figure 5—1—13 Working Principle of = 51-13, Potentimeter Type Foot Peda| Position Sensor Be 4 I FAK A al is FS BR (et a aditMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE Figue 5-115 Engine Hamess 1—Connect with ECU, 2—Conneet w ith air flaw rate sensor unit. 3 —Connect w ith camshaft position sensoe 4 —Connect w ith engine water temper ure sensor 5—Con nect with water emperatire sensoz 6 — Connect with vacuum sensoz 7 —Connect with seed sensog 8 —Connect with EGR val 9—Connect with 3 cylinder 10 — Connect with 4° cylindeg 11 — Connect with 1° eylindes 12 —Connect with 2°4 cylindee 13—Connect with high—p esause oil mil 14—Connectw ith high —pressure fuel pump 5.1.6 Electric ContwlUnit (ECU) GW2 8TC turbo — diesel engine adopts BOSCIL EDC16C39 electric contol unit (ECU). See Figure 5—1 14 EDC Electric Diesel Contd ekectric contol unit sensors provide current working information of diesel to EDC electric control unit (ECU), then electric control unitanalyzes sensor signals at first and gives controlling signals to control fuel injection capacity injection start ing point waste gas recycle and electric heating plug system and so on in accordance with scheduled control strategy. Through the signals such as fuel injection ca pacity engine speed and cooling water tampe mre and x0 on EDC electric control unit detem ines the optimal injection starting point and sends correspond ing control signal tomagnetic vave inside high—pressure fuel pump. High— pressure fuel mil type electric contol diesel engine control device (EDC) mainly consists of three system modules (D The sensors and prescribed value producer to collect operation conditions and expectation They can tansbm different physical parmeters inb ebctwnic sig nals - f (2)ECU teats information into électionic ouput signals accord ing © specifically mathanatical ca leu kr tion methods, (3) Actuator transfoms the electronic output sig nals of ECU ino mechanical parameters Apart fiom direct contol relevant actuators inside control fuel supply systam, ECU also controls other sys tems working processes such as EGR systan, A/C, e etric fan ete they all 1ekting to diese! engine opera tion, 5.1.7 Engine Hamess Sensors connected with GW 2, 8TC turbo —diesel engine hamess are water tamperauue sensox engine speed sensoy camshaft phase sensoy foat pedal position sensor air flow mte sensor high—pressure ihe! mil pressure sen sorete See Figure 5-115, 10 CQQRESEAUN MBAR Za (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM (pms 187EMO 501) Buna aa pus dy, ue way 4 ys aUMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE 5,2 Repair in the Vehicle 521 FuelPilterAssanbly D isassamb ling Sequence @ Fuel hose 2) Fuel filter 3) Drain screw of fiel—water separator N Manat fel pump Fuel outlet joint 1 Assanb ling Sequence Assan bling sequence is verse to disassen bling sequence, Fuel inlet joint '**| Disassembling Preparation Fuel tank filter Disconnect the grounding cab le of battery, clement Disassemble the firel hosé) brah db (1) Disassemble’ the file! hose of fue | filier | See Pigyre 52 +2, (2) Blocking hose end tovavoid fuel overflow. Fige5—2—1 Fuel Filer Disassemble the fel filtet®) Loosen ficed bolts of fel filter bracket and then disassemble the fuel filter Disassemble the dmin screw of fiel—water sepa rato) Assembling Assanb the drain screw of fiel—water separaio) Assanbk the fuel filte®) Assanbk the fuel filter and tighten fixed bolts of bracket Assanbke the fire] host) Connect the fiel hose w ith the frel filter Canty out lowing tasks after assembling please (D Connect the grounding cable of battery. Figure 5 Disassemble and (2 Supply ftel to high— pressure tel punp by Assamble the Fuel Hose prine fuel pump to rmove the air inside fuel supply system. Ge TE te Int Pa A) ll is OR 262 (ret Wal aang neal Condustin Ege Mndctng Company LinedCHAPTER S Figure 5—2—3 Disissanble the Fuel Filter Elan ent me Fie 5—2—4 Fuel Filter 1—Filer tank filter ekment 2—Fuel inlet joint 3—Manual fuel pump, 4—Fuel out Jet joint 5—Electric socket 6—D min screw Figure 5 H igh—Pressure Fuel Pump 1 High — pressure fie! pump, etm jot 3 Hoop 4 — Fuel eum hos, 5—Fuel wtm the—way 6 —Fuel inlet joint — Fue! FUEL SYSTEM 5.22. Filter Elment of Fuel Filter (| Disassembling Loosen and mmove the drain screw and store it well for next usage. Disassemble the filter ekment of five] filter by span ner See Figue 5—2—3 Filter spannes 5 —8840 —0253 —0 J—22700). **) Assembling (1) Cleanout the matching surface of filter cle ment of fue! filter body so that the filter element can joint well (2) Instill drain screw on new filter elenent See Figue 5-2-4. (3) Daub ofl on O—sea! rhg of new filter ekm ent () Fill fue! into new filter elanent to rmove air (5) Tighten new filter element until the O — seal ring of new filler elament contact with scal surface Carefilly please prevent fuel spill (6) Tighten the Mtr element Sr 18-22 cy cles by filter spanner Filter spannee_ 5—8840 —0253—0 J—22700). Deflation. ' QD 0 pe mie the manual. fuel pump to press thelait inside the fuel ‘supply. system -t ‘high > pressure] file! pump. — Oo (2) Disassanb ke the fuel retam pipe of high—pres sure fuel pump (see Figure 5—2—5) and operiteman ual fixel pump until move all air bubble canp ete, (3) Assemble the tel retum hose of high — pres sur fuel pump. (@) Start he engine if the engine cannot be started within 10 seconds repeat deflation mentioned above please (5) Ensure no fiel leakage and tightly tighten manual fie! pump cover Drainage When the water inside fuel—water separator arrives © prescribed level the alam ing lamp of cab panel will bright Drainage shoul be carried out as follow ing steps () Loosen drain scrow, the direction for loose ning and tighten ing should be the same as screw, (2) Operate manual fuel pump for tine after tine for drainage (3) Tighten the drain screw afer dminage (4) Opemte manual fuel pump for tine after tine to check fuel leakage (5) Check if the alam ing lamp is dark fe i te TA A il is SR (Great Mal andg etal Conbastn Exe NanfactungCangany Lintet 263MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE 5.23 Injector Disassembling sequence i jector magnetic valve High-pressure fuel pipe Fuel return pipe of injector DHold-down plate of injector injector Assembling sequence Assembling sequence is reverse to disassembling sequence. Fur 5 Ge TE te Int Pa A) ll is OR 264 (ret Wal aang neal Condustin Ege Mndctng Company Lined ‘6 Disassanbling and Assanbling Sequence for InjecorA ssanblyCHAPTER S Figure 5—2—7 Disassemble the Hames Joint of InjectorMagnetic Valve Figue §—2—8 -Disassmble;the High— Pressue Fuel Pipe Figue 5-2-9 Disassemble the Fuel Retum Pipe of Injector Fisure 5 =10 Disssemble the Bolts of Hold —Down Plate of Injector FUEL SYSTEM ] Disassembling Prepamtion Disconnect the ground ing cab of battery. Disassemble the hamess joint of injectormagnetic valve) Apart fhe engine hamess joint fem the injecormag netic valve plug See Figure 5 Disassemble the high— pressure fiel pipe Loosen four connecting nuts of h igh—p ressure fuiel pipe with four injectors at first then bosen the connect ing bolts between high— pressure fuel pipe and high— pressure filel wil and disassemble the high — pressure fuel pipe See Figue 5—2—8, Disassemble the tel teumpipe of injecto®) Push out the clip spring by tool at first and then pullout the connectors of fuel retum pipe fim every injector See Figure 5—2—9, Disassemble the hod—down p kite of injectofl) Disassemble the bolts of hold —down plate of in Jector and take out hold — down plate of injector and washers of hold —down plate of injector See Figure 5 =2=10, Y Caution Washers of hold —down plate of in Jector are inside the concave hole of cylinder head bolt they are very smalland can not be loosen. W ithout the parts needle valve of injector woul be abnomal womed, fe ie te DA A a is BR al (Get ant inteal Combustion Ene NanzctungConpanyintes— 255MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE Figue 5—2—11 Disassemble the Injector Figur 5 —12 Assemble the Injector Figue 5—2—13 Assanble the Holi — DownPkite of Injector Disassemble the injecto®) Slightly pull out four injectors fim injector holes and then make symbol at than fpr correspond ing cylin derl, 2 3and4 V Attention () Forbidden pollute or damage the needle hole of injector when take out injectors Repair or replace relevant parts if injector has been womed heavily or damaged. (2 Every injector has IQA code and this code has input into ECU, Therefore every injector and ECU (campute) has one — to one comespond ing relation ship, forbidden replacing feely aswell as Its installing position Otherwise engine cannot work nomally (3) Injector after wpair should be signed QA code again, when use the injectorwith different code of high—pressure oil pump, input new injector code int ECU. The same when place ECU, current injector A code should be input [®) Check and Repair Check injectorby KTS650 diagnostic tester or spe cial instuument~ Injector nozzle can be replaced: el ssambling. Assambke the injecioS) Install O — seal ring of injector into 1*' seal grove and then accorling the symbol 1. 2 3 and 4 on the injector insert than into the comespond ing cylinder 2 Sand 4. Assambke the hold—down plate of injec in) Use the open end of hold down phite of injector © clip injectoe another end is pressed at cylinder head bolt Place the washers of hold—down plate of injector into the concave hole of cylinder head bolt align the bulge at the bottan of holi—dawn plate of injector washers concave hole of hold — down p kite of injector and also do not tum the washers now fix fe hold — down pte of injector by fastening bolt of injector When assembling washer concave of hold —down plate of injector should be upwarh and the line frm “ symbol at the washers of ho —down plate of injector io the center of concave hole is perpendicular to the axial line of crankshaftor kt the nearest side of outside ound of washer b concave center facing to engine s rear end, To help locating position daub a little of oil on the bot fam of hold —down plate of injector in advance please oo QQRESEAUN ERR Za (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM FA Tighten tomue for fixed bolts of hok —down plate of injector 25N-m+t5Nem Assanbke the fuel retum pipe of injectof) Ramove upper dust cap of injector insert four short joint of fuel retum pipe into four upper holes of injectors respectivel: Use the clip spring to tight clin other one long pint is installed into fuel retum three — way of high—pressure fuel pump and tigh tly clipped by one small size metal strip type hoop, Figure 5—2—14 Assenble the Fuel Rewn Pipe of Inector Assambk the high—pressu fuel p ip) Install five ends of high — pressure fuel pipes at five end openings of high — pressure fuel mail at first and then install another end of middle high — pressure fuel pipe on high— pressure fuel punp (see Figure 5 2-15), another ends of furhigh—pressure fel pipes are installed on injectors respectively. AL. Tighten torque Hr high—pmssuw fie! punp end 20N-m+2N-em J Tighten torque fr injector end 27N+ mi2Nem Pie 5 15° Assemble the H igh— Pressure Fuel Pipe ‘es ©) Tighten tomue rhigh—pressure fuel wil end 27N+mi2Nem ns Assanbk the hamess joint of injector magnetic valve) Insert engine hamess plugs into fur injectors re spectively: See Figure 5—2-16 V Attention Do not insert incorrect position Figue 5—2—16 Assanble the Hamess Joint of Injector Magnetic ValveMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE 5.24 High—Pressure Fuel Pump Assanbly © Water pump, pulley housing cover assembly Disassembling sequence @ Fuel return hose @ Engine harness @®High-pressure fuel pipe @ Fan assembly © Timing belt, crankshaft (Power steering pump and A/C and camshaft timing compressor transmission belt _ pulley, transition wheel @ Altemator transmission belt and tensioner © Inspection cover @Nigh-pressure fuel pump Assembling sequence Assembling sequence is reverse to disassembling, sequence. Fur 5S=2=17 Disassembling and Assan bling Sequence fori h—Pressure Fuel Pump Assanbhy Ge TE te Int Pa A) ll is OR 268 (ret Wal aang neal Condustin Ege Mndctng Company LinedCHAPTER S 2-18 Fan Assan bly Figure 5 Disassemble the Figur $>2—19 , Pover Swerhe Punp and AC Canprssor,Tangmission Belt Locking bolts Figue 5—2—20 Disissamble the Trunsn ission Belt 21 Disassemble she Inspection Cover Figure 5 FUEL SYSTEM #* Disassembling Prepamtion D Disconnect the grounding cable of battery. 2) Drain coolant fiem cooling system. YY Waming Coolant is poisonous and must be stored inside original container Forbidden people contact it Disassamble the engine hamess1) Disassemble the fan assen bly) Loosen locking bolty disassemble the fan assan bly and water pump pulley, See Figure 5—2—18, Disassemble the power steering pump and A /C cam pressor transn ission belf) Loosen adjusting bolts of power steering pump and disassemble the tansmission belt See Figure 5-2 — 19. Disassemble the altema tor transmission be ED), Loosen fixed bolts Clover side) of altemator and fastening bolts of adjusting pte and then disassanb le the transmission belt See Figure 5—2—20, Disassemble the inspection cove: Loosen fixed bolts of inspection cover and then disassemble the inspection cover See Figure 5 —2— 2MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE igure 5—2—22 Disassemble the W ater Pump, Pulley Housing Cover Assembly Figie 5—2—23 Disussanble and Assanble the High— pressure Fuel Punp 24 Assemble the Fuel Retum Hose 1—High— pressure fie! pump, tum pipe joint 3—Hoop, 4—Fuel eum hose S—Fuel retum three-way 6—Fuel inlet Joint uel Disassamble the water pump, assem bly@) Loosen fixed bolts of water pump pulley housing cover and then disassanble the water pump, pulley— housing cover See Figuie 5—2—22 pulley housing cover Disassamble the fiel retum hosd7) Loosen fixed hoop of fuel retum pipe opening of high—pressure fel pump and then pull outhose See Figure 5—2—23 Disassemble the high— pressure fiel pip@ Loosen the nuts betveen high—pressure fie! pump and high—pressure fuel rail and then disassemble the high—pressue fuel pipe Disassemble the timing belt cmnkshaft and cam shaft tm ing pulley transition wheel and tensione®) Disassemble the high—pressure fie! pun p® (1) Loosen the hexagon nuts to tighten high — pressure fuel punp timing pulley and take out high — pressure fuel, pump \tin ing pulley assem ly-and | then take gut the woodmuff inside the keyway of high+ pres sae fuetpump, — — (2 Loosen three bolts with iocating 1d to tighten high — pressure fie pump and high—prssure fiel pump pads on pulley housing and take ou thigh— pressure fi el pump and high— pressure fel pump pads (3) Take outh gh—pressure fie! pump pads from high— pressure fuel punp. VY Attention Covers every fuel hole at high — pressure fiiel pump by rubber cap (or similar goods) for avoiding impurity enters inta +) Assembling Assambk the high—pressure fuel pun pid) (1) Daub a little of oil both on inner round of hgh —pressure fuel punp pads and on seal ring of high — pressure fuel pump, and then force h igh—pressure fuel pump pads into high pressure fel pump. Align the holes of high—pressure fuel pump to the holes of high —pressure fe] pump pads The fuel release gwove at pad end surface of high—pressure fel pump should be downward, oo QRESEAUN SRR Za (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM When use new timing belt Figure 5 Assamb le the Tin ing Pulley and Timing Belt Figure 5—2—26 Assemble the Fuel Retum Pipe Hose (2) Install the high — pressure fuel pump and high—pressure fuel pump pads on pulley housing and tighten the three bolts Gwith spring washe) with loca ting rod, Finally install the wood ff inside the keyway of high— pressure fuel pump. (3) Tighten and fix the high —pressure furel pump pulley by one hexagon nut (with spring washed . Align the keyway at camshaft pulley flange to the wood mff at high— pressure fuel pump when assembling (4) Install one end of oil retum hose on the outlet pipe opening ofh igh—pressure fiel pump. Connect an other end with fuel retum three—way. and then clip it by two snallmetal sirip ype spring hoops ( 11 7). Preserving the dust cap on the outlet pipe opening of high— pressure fuel pump for ensuring the clean of fuel pipeline al hton tomue M16 nut 70N+ miSN+m MB bolt 2 N+ m5 Nem Assenbk the tin ing belt crankshaft and canshaty tin ig pulley, transition whee! and tensione{)) Asssanb k.the nigh—pressure fuel p ipa) Install one end of high— pressure fuel pipe on the middle open ing of high—pressure fuel mil and another end on the top end opening of high—pressure fiel pipe, EAL Tighten tomue forhigh—pressure fuel pnp end 20N- m+2N-m EA Tighten tomue for high— pressure fuel rail end 27N+mi2Nem Assanbke the fuel reum hosd7) Renove the dust cap of he upper end of high — pressure fuel pump, and then install one end of fuel 1e um hose on the upper outlet pipe joint at rar end of high—pressure el pump and connect another end with the hick end of fuel retum three—way and then clip itby snallmetal strip type spring hoop tightly Ge i te DA A il is SR Get a nto intealCombaston Ene Nanfactung Company Limted 271MAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE Assemble the water pump, pulley housing cover assembl@ (D Assemble two studs on crankshaft hole right side of pulley housing and the hole on water pump top by special tool (2) Can water pump, pulley housing cover as sembly and pulley housing matching surface Place wa ter pump seal rig inp seal grove horizontally and daub sealant 587 on seal ring even. (3) Align water punp, pulley housing assanb y Figue 5—2—27 Assenble the Waer with stds and lightly knock then © their position Pump, Pulley Houshg Cover Assamb Then tighten and fix them using bolt unit (M8 x 70, M8 X55), hexagon flinge nutand hexagon socket head screw, [Tighten torque for hexagon socket head screw 20N+m+5Nem Assanbke the inspection cove) Tighten and fix the inspection cover assembly on pully housing using boltunit see F igure 5 —2 —28, FA) Tighten torque for fixed bolts of inspection Assemb ke the Inspection Cover cover Figure 5 Locking bolts 6Nemti Nem Assemble the altemator tunsn ission bel) Assambk the power steering pump and A/C com pressor transm ission bel) (D Assemble the pover steering pump and A /C cam pressor transn ission belt and adjust belt tension de gree See Figure 5—2—30. (2) Press the middle part of the belt with 98 N 29 Assmble the Altemator forces to check its tension, Transm ission Belt Figure 5-2 Transmission belt deflection 8~10 mm (3) Tighten the fixed bolts for power steering pump and A /C compressor tp prescribed torque 4) Tighten torque for fixed bolts of power steer ing pump and A/C compressor Figure 5—2—30 Assanble the Paver 27? Ne mis Nem Steering Pump and A/C Compressor ~ Trunm ission Belt Ge TE te Int Pa A) ll is OR 272 (ret Wal aang neal Condustin Ege Mndctng Company LinedCHAPTERS PUEL SYSTEM Assemble the fan assembly Ordinal install water pump pulley and fan assem bly on water pump and tighten the locking nuts t pre scribed omue See Figure 5—2—31. ©) Tighten torque for lock ing nuts 8Nem Figue5—2—31 Assmbk the Fan Assen bly Assanbke the engine hamesd) () At first fix the engine hamess at the wire fer ules of generator adjusting bracket lawer/upper case of themostat and then tightly fix fourhamess fernes of en gine at one hamess bracket of upper case of themostat one hamess bracket of air inket joint and wo hamess brackets of high—pressure fuel rail 1espectively (2) After fixed the hamess of engina correspond ing insert the plug of every sensor of the hamess int cam shaft position sensor-water tamper tu re-sensox-en gine water tmperatute senses high pressure’ file ‘mill pressure sensow vacuum reeulaion. high~p ressure fuel Engine Hamess pump, and ®ur injectors (3) Hitch the preheating phe tminals ushg tur connectors of engine hamess respectively and then tight en and fixed than using fur hexagon flange nuts FA Tighten tomue forhex flange nuts 4N-mt1N-m (4) Insert and connect ECU into correspond ing plug of engine hamess Ensure that the serial number at bar code label of ECU is accomlant with the serial number of engineTURBO “DIESEL ENGINE, MAINFENANCE MANUAL OF GW2.87C 1 5.25 Fuel Tank Disassembling sequence Puel tank shield @) Aeration rubber pipe of fuel filler @ Rubber pipe of fuel filler 5) Drain screw @ Damping pad of fuel tank @ Fuel sensor @) Strainer ‘® Fucl outlet rubber pipe of fie! tank 0 Fuel return rubber pipe of fitel tank: Fuel outlet pipe of fuel tank 12 Fuel retum pipe of five tank. (G Fuel pipe holder (9 Fuel tank. Assembling sequence Assembling sequence is reverse to disassembling sequence. FRE S=2 33D isaM INE aNd A SRM IE SeqUENTS Wor FueT Tank On or Tee RNCA ** Disassembling Preparation Fuel tank shield t . = Disconnect the grounding cab ke of battery. Disassemble the ftiel tank shiek) Disassemble the fiel filler covet2) Disassanble the aeration mbber pipe of fie! fille®) Disassemble the mbber pipe of fuel fille) Disassamble the dmin screw) () Loosen drain screw and drain the fuel (2 Tighten the drain screv t prescribed jomue after fuel drainage Tighten tomue frdmin screw Figue 5—2—31 Disassemble the Fuel Tank Shield 29Nem Ge TE te Int Pa A) ll is SOR 274 (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM Disassamble the damping pad of fuel tank@) Disassemble the fiel sensot?) Disassemble the fuel sensor frm fiel liquid level indicator Fucl sensor Disassemble the stra ine) Disassmble the fuel outlet mbber pipe of firel unk) Disassemble the fuel retum rubber pipe of fuel tank Disassamble the fiel outlet pipe of fuel tank Disassemble the fiel retum pipe of fuel anki Disassemble the Biock the fuel pipe joint for preventing fuel leak “uel Sensor age aflerdisassamb les the fuel pipe fium engine side Disassemble the fiel pipe hold ed Disassemble the fuel tank le Assembling Assambke the fie! tani VY Attention Damping pad of fuel tank must be installed on fram ing before assanble the fuel tank on fram ing See Figure 5 -2—36 Damping pad of fuel tank Assanbk. the fiel pipe holed KEL Tighten the fixed bolts of uel pipe hokler to pre scribed omue Q) Tighten tomue for fixed bolts of fuel pipe Figure 5 ~ holder 36 Assemble the Fuel Tank 19Nem Assanbke the fue] retum pipe of fuel tank 7 Bl Assamble the fie] outlet pipe of fel tani Fl culerpipe “fe Connect fuel outk t/retum p pes of fuel tink on en of fuel tank A! re oil gee and tightly tighten the joints by holders See Figure ip hoteer™ reese Md rcton pipe Assanbk the fuel retum subber pipe of fie! tankit) of fuel tank Assmbk the fuel outlet mbber pipe of fuel tank®) “a 2 Assambk the strainef) ey Assanbke the fuel senso) ee Connect the fue! sensor with the fuel liquid level ind kator 37 Disassemble the Fuel Pipe Be ‘eT FA) 8K A al is FS BR (et a adit inteMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE Assanble the damping pad of fue! tank®) Assanblke the drain screw Assanble the mbber pipe of fiel filleél) Assanbke the aeration nubber pipe of fuel fillet) Assamble the fuel filler covet2) Assanbke the fue! tank shieldD) ‘Tighten the fixed bolts of fuel tank shield to pre scribed tomue See Figure 5—2—38. ©) Tighten tomue for fixed bolts of shield 55 N+ m Fisue 38 Assemble the Fuel Tank Shield Follow ing works can be done after assan bling () Fill fuel into fuel tink (2) Connect ground ing cable of battery 5.26 Fuel Liquid Level Indicator Disassembling sequence @ Fuel sensor 2 Fuel liquid level indicator Assembling sequence ‘Assembling sequence is reverse to disassembling sequence, el Ind iene Figie 5—2—39 Disissanbling and Assenbling Sequence tor Fuel Liquid Li ore RTE KC 1 7 BO A 1S (rst al Bandginerral Combustion Engine Mandactung Compa inetCHAPTERS PUEL SYSTEM Fuel liquid level indicator Figure 5—2 Assamb le the Fuel Sensor and Fuel Liquid Level Indicator 40 Disassemble and Figure 5-2 —41 Inside vabin flection Acce lerstor Pedal | Disassembling Preparation Disconnect the giound ing cab k of battes semble the fel sensof) Disassemble tie fuel sensor fiom fiel liquid level indicator See Figure 5—2—40. Disassamble the fuel filler cove! Disassemble the fixed bolts of fuel liquid level in dicator and fie! liquid level indicator See Figure 5 —2 40, YY Attention Covers the fuel tank mouth by cot ton cloth or plastic @r avoit ing impurity or dust enters into the tank after disassemble the fuel liquid level in dicator + Assanbling Assambk the fuel filler covet2) Assamble the fuel liquid level indicator on fuel tak See Figure 52—40, Asssanb lke the- fire) seasoth Assanbke the fel sensor on the fuel liquid level indicator See Figure 5—2—40. 5.27 Electron Accelerator Pedal The accelerator control of GW 2, 8TC turbo—diesel engine is carried out by election accelemtyr pedal har ness and ECU. ECU calculates the fuel supply capaciy of the engine in accordance with pedal disp lacanent signal of peda! position sensor The disp lacanent sensor of potentimeter type ac cekrator pedal works accor ing to voltage distribution cireuit principle and ECU (computed supplies 5 V voltages to sensor circuit Election accelemtor pedal is connected with sliding theostat bash inside sensor through steering shaft the voltage between brush and ground ing will change when the position of electron ac celemtor pedal position sensor changes and the volinge bearing circuit inside ECU (computed will transfer the voltage into the position signal of electmn accelerator pedal Qxztewnanisagza ., Saag AMAINTENANCE MANUAL OF GW2.8TC TURBO “DIESEL ENGINE D isassamb ling Sequence @® Hamess @ Electron accelemior pedal Cinside cab in) Assanb ling Sequence Assanbling sequence is reverse to d isassambling sequence. | Disassembling Disassemble the hames¢i) Loosen the joint between hamess and electron ac celerator peda! position sensor Pigue 5—2—42 Disassemble and Assanbling the Hames Disassemble the election accelerator pedal-(inside, cabin) Disassemble the installing bolts at cab in floot and take out pedal assembly. Inside vabin. Figure 5 Assemble the 43 Disassemble and lection Accelerator Pedal | Assanbling Assambke the election accelembr pedal (inside cab in@ Assanble the hamess)) Connect the joint between sensor p Lig and electron accelerator pedal position sensor 44 ECU oe QRELEAUN MBAR Za (rst al Bandginerral Combustion Engine Mandactung Compa inet