Daewoo Doosan G420FE LP/Dual Fuel Engine G420F LP/Gasoline Dual Fuel Engine Service Manual SB4241E00

Daewoo Doosan G420FE LP/Dual Fuel Engine G420F LP/Gasoline Dual Fuel Engine Service Manual SB4241E00 – PDF DOWNLOAD

FILE DETAILS:

Daewoo Doosan G420FE LP/Dual Fuel Engine G420F LP/Gasoline Dual Fuel Engine Service Manual SB4241E00 – PDF DOWNLOAD

Language : English
Pages :328
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Daewoo Doosan G420FE LP/Dual Fuel Engine G420F LP/Gasoline Dual Fuel Engine Service Manual SB4241E00 – PDF DOWNLOAD

Index
Chapter 1 GENERAL INFORMATION
Precautions before Service 7
Tightening Torque 10
Recommended Lubricants and Capacities 11
Engine Model and Engine Serial Number 12
General Specification 13
Engine Power and Torque 15
Chapter 2 RECOMMENDED
MAINTENANCE
General Maintenance 16
Test Fuel System for Leaks 16
Inspect Engine for Fluid Leaks 16
Inspect Vacuum Lines and Fittings 16
Inspect Electrical System 16
Inspect Foot Pedal Operation 16
Engine Oil Classification 17
Checking Engine Oil Level 18
Replacing Engine Oil and Filter 18
Checking Compressed Pressure 19
Adjusting Timing Belt Tension 20
Cooling System Maintenance 21
Coolant Recommendation 21
Check Coolant Level 21
Inspect Coolant Hoses 21
Checking coolant leaks 22
Specific gravity test 22
Relation between Coolant concentration and
Specific Gravity 22
Checking and Adjusting Drive Belt 23
Adjusting 24
Checking Belt for Damage 24
Ignition System Maintenance 25
Inspect Battery System 25
Inspect Ignition System 25
Inspection of Ignition Timing 25
Inspection of Spark Plug 26
Fuel System Maintenance 28
Replace LP Fuel Filter Element 28
Testing Fuel Lock-off Operation 29
Pressure Regulator/Converter Inspection 29
Inspect Air/Fuel Valve Mixer Assembly 30
Inspect for Intake Leaks 30
Inspect Throttle Assembly 30
Checking the TMAP Sensor 30
Exhaust System Maintenance 30
Inspect Engine for Exhaust Leaks 30
Maintenance Schedule 31
Chapter 3 ENGINE MECHANICAL
SYSTEM
General Information 33
Engine Outline 33
Specifications 34
Specifications 35
Torque Specification 38
Special Tools 39
Troubleshooting 41
Timing Belt System 42
Components 42
Removal 43
Inspection 44
Assembly 46
PCV Valve 48
Outline and Operation Principle 48
Service Procedure 49
Intake and Exhaust System 50
Intake Manifold 50
Exhaust Manifold 52
Cooling System 54
General Description 54
Testing and Adjusting 55
G420F(FE) Service Manual 4 Index
Cooling System Recommendation 58
Coolant Pipe and Hose 60
Water Pump 61
Thermostat 63
Cylinder Head Assembly 65
Lubrication System 74
General Description 74
Testing and Adjusting 75
Oil Pressure Switch 77
Front Case and Oil Pump 78
CAM Shaft, HLA, Timing Chain 83
Components 83
Removal 84
Inspection 85
Crankshaft 90
Flywheel and Housing 94
Piston and Connection Rod 95
Cylinder Block 110
Chapter 4 ENGINE ELECTRICAL
SYSTEM
Specifications 118
Ignition System 119
Coil-On-Plug Ignition System 119
COP Components 119
Inspection of Ignition Timing 122
Inspection of Ignition Coil Drivers (Power TR)
122
Inspection of Ignition Coil 123
Inspection of Spark Plug 124
Charging System 126
General Description 126
Troubleshooting 128
Disassembly and Installation 134
STARTING SYSTEM 139
General Description 139
Diagnosis Procedure 140
Start Relay Tests 142
Troubleshooting143
Starter 144
Chapter 5 ENGINE MANAGEMENT
SYSTEM (EMS)
General Information150
Specifications 150
Service Standard155
Component Location156
G420FE EMS (Engine Management System)
Overview160
General Description 160
LPG Fuel System Operation 163
MPI Gasoline System Operation170
Electronic Throttle System171
Ignition System172
Exhaust System173
SECM175
SECM Wiring Diagrams for G420FE178
G420F EMS (Engine Management System)
Overview180
General Description 180
LPG Fuel System Operation 183
MPI Gasoline System Operation187
Electronic Throttle System187
Ignition System187
Exhaust System187
SECM187
SECM Wiring Diagrams for G420F 188
EMS Inspection and Repair189
Engine Control Module (SECM) 189
Camshaft Position Sensor 191
Crank Shaft Position Sensor 192
MAP (Manifold Absolute Pressure) Sensor 193
IAT (Intake Air Temperature) 194
G420F(FE) Service Manual 5 Index
Sensor 194
Oxygen Sensor (Pre-Catalyst) 195
Oxygen Sensor (Post-Catalyst) 196
ECT (Engine Coolant Temperature) Sensor 197
LP Fuel Temperature Sensor 199
Angle Sensor-Accelerator 200
Transmission Oil Temperature Switch 201
Ground Speed Limit Switch (optional) 202
Electronic Throttle Body 203
Chapter 6 LPG FUEL DELIVERY
SYSTEM
G420FE LP System Inspection and Repair 204
Removal and Installation 204
Hose Connections 205
Removal and Installation of 206
N-2007 LP Regulator 206
Removal and Installation of CA100
Mixer for G420FE 207
Tests and Adjustments 209
N-2007 Regulator Service Testing 210
AVV (Air Valve Vacuum) Testing 211
AVV (Air Valve Vacuum) Testing 212
Connection of the MI-07 Service Tool
212
Idle Mixture Adjustment 213
Parts Description 216
CA100 Mixer for G420FE Engine 216
N-2007 Regulator for G420FE Engine
218
G420F LPG System Inspection and Repair 220
Removal and Installation 220
G420F Fuel System Connections 221
Removal and Installation of N-2001 LP
Regulator/Converter 222
Removal and Installation of CA100
Mixer for G420F 223
Tests and Adjustments 225
N-2001 Regulator Service Testing 225
AVV (Air Valve Vacuum) Testing227
Connection of the MI-07 Service Tool
227
Idle Mixture Adjustment 228
Parts Description 230
CA100 Mixer for G420F Engine 230
N-2001 Regulator for G420F Engine
234
Chapter 7 MPI GASOLINE FUEL
DELIVERY SYSTEM
Specification239
Special Tools 239
Components Location240
Fuel Pressure Test 241
Injector243
Injector Inspection245
Fuel Pump247
Chapter 8 BASIC TROUBLESHOOTING
Preliminary Checks 248
Before Starting 248
Visual/Physical check 248
Basic Troubleshooting Guide 249
Customer Problem Analysis Sheet249
Basic Inspection Procedure 250
Connector Inspection Procedure251
Symptom Troubleshooting Guide Chart 255
Basic Troubleshooting261
Intermittents261
Surges and/or Stumbles 262
Engine Cranking but Will Not Start / Difficult to
Start 263
Lack of Power, Slow to Respond / Poor High
Speed Performance / Hesitation During
Acceleration265
G420F(FE) Service Manual 6 Index
Detonation / Spark Knock 267
Backfire 268
Dieseling, Run-on 268
Rough, Unstable, Incorrect Idle, or Stalling 269
Cuts Out, Misses 271
Poor Fuel Economy / Excessive Fuel
Consumption LPG Exhaust Smell 272
High Idle Speed 273
Excessive Exhaust Emissions or Odors 274
Diagnostic Aids for Rich / Lean Operation 275
Chart T-1 Restricted Exhaust System Check276
Chapter 9 ADVANCED DIAGNOSTICS
Reading Diagnostic Fault Codes 277
Displaying Fault Codes (DFC) from SECM
Memory 277
Clearing Fault (DFC) Codes 277
Fault Action Descriptions 278
Fault List Definitions 278
Table 1 Fault List Definitions 279
Table 2 Diagnostic Fault Codes (Flash Codes)
289
Appendix
Service Tool Software (MotoView) 307
Service Tool Connection to SECM 308
Service Tool Display 309
SECM field update with Service Tool 313
SECM field update with Service Tool 314
Ground Speed Limits (Option) 318
LPG And LPG Fuel Tanks 320
Regulatory Compliance 324
Special Conditions for Safe Use 324
Abbreviations 325

S.M 11/24