Daewoo Doosan G424FE LP/Dual Fuel Engine G424F LP Engine Service Manual SB4251E00 – PDF

Daewoo Doosan G424FE LP/Dual Fuel Engine G424F LP Engine Service Manual SB4251E00 – PDF DOWNLOAD

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Daewoo Doosan G424FE LP/Dual Fuel Engine G424F LP Engine Service Manual SB4251E00 – PDF DOWNLOAD

Language : English
Pages :306
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Daewoo Doosan G424FE LP/Dual Fuel Engine G424F LP Engine Service Manual SB4251E00 – 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
G424F/G424FE 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
Cooling System Maintenance 20
Coolant Recommendation 20
Check Coolant Level 20
Inspect Coolant Hoses 20
Checking coolant leaks 21
Specific gravity test 21
Relation between Coolant concentration and
Specific Gravity 21
Checking and Adjusting Drive Belt 22
Adjusting 22
Checking Belt for Damage 22
Ignition System Maintenance 23
Inspect Battery System 23
Inspect Ignition System 23
Inspection of Ignition Timing 23
Inspection of Spark Plug 24
Fuel System Maintenance 26
Replace LP Fuel Filter Element 26
Testing Fuel Lock-off Operation 26
Pressure Regulator/Converter Inspection 27
Inspect Air/Fuel Valve Mixer Assembly 27
Inspect for Intake Leaks 27
Inspect Throttle Assembly 27
Checking the TMAP Sensor 27
Exhaust System Maintenance 27
Inspect Engine for Exhaust Leaks 27
Maintenance Schedule 28
Chapter 3 ENGINE MECHANICAL
SYSTEM
General Information 30
Engine Outline 30
Technical Specifications 31
Shells Selection Table 33
Recommended Torque Values 36
Troubleshooting 38
Engine Exploded View 39
Intake manifold and gasket 41
Exhaust Manifold and Gasket 45
Timing Belt 47
Timing Belt Tensioner 51
PCV Valve 52
Camshaft Timing Pulley and/or Seal 55
Crankshaft Timing Pulley 55
Crankshaft Front Seal 56
Camshaft Case Cover and Gasket 56
G424F(FE) Service Manual 4 Index
Crankshaft Accessory Pulley 57
Timing Belt Rear Cover 57
Rocker Arms, Linkage, Valve Lifters With
Cylinder Head and Eegine 59
Cooling System 60
Thermostat Housing 66
Water Pump 67
Lubrication System 68
Oil Pan 71
Oil Pump 72
Oil Pump Assembly 73
Camshaft Case Assembly 74
Cylinder Head 78
Valve, Spring or Seal 79
Engine Disassembly 81
Engine Assembly 85
Cylinder Block 90
Crankshaft 91
Pistons and/or Connecting Rods 97
Rings 9999
Chapter 4 ENGINE ELECTRICAL
SYSTEM
Specifications 101
Ignition System 102
Wasted Spark DIS Ignition System 102
Inspection of Ignition Coil 103
Spark Plug Wire Inspection 104
Spark Plug Wire Replacement 104
Spark Plug Replacement 105
Spark Plug Inspection 105
Charging System 107
General Description 107
Troubleshooting Procedure 110
STARTING SYSTEM 115
General Description 115
Diagnosis Procedure 116
Start Relay Tests118
Troubleshooting119
Chapter 5 ENGINE MANAGEMENT
SYSTEM (EMS)
General Information121
Specifications 121
Service Standard126
Component Location127
G424FE EMS (Engine Management System)
Overview131
General Description131
LPG Fuel System Operation 134
MPI Gasoline System Operation141
Electronic Throttle System142
Ignition System143
Exhaust System144
SECM146
SECM Wiring Diagrams for G424FE149
G424F EMS (Engine Management System)
Overview152
General Description152
LPG Fuel System Operation 155
Electronic Throttle System159
Ignition System159
SECM159
SECM Wiring Diagrams for G424F LP Engine
160
G424F(FE) Service Manual 5 Index
EMS Inspection and Repair 161
Engine Control Module (SECM) 161
Camshaft Position Sensor 163
IAT (Intake Air Temperature) Sensor 167
Oxygen Sensor (Pre-Catalyst) 168
Oxygen Sensor (Post-Catalyst) 169
ECT (Engine Coolant Temperature) Sensor 170
LP Fuel Temperature Sensor 172
Angle Sensor-Accelerator 173
Transmission Oil Temperature Switch 174
Ground Speed Limit Switch (optional) 175
Electronic Throttle Body 176
Chapter 6 LPG FUEL DELIVERY
SYSTEM
G424FE LP System Inspection and Repair 177
Removal and Installation 177
Hose Connections 178
Removal and Installation of N-2007 LP
Regulator 180
Removal and Installation of CA100 Mixer
for G424FE 181
Tests and Adjustments 183
N-2007 Regulator Service Testing 183
AVV (Air Valve Vacuum) Testing 185
Connection of the MI-07 Service Tool 185
Idle Mixture Adjustment 186
Parts Description 189
CA100 Mixer for G424FE Engine 189
N-2007 Regulator for G424FE Engine 191
G424F LPG System Inspection and Repair 193
Removal and Installation 193
G424F Fuel System Connections 194
Removal and Installation of N-2001 LP
Regulator/Converter 195
Removal and Installation of CA100 Mixer
for G424F 196
Tests and Adjustments 198
N-2001 Regulator Service Testing 198
AVV (Air Valve Vacuum) Testing 200
Connection of the MI-07 Service Tool 200
Idle Mixture Adjustment 201
Parts Description 203
CA100 Mixer for G424F Engine 203
CA100 Disassembly and Service205
CA100 Disassembled Service206
N-2001 Regulator for G424F Engine207
N2001 Regulator Disassembly Steps: 209
N2001 Disassembled Service 211
Chapter 7 MPI GASOLINE FUEL
DELIVERY SYSTEM
Specification212
Components Location213
Fuel Pressure Test 214
Injector216
Fuel Pump219
Chapter 8 BASIC TROUBLESHOOTING
Preliminary Checks 220
Before Starting 220
Visual/Physical check 220
Basic Troubleshooting Guide 221
Customer Problem Analysis Sheet221
Basic Inspection Procedure 222
Connector Inspection Procedure223
Symptom Troubleshooting Guide Chart 227
Basic Troubleshooting233
Intermittents233
Surges and/or Stumbles 234
Engine Cranking but Will Not Start / Difficult to
Start 235
Lack of Power, Slow to Respond / Poor High
Speed Performance / Hesitation During
G424F(FE) Service Manual 6 Index
Acceleration 237
Detonation / Spark Knock 239
Backfire 240
Dieseling, Run-on 240
Rough, Unstable, Incorrect Idle, or Stalling 241
Cuts Out, Misses 243
Poor Fuel Economy / Excessive Fuel
Consumption LPG Exhaust Smell 244
High Idle Speed 245
Excessive Exhaust Emissions or Odors 246
Diagnostic Aids for Rich / Lean Operation 247
Chart T-1 Restricted Exhaust System Check248
Chapter 9 ADVANCED DIAGNOSTICS
Reading Diagnostic Fault Codes 249
Displaying Fault Codes (DFC) from SECM
Memory 249
Clearing Fault (DFC) Codes 249
Fault Action Descriptions 250
Fault List Definitions 250
Table 1 Fault List Definitions 251
Table 2 Diagnostic Fault Codes (Flash Codes)
261
Appendix
Service Tool Software (MotoView)279
Introduction 279
Connection of the Service Tool 280
MotoView Display Screens 281
SECM field update with Service Tool 293
Ground Speed Limits (Option)297
LPG And LPG Fuel Tanks 299
Regulatory Compliance303
Special Conditions for Safe Use303
Abbreviations 304

S.M 11/24