Doosan G430 LP Service Manual
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Doosan G430 LP Service Manual

G430 lp engine
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Service Manual
G430 LP Engine
Standard Version
Low Emission Version
G20P-3,
GC20P-3, GC25P-3, GC30P-3
G25P-3,
G30P-3
SB4005E01
Oct. 2001

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Summary of Contents for Doosan G430 LP

  • Page 1 SB4005E01 Oct. 2001 Service Manual G430 LP Engine Standard Version Low Emission Version G20P-3, G25P-3, G30P-3 GC20P-3, GC25P-3, GC30P-3...

  • Page 2: Important Safety Information

    Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

  • Page 4: Table Of Contents

    Index GENERAL INFORMATION ........7 Inspect variable venturi air/fuel mixer Shop Safety ............7 (low emission LP truck) ........24 Fuel Information ............ 8 Inspect complete exhaust system for What is LPG? ..........8 leaks, damage ............ 24 Air Temperature Versus Power Output .... 9 Engine Control Unit (ECU) and others Altitude Versus Power Output .......
  • Page 5 General Description .......... 104 EST Distributor Installation (Engine Disturbed) ........66 Testing & Adjusting ........... 105 Ignition Timing - EST System ......66 Cooling System Visual Inspection ....105 Cooling System Tests ........105 LP FUEL SYSTEM ..........69 Thermostat ..........107 General Information ..........
  • Page 6 Valve Rocker Arm Cover Installation ....173 Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance) ....134 Oil Level Indicator and Tube Installation ..174 Water Pump Installation ........174 Crankshaft Rear Oil Seal and Housing Removal ............136 Intake/Exhaust Manifold Installation ....

  • Page 8: General Information

    GENERAL INFORMATION Caution ∆ Prior to working on any engine system remove Shop Safety the ignition key or otherwise disable the starting circuit to prevent someone from attempting to Safety in the workplace is everyone’s responsibility. start the engine while you may be in close Regardless of the type of work you do it is very proximity to rotating or other moving parts.

  • Page 9: Fuel Information

    Fuel Information What is LPG? flammability (0.4% in air). This is achieved by LPG is “liquefied petroleum gas”. The largest adding 1.0#s of ethyl mercaptan, or 1.0#s of component propane thiophane, or 1.4#s of amyl mercaptan per 10,000 combustible hydrocarbon based fuel. It comes from gallons of LPG.

  • Page 10: Air Temperature Versus Power Output

    1.3 Air Temperature Versus Air Temperature Versus Power Output Power Output compartment. As an example an engine that makes The temperature of the air entering an engine is 100 HP breathing air at 60 degrees will only make very important for two reasons. 86 horsepower breathing air at 200 degrees.

  • Page 11: Altitude Versus Power Output

    Altitude Versus Power Output The altitude at which an engine operates has a fuel ratio remains unchanged. However with a dramatic effect on power output. Since atmospheric liquid fuel, as altitude increases, air becomes less pressure (14.7psi at sea level) drops as altitude dense but the liquid fuel does not change therefore increases air becomes less dense and lighter.

  • Page 12: General Description & Operation

    General Description & Lubrication General Description & Operation Operation The oil pump is gear drive from the camshaft. Oil is drawn from the oil pan through a pickup screen and Engine Component Description tube. The gear type oil pump has a pressure regulator valve which controls the lubrication system pressure by Engine Block bypassing excess oil back to the oil pan sump.

  • Page 13: Cleanliness And Care

    CAUTION: Wear safety glasses in order to avoid eye • At the time of installation, components should be damage. installed in the same location and with the same mating surface as when removed. • An engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch.

  • Page 14: Use Of Rtv And Anaerobic Sealer

    4. Assembling components: RTV Sealer • When assembling components, use only the • Room Temperature Vulcanizing (RTV) sealant sealant specified or equivalent in the service hardens when exposed to air. This type sealer is procedure. used where two nonrigid parts (such as the oil pan •...

  • Page 15: Separating Parts

    Separating Parts • Trays or storage containers to keep parts and fasteners organized. • An adequate set of hand tools. IMPORTANT: Many internal engine components will develop specific wear patterns on their • Approved engine repair stand. friction surfaces. • An approved engine lifting device that will adequately support the weight of the components.

  • Page 16: Specifications

    SPECIFICATIONS Technical Data General Description ENGINE TYPE: Inline 4-Cycle L4 COMBUSTION SYSTEM: Naturally Aspirated 1-Venturi Intake Manifold EXHAUST SYSTEM: Cast Iron, Dry VALVE CONFIGURATION: Pushrod Actuated Overhead Valves - 2 Per Cylinder DISPLACEMENT: 2.967 cc (181 CID) BORE: 101.60 mm (4.00 in.) STROKE: 91.44 mm (3.60 in.) COMPRESSION RATIO:...

  • Page 17: Cooling System

    Cooling System WATER PUMP ROTATION: (viewed from front) w/V-Belt Drive - Clockwise (CW) THERMOSTAT: LPG: Opening Temperature: 82°C (180°F) Fully Open Temperature: 96°C (205°F) COOLING WATER CAPACITY (block only): 3.8 L (4.0 qts.) Lubrication System OIL PRESSURE (MIN. HOT): 28 kPa (4 psi) @ 700 RPM 124 kPa (18 psi) @ 2000 RPM OIL TEMPERATURE: Upper Limit : 130°C (266°F)

  • Page 18: Engine Mechanical Data

    Engine Mechanical Data Fastener Tightening Specifications Application N•m lb•ft lb•in Camshaft Retainer Bolts Connecting Rod Cap Nuts Crankshaft Bearing Cap Bolts 75-95 55-70 Crankshaft Rear Oil Seal Retainer Nuts 17-20 150-180 Cylinder Head Bolts Distributor Hold Down Bolt Flywheel Bolts Front Cover Bolts 27-35 Ignition Coil Bracket Attaching Bolts...

  • Page 19: Engine Mechanical Specifications

    Engine Mechanical Specifications (1 of 2) Application Metric English General Data Engine Type Displacement 3.0L 181 CID Bore 101.60 mm 4,000 in Stroke 91.44 mm 3.60 in Compression Ratio 9.25:1 Firing Order 1-3-4-2 Spark Plug Gap 0.9 mm 0.035 in Lubrication System Oil Pressure (Minimum-Hot) 41.4 kPa at...
  • Page 20 Engine Mechanical Specifications (2 of 2) Crankshaft Crankshaft Journal Diameter (All) 58.3666-58.4047 mm 2.2979-2.2994 in Crankshaft Journal Taper Production 0.005 mm (Maximum) 0.0002 in (Maximum) Crankshaft Journal Taper Service Limit 0.0254 mm (Maximum) 0.001 in (Maximum) Crankshaft Journal Out-of-Round Production 0.005 mm (Maximum) 0.0002 in (Maximum) Crankshaft Journal Out-of-Round Service Limit...

  • Page 21: Maintenance

    MAINTENANCE Inspect engine for fluid leaks • Start engine and bring up to operating temperature. G430 Engine requires a certain amount of maintenance. • Turn engine off. Suggested maintenance requirements are contained in this section. • Inspect entire engine for oil and/or coolant leaks. The owner should, however, develop his own main- •...

  • Page 22: Checking/Filling Engine Oil Level

    Checking/Filling Engine Oil Level Changing Engine Oil And Filter IMPORTANT: Care must be taken when checking IMPORTANT : When changing the oil, always change engine oil level. Oil level must be maintained between the oil filter. the "ADD" mark and the "FULL" mark on the dipstick. 1.

  • Page 23: Inspect Vacuum Lines And Fittings

    Inspect vacuum lines and fittings combustion chamber through the sparkplug hole. Recheck compression. 8. Minimum compression recorded in any one cylinder Visually inspect vacuum lines and fittings for physical should not be less than 70% of the highest cylinder, damage such as brittleness, cracks, kinks and and no cylinder should read less than 100 psi (690 misrouting.

  • Page 24: Inspect Coolant Hoses

    specified coolant as required. Replace LP Fuel Filter Element 2. Periodically remove the pressure cap from the filler neck to ensure the coolant recovery system is Park the lift truck in an authorized refueling area with functioning properly. Coolant must be at the top of the forks lowered, parking beake applled and the the filler neck.

  • Page 25: Test Fuel Lock (Electric)

    4. Remove cover (5), magnet (4), spring (3) and Inspect pressure filter element (2) from bottom cover (1). regulator/vaproizer 5. Replace the filter element (2). 6. Check bottom cover O-ring seal (6) for damage, See, pressure regulator/vaporizer in LP fuel system Replace it if necessary.

  • Page 26: Maintenance Schedule

    Maintenance Schedule Interval Hours CHECK POINT General Maintenance Section Test fuel system for leaks Prior to any service of maintenance activity Inspect engine for fluid leaks Check engine oil and filter Change engine oil and filter Inspect accessory drive belts Inspect electrical system Inspect all vacuum lines and fittings Inspect all fuel fittings and hoses...

  • Page 27: Troubleshooting

    TROUBLESHOOTING Engine Performance Symptom Cause 1. Poor engine idle. A. Clogged air breather. B. Improper idle-fuel mixture adjustment. C. Cap or spark-plug wires arcing. D. Low grade fuel. E. Incorrect ignition timing. F. Spark plugs (fouled, burned, cracked porcelain). G. Spark plug wires broken or faulty insulation. H.

  • Page 28: Charging System Problems

    Engine Starting Problems (Continued) Symptom Cause 1. No spark. A. Distributor cap or spark plug leads arcing. B. Spark plugs fouled, burned or cracked porcelain. C. Spark plug wires are broken or have faulty insulation. D. Battery, electrical connections, damaged wiring. E.

  • Page 29: Engine Noise

    Engine Noise 4. Try to isolate the noise to location in engine, front to No definite rule or test will positively determine the back, top to bottom. This can help determine which source of engine noise. Therefore, use the following components are at fault.
  • Page 30 Engine Noise (Continued) Symptom Cause 5. Noise in camshaft area A. Valve lifter. (center of engine). B. Cam bearings. 6. Noise in camshaft area A. Distributor gear. (rear of engine). B. Valve lifter. C. Cam bearings. 7. Noise in crankshaft area A.

  • Page 31: Oil Pressure Diagnostics

    Oil Pressure Diagnostics The following table contains important information for the checking of oil pressure. Condition Information 1. Measuring oil pressure. Use a good automotive oil pressure test gauge. Do not rely on the oil pressure gauge in the instrument panel. 2.

  • Page 32: Oil Pressure Problems

    Oil Pressure Problems Symptom Cause 1. Low oil pressure. A. Low oil level in crankcase. B. Defective oil-pressure gauge and/or sender. C. Oil broken down, contains water, wrong viscosity, engine running too hot or too cold, excessive idling with cold water (condensation). D.

  • Page 33: Water In Engine

    Water in Engine Determine location of water in engine. This information is necessary to determine where the water came from and how it got into the engine. The most common problems are water on top of pistons and/or water in crankcase oil. 1.

  • Page 34: Engine Overheating

    Engine Overheating Symptom Cause 1. Mechanically related. A. Engine rpm below specification for W.O.T. (engine laboring). B. Wrong ignition timing. C. Spark plug wires crossed (wrong firing order). D. Lean fuel mixture. E. Wrong heat range spark plugs. F Exhaust restriction. G.

  • Page 35: Lp Fuel System

    LP Fuel system (Sandard and/or Low Emission Version) This checklist is your guide to the most probable causes of an engine performance complaint when the malfunction is due to carburetion. The troubleshooting approach is designed to diagnose problems in vehicles that have performed properly in the past and where time and/or wear have created the troublesome condition.
  • Page 36 Problem Probable Cause Probable Solution Will Not Start/FCV Fuel container empty Fill fuel container Staying On Do not exceed 80% of liquid capacity. Liquid valve closed Open liquid valve slowly Excess flow valve closed Reset excess flow valve Close liquid valve Wait for click sound Open valve slowly Plugged fuel line...
  • Page 37 Problem Probable Cause Probable Solution Will Not Start/FCV Carburetor malfunction Check carburetor Staying On Remove air/gas valve assembly Clean air/gas valve and carb throat Check diaphragm for holes/damage Check air/gas valve for wear/damage Repair/replace as required Air filter plugged Check air filter Clean/replace as required No spark Check for spark...
  • Page 38 Problem Probable Cause Probable Solution Won’t Run Continuously Fuel container almost empty LPG vapor from liquid outlet Fill fuel container Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for click sound Open valve slowly Clogged fuel filter Repair/replace as required...
  • Page 39 Problem Probable Cause Probable Solution Won’t Run Continuously Faulty vapor connection Check connection Accelerate/Hesitation between pressure regulator No holes in hose During Acceleration and carburetor Clamps must be tight Watch for kinked and/or pinched and/or collapsed hose Throttle butterfly not opening Verify wide open throttle Incorrect full load air/fuel duty Verify full load air/fuel duty cycle...
  • Page 40 Problem Probable Cause Probable Solution Engine Stalls Pressure regulator Test pressure regulator operation malfunction Use test kit Install primary pressure gauge Install secondary pressure gauge Crank engine and observe readings on pressure gauges Compare readings to specifications If readings are out of spec repair/replace pressure regulator Pressure regulator freezes Check level in cooling system...
  • Page 41 Problem Probable Cause Probable Solution Carburetor Backfire Incorrect full load air/fuel duty Verify full load air/fuel duty cycle Faulty vapor connection Check connection between pressure regulator No holes in hose and carburetor Clamps must be tight Watch for kinked and/or pinched and/or collapsed hose Ignition malfunction Check ignition system, repair/replace...
  • Page 42 Problem Probable Cause Probable Solution Poor High Speed Restricted exhaust system Check exhaust system Performance/Lean Measure exhaust back-pressure Condition Compare to specs Engine mechanical See Troubleshooting section Excessive Fuel Carburetor malfunction Check carburetor Consumption/LPG Remove air/gas valve assembly Exhaust Smell/Closed Clean air/gas valve and carb throat Loop System Not Check diaphragm for holes/damage...

  • Page 43: Starting System

    STARTING SYSTEM General Description The starting motor is used to turn the engine flywheel fast enough to make the engine run. The starting motor has a solenoid. When the ignition switch is activated, voltage from the electrical system will cause the solenoid to move the pinion toward the flywheel ring gear of the engine.
  • Page 44 START SWITC.H START RELAP RD/WH STARTER MOTOR BATTERY IDES123S Typical 12 Volt Starting Circuit (1) Test point. (2) Test point. (3) Test Point. (4) Test Point. (5) Test Point. (X) Hold-in coil. (W) Pull-in coil. Diagnosis Procedure 1. Engages the pinion with flywheel. 2.
  • Page 45 The result of these switches and relays is to permit a If the starting motor cranks real slow or does not crank 5 amp dash-mounted switch to turn on a 500 to 1000 at all, do the following procedure: amp motor used to crank an engine. 1.

  • Page 46: Start Relay Tests

    7. Are all the voltages within specifications ? Start Relay Tests If the voltage drops are correct, go to Step 8, to D167422 Relay check the engine. 1. Put the multimeter on the 200 ohm scale. If the voltage drops are too high, repair and/or replace the faulty electrical component.

  • Page 47: Starting Motors

    Starting Motors Remove & Install Electric Starting Motor For complete specifications on the starting motors, see the Starting Motor Coverage chart for the correct 1. Position the lift truck on stands for access Service Module. underneath. 2. Disconnect the battery. STARTING MOTOR COVERAGE Starting Motor Manufacturer/...

  • Page 48: Charging System

    CHARGING SYSTEM Alternators The alternators used on these engines have three General Description phase, full-wave, rectified output. They are the brush type. Refer to the Alternator Coverage chart for The alternator is an electrical and mechanical detailed systems operation information components driven by a belt from engine rotation.
  • Page 49 Daewoo CS-121 Series D187478 IDES044S IDES043S D167411 Rated voltage..........12 volts Polarity is negative ground. Rotation is clockwise. Output at 6500 rpm (cold) ......61 amps Output voltage ........14.0 L 0.5 volts (1) Torque for battery terminal nut..3.6 L 0.8 NIm (32 L 7 lbIin) (2) Torque for pulley nut ...100 L 7 NIm (75 L 5 lbIft) IDES045S LP Engine G430 (3.0L)

  • Page 50: Remove & Install Alternator

    Remove & Install Alternator NOTE : Hood, seat and dry air cleaner have been removed for photographic purposes. 1. Disconnect wire (1) and wire (2) 2. Remove bolt and washer (3), and remove belt (4). 3. Remove alternator (5). NOTE : For the installation of the alternator, reverse the removal steps.

  • Page 51: Ignition System

    IGNITION SYSTEM In most breaker point systems, the primary circuit operates on 3.5 to 4.0 amperes depending on temperature. This current value in itself is a trade-off between contact point life and system output. General Information Maximum point life is realized at approximately one ampere.

  • Page 52: High Energy Ignition Systems

    High Energy Ignition Systems 131-057 Figure 6-1 Integral HEI Distribubor The High Energy Ignition System (figure 6-1) has undergone many improvements since its introduc-tion. The system is an electronic system that requires no scheduled maintenance, provides up to 35,000 volts to fire the spark plugs and increases spark plug life.

  • Page 53: Module

    Module Pulse Generator 131-058 131-059 Figure 6-2 Module and Pulse Generator Figure 6-3 Pulse Generator Construction The system uses an electronic module and a magnetic Since a transistor is turned on and off by electrical pulse generator to control primary circuit current current, a properly timed electrical pulse will control (figure 6-2).

  • Page 54: Magnetic Flux Path

    Applying the principle of electromagnetic induction Magnetic Flux Path which states that a voltage will be induced in a conductor whenever a magnetic field is moved so that A timer core on the main shaft of the distributor has its lines of force (flux) cut across a conductor. During external teeth which align with an equal number or the strengthening and weakening of the magnetic pole piece teeth.

  • Page 55: Dwell Control Circuit

    Dwell Control Circuit 131-062 Figure 6-6 Current vs. Time For the ignition coil to put out maximum secondary time for the primary current to build up to its maximum voltage, the maximum primary current must be current of just over 4 amperes. reached before the primary circuit is broken.

  • Page 56: Ignition Coil

    131-063 Figure 6-7 HEI and Conventional Ignition Coil Construction Because it takes less time to reach full current, coil Ignition Coil saturation can be obtained at much higher engine speeds. Also, since the current is much higher in the So far we have only talked about the magnetic pickup HEI system, heat generation must be controlled so the assembly and the module's role in greater available module can live.
  • Page 57 The inductance values of the primary and secondary The higher voltage output of the HEI system required winding are also different in the HEI coil. Inductance of new insulation materials. To prevent igni-tion failure a coil is the ability of the coil to induce a counter- due to carbon tracking, a special mater-ial is used for voltage while carrying an increasing or decreasing the distributor cap and rotor.

  • Page 58: Hel Models

    HEl Models 131-067 Figure 6-11 Pickup Coil There are two basic HEI distributors used. One has an integral ignition coil mounted in the distributor cap. This model is used on V-8 engines. The second type HEI distributor uses a remotely mounted ignition coil (outside of the distributor) which is similar in appearance to the coil used with the integral unit.
  • Page 59 Pickup Coil The pickup coil is not serviced separately but as an assembly with the bottom plate, pole piece and permanent magnet. This assembly, called the "pole piece and plate" in the parts book, should not be disassembled because the pole piece is centered around the axis of the distributor shaft during production.

  • Page 60: Electronic Spark Timing (Est) Distributor

    Electronic Spark Timing (EST) Distributor Figures 6-14 and 6-15 131-073 Figure 6-14 Distributors and High Energy Ignition Coil An improved ignition coil and distributor system is used with G430 engines (figure 6-14). The 80 mm (3.15 in.) distributor and high efficiency ignition coil are smaller in size and lighter in weight.
  • Page 61 131-074 Figure 6-15 HEI Ignition System (4-Terminal) As the timer core turns inside the magnetic pick-up, its triangular points pass very close to the magnet's points. When this happens, a small volt-age is generated and sent to the HEI module (figure 6-15). The voltage signal coming from the pickup coil is alternating current.

  • Page 62: Spark Plug Wires

    Resistance Testing Spark Plug Wires 1. Disconnect both ends of ignition cable (rotate boot General Description and pull at the boot only) being tested and clean terminals. The spark plug wires are a carbon-impregnated cord 2. Set ohmmeter on high scale and connect ohmmeter conductor encased in an 8 millimeter diameter silicone to each end of cable being tested.

  • Page 63: Delco Electronic Spark Timing (Est) Distributor Service

    Delco Electronic Spark Timing EST Distributor Component Testing (EST) Distributor Service NOTICE General Description In the test procedures that follow, check the ignition coil and each component of the distributor separately to identify defective or good components. These tests can be made with the distributor and coil mounted on the engine or on the repair bench.
  • Page 64 Pickup Coil Testing 600-060 Figure 6-25 Testing Pickup Coil 22664-019 Figure 6-24 Test 2 Tester Connections 1. Remove the distributor cap and rotor. 4. Connect black 4-way and 2-way connectors to 2. Disconnect the pickup coil leads from the module. module terminals.

  • Page 65: Est Distributor Removal

    gnition Coil Testing EST Distributor Removal 1. Remove distributor cap (2 screws). Do not remove plug wires from cap unless necessary. 2. Disconnect distributor primary leads at coil. 3. Crank or turn engine slowly. Align timing marks when rotor is pointing to No. 1 terminal of distributor cap.

  • Page 66: Cleaning And Inspection

    EST Distributor Disassembly Cleaning and Inspection 1. Wash housing, gear, and shaft in cleaning solvent. 2. Inspect housing, gear, and shaft for wear. Replace if worn. 3. Inspect wires and connector on pickup coil. Replace if damaged. EST Distributor Reassembly 1.

  • Page 67: Est Distributor Installation (Engine Not Disturbed)

    EST Distributor Installation EST Distributor Installation (Engine Not Disturbed) (Engine Disturbed) 1. Rotate engine (in normal direction of rotation) until timing mark on torsional damper (or flywheel) lines up with TDC on timing tab and engine is in No. 1 firing position.
  • Page 68 131-088 Figure 6-28 Firing Order Figure 6-30 Engine Timing Tab 1. Connect the timing light to the No. 1 spark plug (figure 6-28). Connect the power-supply leads of 5. Loosen the distributor hold-down clamp and rotate the light to 12V battery. the distributor body to achieve specification of 0 degrees @ TDC.
  • Page 69 IDES096S Timing Plate In Stored Position (6) Timing Plate. IDES097S Timing Plate Rotated 180° (6) Timing Plate. 3) Rotate timing plate (6) 180° and mount it on the converter housing again, using the other mounting holes on plate (6). When plate (6) is mounted, the timing marks should be close to the flywheel as shown.

  • Page 70: Lp Fuel System

    LP FUEL SYSTEM General Information Electric Fuelock Models IDES062S LP Fuel System Components IDES061P The basic components of this liquid petroleum (LP) fuel system are: the fuel tank, the fuel filter and relief valve, fuelock (2), converter (1) and carburetor (3). LP Fuel System Components (1) Converter.

  • Page 71: Converter

    Electric Fuelock Converter Fuelock (2) is electrically activated by an oil pressure switch. When the engine is stopped, or if the engine oil pressure gets lower than the pressure for operation, the oil pressure switch will open. When the oil pressure switch opens, it will close the fuelock, which stops the supply of fuel to the converter.

  • Page 72: Fuel Tank

    The converter is a combination regulator and The vaporizing chamber decreases LP fuel pressure vaporizer. It receives liquid fuel through opening (1) at from the tank to less than atmospheric pressure. tank pressure from the fuelock. The fuel is available This expansion of the pressurized liquid fuel into inside converter vaporizing chamber (9) when vapor, can result in freezing.

  • Page 73: Carburetor

    Carburetor Diaphragm (3) is lifted against the down pressure of metering spring (4). The vacuum that is felt on diaphragm (3) is variable according to engine speed and the position of throttle valve (10) opening. Air valve (2) measures the air flow that goes into the engine, respective to the demands of the engine and throttle valve (10) position.

  • Page 74: Tests Or Adjustments

    Tests or Adjustments 1. Make sure the setting for ignition timing is correct. See Ignition Timing. Adhere to the following warnings when performing any tests or adjustments while the engine is running. 2. Connect the Electrical System Analyzer as shown in Engine RPM Check in the Testing And Adjusting.
  • Page 75 Power Mixture Adjustment CO Meter Method The method of adjustment depends upon the test The power mixture adjustment must be done with the equipment that is available. The power mixture can be engine in a load condition. A CO meter or exhaust adjusted using a CO meter, vacuum gauge or analyzer testing equipment must be used to measure electrical system analyzer.

  • Page 76: Fuel System Leak Check

    Fuel System Leak Check Inner Fuel System Leak Check Outer Fuel System Leak Check WARNING LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. Combustion gases from LP gas fuel system can be a danger.

  • Page 77: Recommendation For Lpfuel Systems

    Converter Leak Test To check the converter for leakage after repair, do the procedure that follows: 1. Put a plug in the fuel outlet openings. 2. Put compressed air in the fuel inlet openings, up to a maximum of 725 kPa (120 psi). 3.

  • Page 78: Lp Converter - Check, Clean

    LP Converter - Check, Clean Test LP-Gas Converter 1. Obtain a test kit. 2. Start engine. 3. Close the liquid outlet valve in the fuel storage container. 4. Run engine out of fuel. Secondary 5. Install the 0-30kPa (0-5 psi) gauge in the primary Primary Test Port Test Port test port.

  • Page 79: Disassembly & Assembly

    Disassembly & Assembly Disassemble LP Gas Carburetor Start By: LP Gas Carburetor a. Remove LP Gas Carburetor. Remove & Install LP Gas Carburetor P0002999 P0002997 1. Remove four screws (1) and cover (2). 1. Disconnect all lines and linkage (not shown). 2.
  • Page 80 P0003004 P0003001 6. Remove nut (13). 3. Remove four screws (5), backup plate (6), diaphragm (7) and the air valve ring from the inner 7. Loosen the bolt and remove stop (16). carburetor body. 8. Remove two screws (14). Remove throttle plate (15).

  • Page 81: Lp Gas Fuelock

    Assemble LP Gas Carburetor LP Gas Fuelock Remove & Install LP Gas Fuelock P0002929 1. Check all parts for damage. Replace damaged P0002926 parts with new as necessary. 2. Make sure all parts are clean and free of dirt and 1.

  • Page 82: Lp Gas Converter

    LP Gas Converter Disassembly of LP Gas Converter Remove & Install LP Gas Converter Start by : Remove LP Gas Fuelock. 1. Remove six screws (1), cover (2), and diaphragm (3) from the converter. 1. Remove lines (1). 2. Remove two bolts and nut (2). 3.
  • Page 83 IDED051P 4. Remove spring and plunger (10) from the intermediate cover. IDED052P 1. Screw (6) 5. Remove intermediate cover (11), diaphragm (12) 2. Cover Assembly, Secondary and the secondary regulator valve (13). 3. Diaphragm Assembly, Secondary Inspection, Assembly of LP Gas Converter 4.

  • Page 84: Lp Fuel System (Low Emission Version)

    (FCV). Reducing the fuel compliant G430 LP engine is different from pressure leans the air/fuel mixture. Increasing the standard G430 LP engine. To reduce emission of exhaust gas, closed loop carburetion system and fuel pressure richens the air/fuel mixture.
  • Page 85 FUELOCK GOVERNER CONVERTER CARBURETOR VALVE MUFFLER ENGINE Open-Loop LP Carburetion System TACHO FUEL SENSOR CONTROL VALVE ENGINE CONTROL INTAKE UNIT BOOST (ECU) OXYGEN SENSOR FUELOCK GOVERNER CONVERTER CARBURETOR VALVE CATALYTIC ENGINE MUFFLER Closed-Loop LP Carburetion System LP Engine G430 (3.0L) - 84 - LP Fuel System (Low Emission Version)

  • Page 86: Fuel Lock (Electric)

    Fuel Lock (Electric) Pressure Regulator/Vaporizer regulator staged, pressure Since LPG is held in the fuel storage container regulator/vaporizers. The regulator is normally under pressure a fuel lock is required to closed, they require a vacuum signal from the mixer automatically control when fuel flows out of the to allow fuel to flow.

  • Page 87: Pressure Regulator Theory Of Operation

    Pressure Regulator Theory of Operation primary/heat exchanger chamber (4) and primary diaphragm chamber (6) reaches 1.5 psi (10.34kpa) it causes a pressure/force imbalance across the primary diaphragm (9) between the primary/heat exchanger chamber (4) and the primary vent chamber (18). This causes the primary diaphragm and lever assembly (9) to pivot (10), against primary spring (3) pressure, raising the primary valve pin (11), closing off the primary valve (2).

  • Page 88: Variable Venturi Air/Fuel Mixer

    opens in response to the negative pressure signal Variable Venturi Air/Fuel Mixer generated by the variable venturi air/fuel mixer. Pressure regulators equipped with blue In the LPG mixers the fuel discharge jet is normally secondary spring (8) require negative 1.5 inches closed.

  • Page 89: Variable Venturi Air/Fuel Mixer Theory Of Operation

    Variable Venturi Air/Fuel Mixer Theory air valve (3) rise’s it lifts the tapered gas-metering of Operation valve (4) off of its seat and exposes the gas discharge jet (2) to the negative pressure signal generated within the mixer bore (air valve vacuum). The variable venturi air/fuel mixer is mounted in the intake air stream between the air cleaner and the This allows the negative pressure signal to travel to...

  • Page 90: Catalytic Muffler

    Catalytic Muffler Performance of Three-Way Catalytic Converter Operating window for converter The catalytic muffler is mounted in the exhaust gas stream of G430 engine. The catalytic muffler facilitates oxidation and reduction reactions that reduce the amount of unwanted constituents in the exhaust gas stream.

  • Page 91: Engine Control (Ecu)

    Engine Control Unit (ECU) In order to obtain maximum effect from the catalyst, an accurate control of the air fuel ratio is required. Engine The engine control unit (ECU) uses an exhaust gas oxygen sensor (EGO) in the exhaust system to send information about exhaust gas content to the controller.

  • Page 92: Oxygen Sensor

    Oxygen Sensor Vacuum Switch (MAP) Cover Housing Connector Lead wire Sensor device . Electrical 2. Vacuum port The oxygen sensor installed on the exhaust manifold makes use of the principles of a solid 3. Main body electrolyte oxygen concentration cell. The oxygen concentration cell is characterized by a sharp The vacuum switch is a simple direct acting contact change of the output voltage in the vicinity of the...

  • Page 93: Fuel Control Valve

    Fuel Control Valve 1. Carburetor AVV port connection 2. Vaporizer secondary vent chamber connection 3. Electrical connectors 4. Balance line connection The fuel control valve is a three way valve, operated by a pulse width modulated electronic signal applied to the electrical connectors (3) by the fuel system ECU.

  • Page 94: Tests Or Adjustments

    Tests or Adjustments 7. Clean mixer throat with approved carburetor cleaner. 8. Inspect air valve and mixer throat for wear, Adhere to the following warnings when performing any repair/replace as required. tests or adjustments while the engine is running. WARNING Work carefully around an engine that is running.

  • Page 95: Lp Converter-Check, Clen

    Inspection of Fuel Lock Valve NOTICE The idle air/fuel mixture is factory set, therefore, no further adjusstments are required. The part throttle air/fuel mixture is factory set, therefore, no further adjusstments are required. The full power air/fuel mixture is factory set, therefore no, further adjustments are required, either.

  • Page 96: Inspection Of Vacuum Switch(Map)

    Inspection of Vacuum Switch(MAP) Caution: The right measurement cannot be performed if oxygen sensor connector is separated before engine starting. 3. Measure the oxygen sensor output voltage. Standard value : 0.6 - 1.0 V 4. If there is a deviation from the standard value, replace the oxygen sensor.

  • Page 97: Disassembly & Assembly

    Disassembly & Assembly LP Converter Removal steps 1. Vacuum hose 9. Vacuum terminal 2. Vacuum hose 10. Balance hose 3. Vacuum hose 11. Jet 4. Fuel control valve 12. Elbow fitting 5. LPG shut off valve assembly 13. Elbow fitting 6.

  • Page 98: Governor System

    GOVERNOR SYSTEM Components General Description Governors are regulating devices which allow engine speed to remain constant in both loaded and unloaded operating conditions. There are several different types of governor designs such as mechanical, hydraulic, electric and velocity used to control engine speed. Governors normally control engine speed by limiting the amount of air and fuel entering the engine.

  • Page 99: Governor Operation

    Stabilizer Piston Governor Operation Engine Stopped 7226-400-017 Figure 8-9 Stabilizer Piston 7226-400-018 While the governor valve is limited to a specific Figure 8-10 During Engine Stopped opening angle, engine speed will oscillate due to pulsations in the intake system of the engine. These When the engine is not operating, the governor valve pulses, while a normal condition in engine operation, is held in the open position by the pressure exerted on...

  • Page 100: Adjustment Procedures

    High Engine Load Adjustment Procedures 7226-400-020 7226-400-014 Figure 8-12 Under High Engine Load Figure 8-13 Aisan Governor Assembly #7172730 When the engine is operating at high engine loads the When the engine is subjected to a load, the engine venturi vacuum will be lowered closer to atmos-pheric speed must be 100 RPM or less than the engine pressure.
  • Page 101 Surging If surging is observed, perform the following steps: 1. Turn ADJUSTING SCREW clockwise approximately 90 degrees. (Increase of maxi-mum engine speed without load with this adjustment should be less than 100 RPM. 2. Turn ADJUSTING SCREW BUSHING counterclockwise until the maximum engine speed without load comes into specification.

  • Page 102: Lubrication System

    LUBRICATION SYSTEM General Description 131-001 Figure 10-1 Engine Lubrication Diagram Engine operation is the same as any typical internal The main gallery supplies pressure oil to the camshaft combustion gasoline engine. The pressurized bearings and main bearings. Oil flows to the lubrication oil is supplied by a gear pump mounted on connecting rod bearings through holes drilled in the the rear main bearing cap.

  • Page 103: Testing & Adjusting

    Testing & Adjusting Oil leakage into the combustion area of the cylinders can be the cause of blue smoke. There are three possible ways for oil leakage into the combustion area Adhere to the following warnings when performing any of the stems. tests or adjustments while the engine is running.

  • Page 104: Oil Pressure Check

    6. Oil pressure relief valve worn or stuck in the OPEN Oil Pressure Check position. 7. Oil filter bypass valve stuck open. Oil filter is restricted. Replace oil filter. High Oil Pressure Oil pressure will be high if the oil pressure relief valve in the oil pump cannot move from the closed position.

  • Page 105: Cooling System

    COOLING SYSTEM General Description Cooling System Schematic (1) Cylinder head. (2) Thermostat. (3) Recovery tank. (5) Radiator top hose. (6) Radiator pressure cap. (7) Cylinder walls. (8) Radiator. (9) Radiator lower hose. (10) Water pump. Water pump (10) is installed on the front of the thermostat open.

  • Page 106: Testing & Adjusting

    Testing & Adjusting 3. Look for leaks in the system. 4. Look for bent radiator fins. Be sure that air flow Adhere to the following warnings when performing any through the radiator does not have a restriction. tests or adjustments while the engine is running: 5.
  • Page 107 Pressure Cap Test Cooling System Leak Check To test the cooling system for leaks, use the following procedure: WARNING If the engine has been in operation and the coolant is hot, slowly loosen the pressure cap to the first stop and let the pressure out of the cooling system, then remove the pressure cap.

  • Page 108: Thermostat

    Thermostat Thermostat Test To test the thermostat opening temperature, use the following procedure: WARNING The pan, water and thermostat will be very hot and can cause burns. Do not touch the pan, water or thermostat. Handle the components with an insulated device for protection. 1.

  • Page 109: Cooling System Heat Problems

    Cooling System Heat Problems Cooling System Recommendation To check if there is a good reason for heat problems Coolant Information do the checks that follow: NOTICE 1. The indications of a heat problem are as follows: DAEWOO recommends that the coolant mix contain a.
  • Page 110 Coolant Water DAEWOO recommends selecting automotive antifreeze suitable for automotive gasoline engines. Hard water, or water with high levels of calcium and The antifreeze should meet ASTM-D3306 standard. magnesium ions, encourages the formation of insoluble chemical compounds by combining with cooling system additives such as silicates and Make proper antifreeze additions.

  • Page 111: Belt Adjustment

    Belt Adjustment V-Belt Diagnosis Belts and pulleys wear evenly with use. Unusual signs Drive belts must grip the entire contact area of the of wear indicate some correction is needed. The pulley. When drive belts are too loose, the belts can correction of any of the listed conditions will help slip, tear, burn, or grab and snap.

  • Page 112: Service Procedures

    Gouged Edge Service Procedures A gouged edge in a belt can be caused by a damaged pulley, a misaligned pulley, or the belt being too loose Draining and Filling the Cooling or too long. Check the pulley and the belt for proper System alignment and tension.

  • Page 113: Flushing The Cooling System

    Filling Radiator Service 1. Check the radiator drain cock to be sure it is Radiator Internal Deposits closed. A radiator with a dirty, obstructed, or leaking core will 2. Check the engine drain plug to be sure it is tight. cause the engine to overheat.

  • Page 114: Thermostat Replacement

    Thermostat Replacement CLEAN : • Thermostat housing and coolant outlet seal-ing surfaces. Remove or Disconnect Install or Connect 1. Thermostat in its housing. 2. New gasket into position (if necessary). 3. Coolant outlet. 4. Bolt. Tighten • Bolts to 28 N•m (21 lb. ft). 5.

  • Page 115: Water Pump Replacement

    Water Pump Replacement Install or Connect 1. Coolant pump to the engine block. Remove or Disconnect 2. New gaskets, 3. Bolts. TIGHTEN Bolts to 41 N•m (30 lb•ft.) 4. Lower radiator (outlet) hose and heater hose to the coolant pump. Bypass hose on the 7.4L engine. 5.

  • Page 116: Remove & Install Water Temperature Sender

    Water Temperature Sender Remove & Install Water Temperature Sender 1. Disconnect one wire connection (1). 2. Remove water temperature sender (2). NOTE: For the installation of the water temperature sender, reverse the removal steps. 3. Use thread sealant on the water temperature sender threads.

  • Page 117: Base Engine Service Procedure

    BASE ENGINE SERVICE PROCEDURE Disassembled View (1 of 4) VE001-3L (1) Valve Rocker Arm Cover Bolt. (2) Valve Rocker Arm Cover Reinforcement. (3) Valve Rocker Arm Cover. (4) Oil Filler Cap. (5) Valve Rocker Arm Cover Gasket. (6) Efe Valve Thermostat. (7) Intake Manifold. (8) Intake Manifold Nut. (9) Intake/Exhaust Manifold Clamp. (10) Intake/Exhaust Manifold Washer.

  • Page 118: Disassembled View (2 Of 4)

    Disassembled View (2 Of 4) VE002-3L (1) Engine Block. (2) Piston Pin. (3) Piston Ring Kit. (4) Piston. (5) Connecting Rod. (6) Connecting Rod Bolt. (7) Connecting Rod Bearing Kit. (8) Connecting Rod Cap. (9) Connecting Rod Nut. (10) Oil Nozzle. (11) Camshaft Bearings. (12) Camshaft.

  • Page 119: Disassembled View (3 Of 4)

    Disassembled View (3 Of 4) VE003-3L (1) Cylinder Head. (2) Valve Rocker Arm Stud. (3) Valve Stem Key. (4) Valve Spring Cap Intake. (5) Valve Stem Oil Shield. (6) Valve Spring. (7) Valve Stem Oil Seal. (8) Valve Spring Cap Exhaust(9) Exhaust Valve. (10) Intake Valve. LP Engine G430 (3.0L) - 118 - Base Engine Service Procedure...

  • Page 120: Disassembled View (4 Of 4)

    Disassembled View (4 Of 4) (1) Drive Gear. (2) Driven Gear. (3) Oil Pressure Relief Valve. (4) Oil Pressure Relief Valve Spring. (5) Oil Pump Screen. (6) Oil Pump. (7) Oil Pump Cover Gasket. (8) Oil Pump Cover. (9) Oil Pump Cover Washer. (10) Oil Pump Cover Bolt. LP Engine G430 (3.0L) - 119 - Base Engine Service Procedure...

  • Page 121: Draining Fluids And Oil Filter Removal

    Draining Fluids and Oil Filter Removal VE007-3L 3. Remove right rear engine block coolant plug and allow the coolant to drain. VE005-3L 1. Remove the oil pan drain plug and allow the oil to drain. VE008-3L 4. Remove the left rear engine block coolant plug and allow the coolant to drain.

  • Page 122: Engine Flywheel Removal

    Engine Flywheel Removal Distributor Removal IMPORTANT: Note the position and direction of the engine flywheel before removal. The engine flywheel must be reinstalled to the original position and direction. VE009-3L 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel. VE010-3L 1.

  • Page 123: Ignition Coil Removal

    Ignition Coil Removal Spark Plug Removal VE011-3L VE013-3L 1. Remove the ignition coil bracket attaching bolts. 1. Remove the spark plugs. 2. Remove the ignition coil. Intake/Exhaust Manifold Removal Lift Bracket Removal VE014-3L VE012-3L 1. Remove the intake/exhaust manifold bolts. 2.

  • Page 124: Crankshaft Pulley Removal

    Crankshaft Pulley Removal Pushrod Cover Removal Tools Required • J 24420-C Universal Crankshaft Pulley Remover VE020-3L 1. Remove the pushrod cover bolts. VE018-3L 2. Remove the pushrod cover. 1. Use the J 24420-C in order to remove the 3. Remove the gasket. crankshaft pulley.

  • Page 125: Intake/Exhaust Manifold Disassemble And Assemble

    Intake/Exhaust Manifold Intake/Exhaust Manifold Disassemble and Assemble Clean and Inspect If necessary to replace either the intake or exhaust Clean and inspect the following areas: manifold, separate them as follows: VE016-3L VE015-3L • The manifold bolts and studs. 1. Remove the one attaching bolt and the two nuts at •...

  • Page 126: Water Pump Removal

    Water Pump Removal Valve Rocker Arm and Pushrod Removal Make sure the coolant is drained. VE017-3L VE021-3L 1. Remove the water pump bolts. 1. Remove the following components from the cylinder head: 2. Remove the water pump and gasket. (1) The valve rocker arm nuts (1). (2) The valve rocker arm balls (2).

  • Page 127: Measuring Camshaft Lobe Lift

    Measuring Camshaft Lobe Lift Tools Required • J 8520 Camshaft Lobe Lift Indicator VE023-3L 2. Remove the valve pushrods. 3. Place the following parts in a rack so that they can be reinstalled in their original locations: VE022-3L • The valve rocker arms. •...

  • Page 128: Valve Train Components Inspect (Cylinder Head)

    Valve Train Components Inspect Valve Lifter Removal (Cylinder Head) Tools Required Inspect the following areas: • J 3049 Valve Lifter Remover (Plier Type) • J 9290-01 Valve Lifter Remover (Slide Hammer Type) VE024-3L VE025-3L • The valve rocker arms and ball at the mating surfaces. These surfaces should be smooth and free of scoring or other damage.

  • Page 129: Cylinder Head Removal

    Cylinder Head Removal Oil Pan Removal VE028-3L VE027-3L 1. Remove the oil pan bolts. 1. Remove the cylinder head bolts. 2. Remove the oil pan. 3. Remove the gasket. NOTICE After removal, place the cylinder head on two wood 4. Discard the gasket. blocks to prevent damage.

  • Page 130: Oil Level Indicator And Tube Removal

    Oil Level Indicator and Tube 2. Remove the engine front cover. Removal 3. Remove the gasket. 4. Discard the gasket. VE128-3L VE031-3L 1. Remove the oil level indicator from the tube. 2. Use a drift punch in order to remove the oil level 5.

  • Page 131: Measuring Crankshaft And Camshaft Sprocket Runout

    Measuring Crankshaft and Measuring Timing Sprocket Camshaft Sprocket Runout Teeth Backlash Tools Required Tools Required • J 8001 Dial Indicator • J 8001 Dial Indicator VE032-3L VE033-3L 1. Use the J 8001 in order to measure the crankshaft 1. Use the J 8001 in order to measure the backlash and camshaft sprocket runout.

  • Page 132: Crankshaft Sprocket Removal

    Crankshaft Sprocket Removal Tools Required • J 6978-E Crankshaft Sprocket Puller VE125-3L IMPORTANT: All camshaft journals are the same diameter, so care must be used in removing the camshaft to avoid damage to the bearings. VE034-3L 2. Carefully rotate and pull the camshaft out of the bearings.

  • Page 133: Timing Gear Oil Nozzle Removal

    Timing Gear Oil Nozzle Removal Piston, Connecting Rod and Bearing Removal Tools Required • J 5239 Connecting Rod Guide Tool • J 24270 Ridge Reamer VE127-3L 1. Remove the oil nozzle with pliers. VE036-3L 1. Remove the ring ridge as following: (1) Turn the crankshaft until the piston is at the bottom of the stroke.
  • Page 134 VE037-3L VE038-3L IMPORTANT: Place matchmarks or numbers on the 5. Use the J 5239 in order to remove the connecting connecting rods and the connecting rod caps. Upon rod and the piston out of the engine block. removal of the piston and connecting rod assembly, install the connecting rod caps to the matching 6.

  • Page 135: Crankshaft And Bearings Clean And Inspect (Connecting Rod Bearing Clearance)

    Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance) IMPORTANT: Connecting rod bearings are a precision insert type. Connecting rods are of a powdered metal design and cannot be shimmed or filed for bearing fit. If clearances are found to be excessive, a new bearing and/or connecting rod are required .
  • Page 136 VE041-3L VE037-3L 6. Install the gauging plastic (1) onto the connecting 8. Remove the connecting rod nuts. rod bearing journal. Install the gauging plastic the full width of the journal. 9. Remove the connecting rod cap and bearing. VE037-3L VE042-3L 7.

  • Page 137: Crankshaft Rear Oil Seal And Housing Removal

    Crankshaft Rear Oil Seal and Crankshaft, Bearings Housing Removal Bearing Cap Removal VE043-3L VE045-3L 1. Remove the crankshaft rear oil seal housing bolts. 1. Remove the crankshaft bearing cap bolts. 2. Remove the crankshaft rear oil seal housing, seal 2. Remove the crankshaft bearing caps. and gasket.

  • Page 138: Crankshaft And Bearings Clean And Inspect

    Crankshaft and Bearings Clean and Inspect Tools Required • J 7872 Magnetic Base Indicator Set CAUTION: Wear safety glasses in order to avoid eye damage. VE039-3L 5. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
  • Page 139 VE048-3L VE050-3L 8. Inspect the crankshaft bearings for improper 10. Support the crankshaft front and rear journals on seating indicated by bright, polished sections of the V-blocks. bearing. • If the lower half of the bearing is worn or 11. Measure the crankshaft run-out at front and rear damaged, both the upper and lower halves must intermediate journals with J 7872.

  • Page 140: Crankshaft And Bearings Clean And Inspect (Main Bearing Clearance)

    Crankshaft and Bearings Clean and Inspect (Main Bearing Clearance) IMPORTANT: Crankshaft main bearings are a precision insert type. Main bearing caps are machined with the engine block for proper clearance and cannot be shimmed or filed for bearing fit. Crankshaft bearing clearances are critical. If the clearances are found to be excessive, new bearings and/or engine block and cap repair may be required.
  • Page 141 • If clearance cannot be brought to specifications, grind the crankshaft for use with the next undersized bearing. VE045-3L 5. Remove the crankshaft bearing cap bolts. 6. Remove the crankshaft bearing caps. VE053-3L 9. Use a dial indicator or feeler gauge in order to measure end play between the front of the rear of the crankshaft bearing cap and the crankshaft thrust surface in order to determine the crankshaft...

  • Page 142: Camshaft Bearing Removal

    Camshaft Bearing Removal Tools Required • J 6098-01 Camshaft Bearing Remover/Installer VE055-3L 3. Use the J 6098-01 in order to remove the front and rear camshaft bearings. (1) Assemble the bearing tool to the driver. (2) Drive the front and rear camshaft bearings out VE054-3L of the block bore.

  • Page 143: Distributor Lower Bushing And Thrust Washer Removal

    Distributor Lower Bushing Oil Filter Bypass Valve Removal and Thrust Washer Removal and Installation Tools Required • J 9534 Distributor Lower Bushing Remover • J 6585 Slide Hammer VE058-3L 1. Check the spring and fiber valve for operation. VE056-3L 2. Inspect for a cracked or broken valve. 3.

  • Page 144: Cylinder Block Clean And Inspect

    Cylinder Block Clean and Inspect Cylinder Bore Measurements 1. Clean the following areas: Tools Required • The engine block in solvent, removing all sludge, dirt • J 8087 Cylinder Bore Gauge or debris VE060-3L 1. Use the J 8087 in order to check cylinder bore taper and our-of-round as follows: (1) Set the gauge so that the thrust pin must be forced in about 1/4 in to enter the gauge in the...

  • Page 145: Cylinder Boring And Honing

    Cylinder Boring and Honing NOTICE Boring Procedure Handle the pistons with care. Do not force the pistons through the cylinder until you hone the cylinder to the 1. Before you start the honing or reboring process, correct size. The piston can be distorted through measure all new pistons with the micrometer, careless handling.

  • Page 146: Distributor Lower Bushing And Thrust Washer Installation

    Distributor Lower Bushing Piston and Connecting Rod and Thrust Washer Installation Disassemble Tools Required Tools Required • J 9535 Distributor Lower Bushing Installer • J 24086-C Piston Pin Removal Set VE061-3L VE063-3L 1. Use the J 9535 in order to drive the thrust washer (if 1.

  • Page 147: Piston And Connecting Rod Clean And Inspect

    Piston and Connecting Rod Clean and Inspect VE066-3L CAUTION: Wear safety glasses in order to avoid eye damage. VE065-3L 2. Clean the connecting rod in cleaning solvent. 1. Clean the piston ring grooves with a groove cleaner. 3. Clean the varnish from the piston skirts and the pins with cleaning solvent.
  • Page 148 VE067-3L VE069-3L 10. Measure the pin bore-to-piston clearance. 11. Measure the piston compression ring end gap. (1) The piston pin bores and the piston pins must be free of varnish or scuffing when being IMPORTANT: Fit each compression ring to the measured.

  • Page 149: Piston Selection

    Piston Selection IMPORTANT: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores must not have excessive wear or taper. A used piston and pin set may be reinstalled if, after cleaning and inspection, they are within specifications.

  • Page 150: Piston And Connecting Rod Assemble

    Piston and Connecting Rod Assemble Tools Required • J 24086-C Piston Pin Removal Set IMPORTANT: When assembling the piston and connecting rod, the flange or the heavy side on the connecting rod must face toward the front of the piston (stamped arrow in top of the piston head).

  • Page 151: Camshaft And Bearings Clean And Inspect

    Camshaft and Bearings Clean and Inspect Tools Required • J 7872 Magnetic Base Indicator Set CAUTION: Wear safety glasses in order to avoid eye damage. VE0123-3L 2. Install piston rings onto piston. The mrked side of the piston rings must face toward the top of the piston.
  • Page 152 VE076-3L VE078-3L 6. Inspect the camshaft bearings for proper fit in the 9. Support the camshaft front and rear journals on V- engine block. Camshaft bearings have an blocks. interference fit to the engine block and should not be loose in their engine block bearing bores. 10.

  • Page 153: Camshaft Sprocket And Retainer Removal And Installation

    Camshaft Sprocket and Retainer Removal and Installation Removal Tools Required • J 791 Camshaft Sprocket Remover VE080-3L 2. If the inspection indicated that the camshaft, gear or retainer should be replaced, the gear must be removed from the camshaft s follows: (1) Place the camshaft through the J 791.

  • Page 154: Camshaft Bearing Installation

    nstallation Camshaft Bearing Installation Tools Required • J 6098-01 Camshaft Bearing Installer IMPORTANT: • A loose camshaft bearing may be caused by an enlarged, out of round or damaged engine block bearing bore. • The outer front and rear camshaft bearings must be installed first.

  • Page 155: Oil Pump Disassemble

    Oil Pump Disassemble VE054-3L VE082-3L 2. Use the J 6098-01 in order to install the inner camshaft bearings. Repeat the following steps for each of the inner camshaft bearings: 1. If necessary, remove the oil pump screen. (1) With the nut (4) and the thrust washer (3) •...

  • Page 156: Oil Pump Clean And Inspect

    Oil Pump Clean and Inspect IMPORTANT : The internal parts of the oil pump are not serviced separately. If the oil pump components are worn or damaged, replace the oil pump as an assembly. The oil pump pipe and screen are to be serviced as an assembly.

  • Page 157: Oil Pump Assemble

    Oil Pump Assemble Tools Required • J 21882 Oil Suction Pipe Installer IMPORTANT: Replace the pressure relief valve spring when you reuse the oil pump. VE084-3L 2. Coat the drive gear, the driven gear and the housing gear surfaces with clean engine oil. 3.

  • Page 158: Cylinder Head Disassemble

    Cylinder Head Disassemble Tools Required • J 8062 Valve Spring Compressor IMPORTANT: Mark, organize or sort the cylinder head components for assembly. Return the components to their original location during assembly. VE087-3L 6. Inspect the pump for smoothness of operation by turning the oil pump driveshaft by hand.

  • Page 159: Cylinder Head Clean And Inspect

    Cylinder Head Clean and Inspect Tools Required • J8089 Carbon Remover Brush • J9666 Valve Spring Tester • J8001 Dial Indicator CAUTION: Wear safety glasses in order to avoid eye damage. VE090-3L 3. Remove the valve stem keys (1). 4. Remove the cap from the valve spring (2&6). 5.
  • Page 160 VE092-3L VE094-3L 3. Inspect the following areas: 5. Excessive valve stem-to-bore clearance will cause (1) The cylinder head for cracks in the exhaust excessive oil consumption and may cause a valve ports and the combustion chambers. to break. Insufficient clearance will result in noisy and sticky (2) The cylinder head for external cracks in the functioning of the valve and will disturb the engine water chamber.

  • Page 161: Valve Guide Reaming/Valve And Seat Grinding

    VE095-3L VE097-3L 6. Inspect the valve springs for squareness. 8. Measure the cylinder head for warpage with a straight edge and a feeler gauge. A cylinder head with excessive warpage must be repaired or replaced. Refer to Engine Mechanical Specifications. Valve Guide Reaming/Valve and Seat Grinding VE096-3L...
  • Page 162 VE096-3L VE097-3L 4. Reconditioning the valve seats is very important. 6. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the 5. Recondition the valve seat after reaming the valve head and the stem. guide bores or installing the new valve guides.

  • Page 163: Rocker Arm Stud Removal And Installation

    Rocker Arm Stud Removal and Installation Tools Required • J 5802-01 Rocker Arm Stud Remover • J 6880 Rocker Arm Stud Installer Rocker arm studs with damaged threads or with loose fit in cylinder head should be replaced with new, oversize studs.

  • Page 164: Cylinder Head Assemble

    Cylinder Head Assemble Tools Required • J 8062 Valve Spring Compressor VE89-3L CAUTION: Wear safety glasses in order to avoid eye damage. 7. Use the J 8062 in order to compress the valve spring. VE090-3L 8. Install the valve stem keys. (1) Use grease to hold the keys in place while 1.

  • Page 165: Crankshaft, Bearings And Bearing Cap Installation

    Crankshaft, Bearings Bearing Cap Installation Important • Crankshaft bearing caps must be installed to the proper location and direction. • When installing the crankshaft bearings, align the locating tabs on the bearings with the locating notches in the engine block journal bore and the bearing cap.

  • Page 166: Crankshaft Rear Oil Seal And Housing Installation

    Crankshaft Rear Oil Seal and Housing Installation Tools Required • J 35621 Crankshaft Rear Oil Seal Installer IMPORTANT: Always use a new crankshaft rear oil seal and new crankshaft rear oil seal housing gasket when you install the crankshaft rear oil seal housing. VE104-3L 3.

  • Page 167: Piston, Connecting Rod And Bearing Installation

    Piston, Connecting Rod and Bearing Installation Tools Required • J 5239 Guide Set • J 8037 Piston Ring Compressor Important • The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and connecting rod assembly into the proper cylinder bore.

  • Page 168: Timing Gear Oil Nozzle Installation

    Timing Gear Oil Nozzle Installation VE037-3L VE127-3L 8. Install the connecting rod cap and nuts. Tighten 1. Drive the new nozzle in place (oil hole facing up) Tighten the nuts evenly to 61 N•m (45 lb•ft). with a suitable light plastic or rubber hammer. Crankshaft Sprocket Installation Tools Required •...

  • Page 169: Camshaft Installation

    Camshaft Installation Engine Front Cover and Oil Seal Installation IMPORTANT: If camshaft replacement is required, the valve lifters must also be replaced. Tools Required • J 35468 Engine Front Cover Aligner and Oil Seal Installer VE108-3L 1. Carefully rotate and install the camshaft into the engine.

  • Page 170: Oil Pump Installation

    Oil Pan Installation IMPORTANT: Apply the sealer 25 mm (1.0 in) in either direction of the radius cavity of the junctions. VE030-3L 2. Install the engine front cover gasket. 3. Install the engine front cover and bolts. Tighten Tighten engine front cover bolts to 3.4 N•m (30 lb•in). Oil Pump Installation VE111-3L IMPORTANT: Inspect the oil pump and engine block...

  • Page 171: Crankshaft Pulley Installation

    Crankshaft Pulley Installation Cylinder Head Installation Tools Required • J 8792 Crankshaft Pulley Installer VE114-3L 1. Install the new cylinder head gasket over the VE112-3L locating pins. 1. Coat the front cover oil seal contact area of the 2. Install the cylinder head over the locating pins and crankshaft pulley with clean engine oil.

  • Page 172: Valve Lifter Installation

    Valve Lifter Installation Valve Rocker Arm and Pushrod Installation IMPORTANT: Be sure to keep parts in order. Parts must be installed from where they were removed. VE116-3L 1. Coat the bottom of the valve lifters with prelube, GM P/N 1052365 or equivalent. VE023-3L 2.
  • Page 173 VE117-3L VE117-3L 3. Adjust the valve rocker arm nuts as follows: (5) Turn the crankshaft 1 revolution until the mark on the crankshaft pulley lines up with “0” on the (1) Turn the crankshaft until the mark on the timing tab. crankshaft pulley lines up with “0”on the timing This is number 4 top dead center.

  • Page 174: Pushrod Cover Installation

    Pushrod Cover Installation Valve Rocker Arm Cover Installation VE118-3L VE119-3L 1. Install the pushrod cover gasket. 1. Install the valve rocker arm cover gasket. 2. Install the pushrod cover. 2. Install the valve rocker arm cover. 3. Install the pushrod cover bolts. 3.

  • Page 175: Oil Level Indicator And Tube Installation

    Oil Level Indicator and Tube Intake/Exhaust Manifold Installation Installation VE120-3L VE014-3L 1. Install the oil level indicator tube into the engine block. 1. Install the intake/exhaust manifold gasket over the 2. Use a light plastic or rubber hammer in order to tap locating pins on the cylinder head.

  • Page 176: Spark Plug Installation

    Spark Plug Installation Ignition Coil Installation VE013-3L VE011-3L 1. Install the spark plugs. 1. Install the ignition coil. Tighten 2. Install the ignition coil bracket attaching bolts. Tighten the spark plugs to 30 N•m (22 lb•ft). Tighten Tighten the attaching bolts to 22 N•m (16 lb•ft). Lift Bracket Installation VE012-3L 1.

  • Page 177: Distributor Installation

    Distributor Installation Engine Flywheel Installation IMPORTANT: To ensure correct ignition timing, the IMPORTANT: Note the position and direction of the distributor must be installed in the correct position. engine flywheel before removal. Position the engine at top dead center on number one The engine flywheel must be reinstalled to the original cylinder.

  • Page 178: Engine Block Coolant Plug/Oil Filter Installation

    Engine Block Coolant Plug/Oil Filter Installation VE006-3L 3. Install the oil filter. VE008-3L 1. Install the left rear engine block coolant plug. VE005-3L 4. Install the oil pan drain plug. VE007-3L 2. Install the right rear engine block coolant plug. LP Engine G430 (3.0L) - 177 - Base Engine Service Procedure...

  • Page 179: Special Tools And Equipment

    SPECIAL TOOS AND EQUIPMENT J791 J 5590 Camshaft Sprocket Remover Crankshaft Sprocket Installer J 3049-A J 5715 or J 6036 Valve Lifter Remover Rocker Stud Hole Reamer J 3936-03 J 5802-01 Piston Ring Groove Cleaner Rocker Arm Stud Remover J 4822 J 6098-01 Valve Guide Reamer Camshaft Bearing...
  • Page 180 J 6880 J 8062 Rocker Arm Stud Remover Valve Spring Compressor J 6978-E J 8087 Crankshaft Sprocket Puller Cylinder Bore Gauge J 7872 J 8089 Magnetic Base Dial Indicator Carbon Remover Brush J 8001 J 8520 Dial Indicator Camshaft Lobe Lift Indicator J 8037 J 8792 Piston Ring Compressor...
  • Page 181 J 9290-01 J 24086-C Valve Lifter Remover Piston Pin Remover/ (Slide Hammer Type) Installer Set J 9534 J 24270 Distributor Lower Bushing Ridge Reamer Remover J 9535 J 24420-C Distributor Lower Bushing Universal Crankshaft Pulley Installer Remover J 9666 J 35468 Valve Spring Tester Engine Front Cover Aligner and Oil Seal Installer...

  • Page 182: Low Emission Version Only

    ITK-1 Pressure Gauge Kit FSA-1000 Fuel System Analyzer (Low Emission Version Only) The IMPCO ITK-1 pressure gauge kit is designed for testing and troubleshooting IMPCO gaseous See instructions for proper usage to check air/fuel fuel systems. The kit contains the following: mixture.

This manual is also suitable for:

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