Daewoo G424 Gasoline Service Manual
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Daewoo G424 Gasoline Service Manual

Daewoo G424 Gasoline Service Manual

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Service Manual
G424 Gasoline/LP Engine
G424 LP Engine (Low Emission Version)
G20E-3, G25E-3,
GC20E-3, GC25E-3, GC30E-3
G30E-3
SB2215E01
O c t . 2 0 0 1

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  • Page 1 SB2215E01 O c t . 2 0 0 1 Service Manual G424 Gasoline/LP Engine G424 LP Engine (Low Emission Version) G20E-3, G25E-3, G30E-3 GC20E-3, GC25E-3, GC30E-3...

  • Page 2: Important Safety Information

    If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 3: Table Of Contents

    Index GENERAL INFORMATION ........4 Alternator ............47 How to Read This Manual ........4 Precaution Before Service ........6 IGNITION SYSTEM ..........50 General ..............8 Breakerless Ignition System ....... 50 Tightening Torque ..........9 Distributor............51 Sealant ..............12 Removal and Installation ........
  • Page 4 DUAL FUEL SYSTEM ........... 102 General ..........187 Engine ............ 189 GOVERNING SYSTEM ......... 103 Carburetor ..........190 General Description .......... 103 Electrical Components ......192 Governor,Disassembly and Reassembly ..104 SPECIAL TOOLS ..........195 LUBRICATION SYSTEM ........106 General Description .......... 106 Testing and Adjusting ........

  • Page 5: General Information

    GENERAL INFORMATION How To Read This Manual Scope of Explanation This book describes the service procedures for the engine removed from the vehicle. For procedures concerning removal of the engine from the vehicle and on-vehicle inspection and servicing, refer to the appropriate service manuals separately prepared for the individual models. Maintenance and Servicing Procedures •...
  • Page 6 FRONT CASE AND OIL PAN REMOVAL AND INSTALLATION 6EN1898 Removal steps 1. Oil filter 17. Oil pump case assembly 18. Front case gasket 2. Oil pressure switch 19. Oil pump cover 3. Drain plug 20. Oil pump drive gear 4. Drain plug gasket 21.

  • Page 7: Precaution Before Service

    Precautions Before Servce Removal and Disassembly For prevention of wrong installation or reassembly and for ease of operation, put mating marks to the parts where no function is adversely affected. 1EN0018 Special Tool Be sure to use Special Tools when their use is specified for the operation.
  • Page 8 Replacement Part When oil seal, O-ring, packing and gasket have been removed, be sure to replace them with new parts. However, rocker cover gasket may be reused if it is not damaged. 1EN0022 Rubber Parts Do not stain timing belt and V-belt with oil or water. Therefore, do not clean the pulley and sprocket with detergent.

  • Page 9: General

    General Engine models and numbers Engine model Fuel type G424 Gasoline, LPG, LPG (Low Emission Version) Indication of engine model and number The engine model and serial number are stamped on the right side of cylinder block surface. Engine model Engine number 4G64 AA0001 to YY9999...

  • Page 10: Tightening Torque

    Tightening Torque Major Bolts and Nuts Torque Item Remarks kg•m lb•ft N•m Water pump pulley bolt Crankshaft pulley bolt 18.1 Ignition system Spark plug 18.1 Distributor nut Timing belt cover bolt Tensioner spring spacer 35.4 Tensioner belt Tensioner bolt 35.4 Oil pump sprocket nut 39.8 Crankshaft bolt...
  • Page 11 Torque Item Remarks kg•m lb•ft N•m Drain plug 28.9 Oil pan bolt Oil screen bolt/nut 13.7 Oil pressure switch Front case, Plug 17.4 doil pan Flange bolt 26.8 Relief plug 32.5 Oil filter bracket 13.7 Oil pump cover bolt 12.3 Oil pump cover screw Front case bolt 17.4...
  • Page 12 General Bolts and Nuts Tightening Torque Standard Bolts and Nuts Torque, kg•m (lb•ft) [N•m] Nominal Pitch Bolt, stud, nut (with spring washer) Flange bolt, flange nut diameter Head mark 4 Head mark 7 Head mark 10 Head mark 4 Head mark 7 0.5 (0.5) [3.6] 0.6 (4.3) [5.9] 0.9 (6.5) [8.8]...

  • Page 13: Sealant

    Sealant Part to be Applied Brand Semi circular packing AAD Part No.8672 or equivalent Rocker cover AAD Part No.8672 or equivalent Oil pressure switch AAD Part No.8672 or equivalent Oil pan Silicone RTV sealant or eguivalent Rear oil seal case Silicone RTV sealant or eguivalent Rear plate bolt AAD Part No.8672 or equivalent...

  • Page 14: Specifications

    SPECIFICATIONS General Specifications Engine model G424 Item Type Water-cooled, 4-cycle, gasoline-powered and L.P.G.-powered No. of cylinders and arrangement 4, in-line Combustion chamber type Semi-spherical Valve mechanism Total displacement, cm (cc) [cu in.] 2350 (2350) [143] Bore x stroke, mm (in.) 86.5 100 (3.41 3.94)

  • Page 15: Service Specification

    Service Specifications Unit : mm(in.) Standard value Limit Remarks Item Flatness of gasket surface 0.03 (0.0012) Total resurfacing depth of both Grinding limit 0.2 (0.008) cylinder head and cylinder block Overall height 89.9 to 90.1 (3.539 to 3.547) 0.05 (0.0020) 13.05 to 13.07 (0.5138 to 0.5146) Oversize rework 0.25 (0.0098)
  • Page 16 Unit : mm(in.) Item Standard value Limit Remarks 0.8 (0.031) End gap No. 1 ring 0.25 to 0.40 (0.0098 to 0.0157) No. 2 ring 0.8 (0.031) 0.45 to 0.60 (0.0177 to 0.0236) Oil ring 1.0 (0.039) 0.20 to 0.60 (0.0079 to 0.0236) Ring-to-ring groove No.
  • Page 17 Unit : mm(in.) Item Standard value Limit Remarks Nominal output, kW Voltage, V 11.0 No-load characterstics Current, A 90 or less Speed, rpm 3000 Outer diameter 29.4 (1.16) 28.8 (1.13) Commutator Runout 0.05 (0.0020) 0.1 (0.0039) Undercut 0.5 (0.020) 0.2 (0.008) Pinion gap 0.5 to 2.0 (0.020 to 0.079) Brush length...

  • Page 18: Maintenance

    MAINTENANCE 1. Stop engine if in use. 2. Allow sufficient time (approximately 2 minutes) for G424 engine requires certain amount the oil to drain back into the oil pan. maintenance. Suggested maintenance requirements 3. Remove dipstick. Wipe clean and reinstall. Push are contained in this section.

  • Page 19: Inspect Accessory Drive Belts

    • Lube oil filter gasket with engine oil. • On open systems carefully remove cooling system pressure cap. Coolant level will be approximately 30- • Install oil filter as per filter manufacturers 40 mm below pressure cap sealing surface. If level is instructions.

  • Page 20: Replace Lp Fuel Filter Element

    Replace LP Fuel Filter Element Park the lift truck in an authorized refueling area with the forks lowered, parking beake applled and the transmission in NEUTRAL. 4. Remove cover (5), magnet (4), spring (3) and filter element (2) from bottom cover (1). 5.

  • Page 21: Replace Gasoline Fuel Filter

    Replace Gasoline Fuel Filter Inspect Complete Exhaust (Gasoline Truck and Dual System for Leaks, Damage Fuel Truck) • Perform visual inspection of exhaust system. • Repair any/all leaks found. WARNING Engine Control Unit(ECU) Fuel leaked or spilled onto hot surfaces or and others electrical components can cause a fire.

  • Page 22: Maintenance Schedule

    Maintenance Schedule Interval Hours Every Every Every Every Every 1000hrs 250hrs 500hrs 1000hrs 2000hrs Daily CHECK POINT a year a month 3 months 6 months 18 months 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...

  • Page 23: Engine System

    ENGINE SYSTEM Engine Overview The cylinder blocks are made of the special cast iron The camshaft is located on the top of the cylinder and employ 5-bearing, deep skirt system. heads and driven by cog type timing belt. The cylinder heads have hemisphere combustion Dual type exhaust manifold is employed in order to chambers, are of cross flow type arranged with V-type reduce output loss by exhaust interference.
  • Page 24 Gasoline Engine G424 Service Manual Engine System...
  • Page 25 LPG Engine ( Low Emission Version) G424 Service Manual Engine System...

  • Page 26: Timing System

    Timing System The timing belt is meshed with the sprockets, the crankshaft sprocket becomes the drive sprocket, and thus functions to drive the camshaft and oil pump. Timing belt The timing belt is the cogged type, using rubber as its basic material, and it employs a high-strength glass fiber core which does not expand or contract.

  • Page 27: Silent Shaft Mechanism

    Silent Shaft Mechanism The silent shaft mechanism function mainly to figure below. The right silent shaft rotates in the same eliminate, by the action of the silent shafts direction as the crankshaft, and the left silent shaft incorporated at both sides of the cylinder block, the rotates in the opposites direction.

  • Page 28: Auto Lash Adjuster

    Auto Lash Adjuster Construction These engines have auto lash adjusters that eliminate the need for valve clearance adjustment and reduce noises of the valve system. The auto lash adjuster automatically absorbs change in the valve clearance caused by engine temperature change or wear of parts and adjusts the valve clearance always to zero.

  • Page 29: Intake And Exhaust System

    Intake and Exhaust System Gasoline Engine The intake manifold employs the shape having good intake performance. The exhaust manifold employs a dual type and intend the reduction of output loss due to exhaust interference. G424 Service Manual Engine System...
  • Page 30 LPG Engine (Low Emission Version) G424 Service Manual Engine System...

  • Page 31: Electrical System

    Electrical System Wiring Diagram (Gasoline Engine) Stating motor is of the gear reduction type. Distributor is of a breakerless type and employs the ignition advancer which uses jointly centrifugal type and vacuum type. G424 Service Manual Engine System...
  • Page 32 Wiring Diagram (LPG Engine, Low Emission Version) G424 Service Manual Engine System...

  • Page 33: 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 34 START SWITC.H START RELAP RD/WH STARTER MOTOR BATTERY 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 2. Is a high current switch rated about 1000 amps that The following simplified procedure is intended to help actually turns on the starting motor.
  • Page 35 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 36: Start Relay Test

    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 37: Starter Motor

    Starter Motor Planetary Gear Reduction Drive Type The starter motor is small in size light weight and high- output type. Rotation of the motor are reduced by the reduction gear, and high torque is transmitted to the pinion gear. Operation 1.
  • Page 38 2. The plunger of the magnetic switch is then attracted, and the pinion is pushed out by the shift lever, meshing with the ring gear. As a result of the movement of the plunger, the contacts of the magnetic switch close, and, as a result, the starter is turned by the high current from the battery directly to the B terminal, and the engine is activated.
  • Page 39 When the internal gear is fixed as in the case of the starter motor, the carrier rotates in the same direction as the sun gear. This may be used to determine the reduction ratio easily. Namely, the carrier reduction ratio = (43 + 11) / 11 = .

  • Page 40: Removal And Installation

    Removal and Installation Removal steps 6EN0867 1. Bolt 2. Starter Inspection Pinion Gap Adjustment (1) Disconnect the field coil wire from terminal M of the magnetic switch. (2) Connect a 12 V battery between terminal S and starter motor body (positive terminal to terminal S). Caution: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning out.
  • Page 41 Pull-in Test of Magnetic Switch (1) Disconnect field coil wire from terminal M of magnetic switch. (2) Connect a 12V battery between terminal S and terminal M. Caution: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. Disconnect (3) If pinion moves out, then pull-in coil is good.
  • Page 42 Free Running Test (1) Place starter motor in a vise equipped with soft jaws and Variable resistance connect a fully-charged 12-volt battery to starter motor as follows: Ammeter (2) Connect a ammeter (100-ampere scale) and carbon pile Starter rheostat in series with battery positive post and starter Battery motor motor terminal.

  • Page 43: Disassembly And Reassembly

    Disassembly And Reassembly 6EN1917 Disassembly steps 1. Screw 12. Packing A 2. Magnetic switch 13. Packing B 3. Screw 14. Plate 4. Screw 15. Planetary gear 5. Rear bracket 16. Lever 6. Brush holder 17. Snap ring 7. Brush 18. Stop ring 8.
  • Page 44 Disassembly Service Points “S” teminal Maguetic switch Magnetic switch removal “B” terminal Disconnect the field coil wire from terminal M of the magnetic switch “M” terminal Fieldcoid wire Armature/ball removal Caution: When removing the armature, take care not to lose 6EN0610 the ball (Which is used as a bearing) in the armature end.
  • Page 45 nspection 1. Commutator (1) Place the armature on a pair of V-blocks and check the runout using a dial gauge. Standard value: 0.5 mm (0.020 in.) Limit: 0.1 mm (0.004 in.) 1EN0298 (2) Check the outer diameter of the commutator. Standard value: 29.4 mm (1.16 in.) Limited: 28.8 mm (1.13 in.) 1EN0302...
  • Page 46 4. Brush (1) Brushes that are worn beyond wear limit line, or oil soaked, should be replaced. (2) When replacing ground brush, side the brush from brush holder by prying retainer spring back. Wear limit line 1EN0292 5. Armature Coil Short Circuit Test (1) Place armature on a growler.
  • Page 47 Reassembly Service Points Stop ring/snap ring Installation Using a suitable pulling tool, pull overrunning clutch stop Stop ring over snap ring. Overrunning Stop ring G424 Service Manual Starting System...

  • Page 48: Charging System

    Part Number Series The air exits the front of the alternator, cooling it in the process. The Daewoo CS-121 series also has an D167411 Daewoo/CS-121 internal fan. This fan is mounted on the rotor. This...
  • Page 49 D187478 Daewoo CS-121 Series 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)
  • Page 50 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 Breakerless Ignition System Ignition System Schematic (1) Battery. (2) Ignition switch. (3) Coil. (4) Distributor. (5) Spark Plug. The ignition system has battery (1), ignition switch (2), soft iron core. The primary has a small number of turns coil (3), distributor (4) with inner electronics of heavy wire, and the secondary has many thousand circuits and spark plugs (5).

  • Page 52: Distributor

    Distributor The distributor is the contactless type and is equipped with a centrifugal advancer and vacuum advancer. The distributor is installed at the front side surface of the cylinder head, and is driven directly by the camshaft. G424 Service Manual Ignition System...
  • Page 53 Governor advance mechanism In the figure below, pin A rotates together with the In the cam base, the movement of pin B becomes shaft. A governor weight is installed to this pin A. rotation of the cam in the direction of rotation. In other There is a pin B on the governor weight which fits into words, the cam advances in relation to the shaft.
  • Page 54 Vacuum advance mechanism There is a diaphragm within the vacuum controller, out by the air/fuel mixture flowing near the vacuum with a spring at the negative-pressure (vacuum) side port, thus resulting in a negative-pressure (vacuum) which pressure against the diaphragm. A link is condition.

  • Page 55: Removal And Installation

    Removal and Installation Removal steps 7. Vacuum 1. Drive belt 8. Ignition 2. Water pump pulley 9. Harness 3. Crankshaft pulley 10. Distributor 4. Spark plug cable 5. Spark plug 6. High tension cable G424 Service Manual Ignition System...

  • Page 56: Inspection Ignition Coil/Cables

    Inspection High voltage Ignition Coil terminal Perform the following measurements. Replace the ignition coil if the standard values are not met. (1) Measure the resistance values of the primary and – secondary coils and of the external resistor with a tester. If the readings are within the standard limits, it follows that there is no short or open circuit in the ignition coil.

  • Page 57: Distributor, Disassembly And Reassembly

    Disassembly and Reassembly Disassembly steps 1. Distributor cap 8. Breaker assembly 2. Rotor 9. Snap ring 3. Cover 10. Vacuum control 4. Signal rotor 11. Connector assembly 5. Pickup coil assembly 12. O-ring 6. Ignitor 13. Distributor housing 7. Heat sink G424 Service Manual Ignition System...
  • Page 58 Inspection Pickup Coil (1) Using a tester, check the resistance of the pickup coil. Standard value: 420 to 540Ω 1EL0052 (2) Check to make sure the pointer of the tester oscillates when the tip of a screwdriver is moved past by the core of the pickup col assembly.

  • Page 59: Gasoline Fuel System

    GASOLINE FUEL SYSTEM General Description The fuel pump pulls the fuel from fuel tank. The fuel flows through filter, which is installed on top of the fuel tank, to carburetor where the fuel is mixed with air at the correct ratio. This air and fuel mixture then goes to the inlet manifold.

  • Page 60: Geasoline Carburetor, Operation

    Gasoline Carburetor - Operation Construction of Carburetor (1) Float. (2) Front chamber cover. (3) Primary inner venturi. (4) Choke valve. (5) Accelerator pump nozzle. (6) Idle compensator. (7) Membrane cover. (8) Enrichment jet. (9) Plug. (10) Throttle body. (11) Primary throttle valve. (12) Mixture adjusting screw. (13) Bypass screw.
  • Page 61 1. Air system Air passed through the air cleaner flows through the choke bore and venturi into the clearance of the throttle valve and supports idle running of the engine. When engine speed increases to off-idle and more, intake air is metered by the venturi. Air flow to be fed to the cylinders is controlled by the throttle valve.

  • Page 62: Idle System

    3. Idle system This system provides adequate air-fuel-mixture richness of air-fuel-mixture necessary for good idling. richness for smooth engine running ranging from slow- The bypass screw is for the purpose of adjusting the idle to light-load operation. flow of primary air-fuel-mixture to the bypass hole so Fuel from the float chamber is sent through the main as to provide sufficient mixture richness mainly for jet to the pilot jet where metering of fuel is made.
  • Page 63 Idle Compensator Main Metering System The idle compensator uses a bimetal. When the Fuel metered by the main jet is bled by air from the carbretor ambient temperature rises during idle or main air jet and enters the bleed pipe through its “off idle”...
  • Page 64 5. Enrichment system Enrichment and Accelerator-Pump systems The enrichment system provides additional fuel membrane is pushed by the pump lever linked to feed to the main metering system during high- the throttle valve and forces fuel to flow under speed large-torque operation. pressure.

  • Page 65: Removal And Installation

    Removal and Installation 6EN1893 Removal steps 1. Return set hose assembly 8. Fuel pipe 2. Oil seal 9. Fuel hose 3. Air horn 10. Fuel pipe 4. Gasket 11. Fuel pump 5. Carburetor 12. Gasket 6. Air governor 13. Insulator 7.
  • Page 66 Removal Service Points Carburetor removal (1) Hold the carburetor in a level position while using care not to let fuel spill, remove it from the intake manifold. (2) Turn the carburetor upside down on a pan to drain fuel. Fuel pump removal Placing the piston in No.1 cylinder at TDC on the compression stroke makes the fuel pump stroke lift the smallest, allowing easy removal of the pump.

  • Page 67: Gasoline Carburetor Disassembly And Reassembly

    Gasoline Carburetor Disassembly and Reassembly Disassembly steps 1. Throttle return spring 2. Damper spring 3. Choke rod 4. Screw 5. Float chamber cover 6. Float chamber cover gasket 7. Cover 8. Packing 9. Bimetal 10. O-ring 11. Accelerator wire bracket 12.
  • Page 68 Service Points of Disassembly The following parts must not be disassembled at the time of disassembly. (1) Choke valve and choke shaft (2) Inner venturi (3) Throttle valve and throttle shaft Return spring/choke rod removal (1) When the spring is removed, avoid prying it with undue force or any other attempt that can cause damage to it.
  • Page 69 Inspection 1. General Inspection Check the following and repair or replace parts if faulty. (1) Check fuel passages (jets) and air passages (jets or orifices) for clogging. If clogged, wash thoroughly with cleaning solvent or detergent and remove dirt by compressed air.
  • Page 70 4. Inspection of Mixture Adjusting Screw (MAS) Check tapered end of mixture adjusting screw (MAS) for damage from over tightening, etc. Check for damage 6EN1888 5. Throttle Body Check Make sure that the throttle shaft moves smoothly. If any sticky movement is found, thoroughly clean the shaft, and then coat it with a small amount of engine oil.
  • Page 71 (2) Main jets have size symbols stamped on their ends for identification. Size symbols : 132.5 132.5 Size symbol 6EN0869 Check ball/weight installation Weight Install the acceleration check ball and weight. Check ball Float/float pin installation After the float and float pin have been installed, make sure that the float is in a level position.
  • Page 72 nspection and Adjustment After Reassembly Choke shaft Choke lever 1. Fast Idle Opening (1) Move the choke lever to place the choke valve in fully closed position. 6EN0859 (2) Measure the clearance “A” (primary throttle valve to Primary throttle throttle bore). valve NOTE: Refer to the table in SERVICE SPECIFICATIONS for the clearance.
  • Page 73 3. Ports (1) Connect a hand vacuum pump and check each port for clogging. (2) If clogged, clean the port and then blow air into it. 6EN0861 G424 Service Manual Gasoline Fuel System...

  • Page 74: Lpg Fuel System

    LP FUEL SYSTEM General Description Electric Fuelock Model IDES061P LP Fuel System Components (1) Converter. (2) Fuelock. (3) Carburetor. (4) Coolant ontlet line (5) Coolant inlet line. (6) Balance hose. (7) LP fuel line to carburetor IDES062S engine coolant that flows in line (5) and out line (4). Carburetor vacuum activates the converters operation LP Fuel System Components and the fuel flows to the carburetor through line (7).

  • Page 75: 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 76: 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 77: Carburetor

    Carburetor valve (2) measures the air flow that goes into the engine, respective to the demands of the engine and throttle valve (10) position. The air pressure drop of 1.3 to 2.7 kPa (0.2 to 0.4 psi) is controlled by metering spring (4) which permits the force necessary to pull in the fuel into the air flow.

  • Page 78: 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 79 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 ana- adjusted using a CO meter, vacuum gauge or electri- lyzer testing equipment must be used to measure the cal system analyzer.

  • Page 80: Fuel System Leak Check

    Inner Fuel System Leak Check 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 81: Recommendation For Lp Fuel System

    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 82: 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. 5. Install the 0-30kPa (0-5 psi) gauge in the primary Secondary test port.

  • Page 83: Disassembly And Assembly

    Disassembly & Assembly LPG Carburetor Remove & Install LP Gas Carburetor 6EN1890 Removal steps 1. Throttle return spring 6. Throttle body 2. Accel wire assembly 7. Carburetor gasket 3. Return spring support 8. Air governor 4. LPG carburetor 9. Air governor gasket 5.
  • Page 84 Disassemble LP Gas Carburetor Start By: a. Remove LP Gas Carburetor. P0004825 4. Remove power mixture screw (8), idle mixture screw (9) and the spring. Remove four screws (10). Remove throttle body assembly (11) and the P0004821 gasket. 1. Remove four screws (1) and cover (2). P0003003 P0004822 5.

  • Page 85: Lp Gas Fuelock

    Assemble LP Gas Carburetor LP Gas Fuelock Remove & Install LP Gas Fuelock P0004829 1. Check all parts for damage. Replace damaged parts with new as necessary. P0002926 2. Make sure all parts are clean and free of dirt and foreign material.

  • Page 86: Lp Gas Converter

    LP Gas Converter Disassembly of LP Gas Converter Remove & Install LP Gas Converter Start by : Remove LP Gas Fuelock. IDED048P 1. Remove six screws (1), cover (2), and diaphragm (3) from the converter. P0004817 1. Remove lines (1). 2.
  • Page 87 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 88: Lpg Fuel System (Low Emission Version)

    LPG FUEL SYSTEM (LOW EMISSION VERSION) General Description Air cleaner (MAP) Schematic of G424 LP fuel system (low emission version) G242 LP engine (Low Emission Version) is different regulate the air/fuel mixtures, correcting for proper from standard G424 LP engine. To reduce emission of air/fuel.
  • Page 89 FUELOCK GOVERNER VALVE CONVERTER CARBURETOR MUFFLER ENGINE Open-loop LP Carburetion System : G424 LP engine TACHO FUEL SENSOR CONTROL VALVE ENGINE CONTROL INTAKE UNIT BOOST (ECU) OXYGEN SENSOR FUELOCK GOVERNER VALVE CONVERTER CARBURETOR CATALYTIC ENGINE MUFFLER Closed-loop LP Carburetion System : G424 LP engine (low emission version) G424 Service Manual LPG Fuel System(Low Emission Version)

  • Page 90: Lp Carburetor

    LP Carburetor ports (9) in the air valve (3). A pressure / force imbalance begins to build across the air valve (Variable Venturi) diaphragm (5) between the air valve vacuum chamber (8) and atmospheric pressure below the diaphragm The variable venturi air/fuel mixer is mounted in the (10).

  • Page 91: Vacuum Switch (Map)

    Vacuum Switch (MAP) Vacuum Switch 1. Electrical 1. Electrical 2. Vacuum port 2. Vacuum port 3. Main body 3. Main body The vacuum switch is a simple direct acting contact The vacuum switch is a simple diaphragm unit, pressure switch, consisting of a main body (3), an consisting main body...

  • Page 92: Lp Converter

    chamber and the primary atmospheric chamber (18) LP Converter This causes the primary diaphragm and lever assembly (9) to pivot (10) against primary spring (3) pressure, raising primary valve pin (11), closing off the primary valve (2). Since fuel pressure falls from tank pressure, a liquid liquefied petroleum gas evaporates.

  • Page 93: Fuel Control Valve

    Fuel Control Valve Fuel Lock - Off 6EV2142 6EN2139 1. Carburetor AVV port connection 2. Vaporizer secondary vent chamber connection 1. Solenoid coil 3. Electrical connectors 2. Fuel inlet connection 4. Balance line connection 3. Fuel outlet connection 4. Electrical connector The fuel control valve is a three way valve, operated by a pulse width modulated electronic signal applied to The fuel lock-off unit is a direct acting plunger style...

  • Page 94: Engine Control Unit (Ecu)

    Engine Control Unit (ECU) 6EV2149 In order to obtain maximum emission reductions from cycle at a constant rate. This decreases the flow of air the exhaust gas catalyst, accurate control of the valve vacuum (AVV) through the FCV to the engines operating air fuel ratio (AFR) is required.

  • Page 95: Oxygen Sensor

    Oxygen Sensor Connector Cover Housing Lead wire Sensor device 6EN2146 The oxygen sensor installed on the exhaust manifold makes use of the principles of a solid electrolyte oxygen Stoichiometric ratio concentration cell. The oxygen concentration cell is characterized by a sharp change of the output voltage in the vicinity of the stoichiometric air/fuel ratio.

  • Page 96: 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 97: Tests Or Adjustments

    Tests or Adjustments Adhere to the following warnings when performing any tests or adjustments while the engine is running. WARNING Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. 9.

  • Page 98: Lp Converter-Check,Clean

    LP Converter-Check, Clen Inspection of Vacuum Switch See, “LP Converter-Check, Clean” in LP Fuel System Section. Inspection of Fuel Lock - Off 6EN2132 1. Connect a hand vacuum pump to the nipple of the vacuum switch. 6EN2135 2. Using a vacuum pump, vacuum (0.7 or more kPa) is applied to a vacuum sensor, and the existence of continuity between sensor terminals is checked.

  • Page 99: Inspection Of Oxygen Sensor

    Inspection of Oxygen Sensor Blue code White code Oxygen sensor side (1) Before checking, warm up the engine until engine coolant temperature reaches 80 to 95 °C (2) In the state where engine is poerated disconnent the oxygen sensor connector and connect a voltmeter. Caution The right measurement cannot be pertormed if oxygen sensor connector is separated before engine starting...

  • Page 100: Disassembly And Assembly

    Disassembly & Assembly LPG Carburetor Removal and Installation of LP Gas Carburetor 6EN2143 Removal steps 1. Bracket - Accel Wire 2. LPG Carburetor 3. Carburetor Gasket 4. Air Governor 5. Governor Gasket 6. Fuel pump Cover 7. Bolt G424 Service Manual LPG Fuel System(Low Emission Version)
  • Page 101 Disassembly & Assembly of LP Gas Carburetor 6EN2147 Removal steps 1. Bolt 2. LPG mixer 3. Gasket 4. Vacuum switch 5. Fitting 6. Vacuum switch (MAP) 7. Idle adjustment screw 8. Idle adjustment screw spring 9. Throttle body assembly G424 Service Manual LPG Fuel System(Low Emission Version)

  • Page 102: Lp Gas Converter

    LP Gas Converter Removal & Installation of LP Gas Converter 6EN2148 Removal steps 1. Vacuum hose 9. Vacuum terminal 2. Vacuum hose 10. Balance hose 11. Jet 3. Vacuum hose 12. Elbow fitting 4. Fuel control valve 5. LPG shut off valve assembly 13.

  • Page 103: Dual Fuel System

    DUAL FUEL SYSTEM IDES071S Dual Fuel Basic Schematic (1) Gasoline inlet line (from gasoline tank). (2) Mechanical fuel pump. (3) LP mixer. (4) Balance hose. (5) LP electric fuelock. (6) LP fuel line. (7) Gasoline electric fuelock. (8) Converter. (9) Selector switch. (10) Carburetor. (11) Elbow. (12) LP fuel line. (13) LP fuel filter.

  • Page 104: Governing System

    GOVERNING SYSTEM General Description Sectional View of Air Governor (1) Body. (2) Stabilizer rod. (3) Stabilizer piston. (4) Throttle plate. (5) Throttle plate shaft. (6) Bearing. (7) Nipple. (8) Spring. (9) Bush nut. (10) Adjusting screw. (11) Plate. (12) Cam The air governor is located to the underside of the 2.

  • Page 105: Governor,Disassembly And Reassembly

    Air Governor Disassembly and Reassembly 6EN0862 Disassembly steps 1. Ventilation hose 2. Gasket 3. Sealing cap 4. Cover plate assembly 5. Gasket 6. Adjusting nut 7. Adjusting screw Disassembly Service Points 8. Plate assembly 9. Valve assembly 10. Valve shaft assembly Caution: Since the air governor has been adjusted and sealed 11.
  • Page 106 Inspection 1. Check the plate assembly (8) composed of a ribbon spring and coil spring for cracks and any other damage. Stabilizer 2. Check the valve shaft for wear, and also make sure that it Piston shaft piston Valve rotates smoothly when mounted in the body. 3.

  • Page 107: Lubrication System

    LUBRICATION SYSTEM General Description Cam shaft Oil pressure switch Oil filter Crankshaft Oil pump Oil pan Oil pickup Lubricating system is the full-flow filtered pressure- OIl Filter feed oil system and the oil reserved in the oil pan is fed with pressure to each part of engine. After the oil pressure is adjusted through the relief valve, the oil is fed to the cylinder blocks and cylinder head.

  • Page 108: Testing And Adjusting

    Testing & Adjusting NOTE : In normal case, the recommended engine oil for G424 engine is SAE 10W - 30. Adhere to the following warnings when performing any But, if the excessive valve noise occurs up to five tests or adjustments while the engine is running. minutes after a cold start and if the maximum ambient temperature is lower than 10°C (50°F), it is WARNING...
  • Page 109 NOTE: Too much oil consumption can also be the result if oil with the wrong viscosity is used. Oil with a When some components of the engine show bearing thin viscosity can be caused by fuel leakage into the wear in a short time, the cause can be a restriction in an crankcase, or by increased engine temperature.

  • Page 110: Oil Pressure Check

    Oil Pressure Check Oil Pressure Check (1) LP pressure switch. (2) Oil pressure switch. (two-terminals) (one-terminal) 1. With the engine OFF, make sure the oil level is correct. Connect the analyzer to the engine as shown in Engine RPM Check in the Testing And Adjusting.

  • Page 111: 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 will go through radiator top hose (5) and into the top tank cylinder block.

  • Page 112: Testing And Adjusting

    Testing & Adjusting 4. Look for bent radiator fins. Be sure that air flow through the radiator does not have a restriction. Adhere to the following warnings when performing any 5. Inspect the drive belts for the fan. tests or adjustments while the engine is running: 6.
  • Page 113 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 114: Thermostat

    Thermostat The thermostat is the wax pellet type. A jiggle valve When the temperature increases further and reaches (which improves air bleeding during water supply) is a certain specified temperature, the valve opens fully, provided on the flange part. When the thermostat is allowing even more coolant to circulate through the closed, the circulation of coolant is stopped, thereby radiator.

  • Page 115: Cooling System Heat Problem

    NOTICE 1. The indications of a heat problem are as follows: DAEWOO recommends that the coolant mix contain a. High coolant temperature indicator light is on or 50% commercially available automotive antifreeze, needle of coolant temperature gauge is in red and 50% water.
  • Page 116 Add antifreeze mixed with water to the same freeze protection as your cooling system. DAEWOO prefers the use of distilled water or deionized water to reduce the potential and severity of chemical insolubility.

  • Page 117: Belt Adjustment

    Belt Adjustment V-Belt Diagnosis Belts and pulleys wear evenly with use. Unusual signs of wear indicate some correction is needed. The Drive belts must grip the entire contact area of 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 118: Serivce Procedure

    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 119: Flushing The Cooling System

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

  • Page 120: Removal & Install 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. G424 Service Manual Cooling System...

  • Page 121: Base Engine Service Procedure

    BASE ENGINE SERVICE PROCEDURE Timing Belt Removal and Installation Removal steps 1. Timing belt front cover upper 12. Tensioner B 2. Timing belt front cover lower 13. Timing belt B 3. Timing belt 14. Counterbalance shaft sprocket 4. Tensioner spacer 15.
  • Page 122 Removal Service Points Timing belt removal (1) When the timing belt is to be re-used, make an arrow mark on the back surface on the belt to indicate the rotating direction with a chalk or the like so that the belt can be installed in the same direction.
  • Page 123 Crankshaft sprocket removal MD998778 (1) If it is difficult to remove the sprocket, use the special tool. 6EN0642 Timing belt “B” removal (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.
  • Page 124 Crankshaft sprocket removal MB990767 (1) Using the special tool show in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft sprocket bolt. MD998719 6EN0668 Inspection 1. Timing Belt Replace belt if any of the following conditions exist. (1) Hardening of back rubber.

  • Page 125: Installation Service Points Of Base Engine

    (7) Abnormal wear on teeth Earlier stage: Rubber exposed Canvas worn (canvas fibers napped, rubber lost, discolored whitish, and unclear canvas texture) Latter stage: Canvas lost, rubber exposed (tooth width thinner) Tooth missing (8) Missing tooth 8EN0068 Installation Service Points Camshaft sprocket installation (1) Using the special tools show in the illustration, lock the MB990767...

  • Page 126: Timing Belt B Installation

    Timing belt “B” installation (1) Align timing mark on the crankshaft sprocket “B” and Timing marks timing counterbalance shaft sprocket with the marks on the front (on fron marks case respectively. case) (2) Install the timing belt “B” on the crankshaft sprocket “B” and counterbalance shaft sprocket.
  • Page 127 Crankshaft bolt installation (1) Using the special tool, hold the flywheel. (2) Install the crankshaft pulley in position. MD998781 6EN0634 Oil pump sprocket installation (1) Insert a phillips screwdriver (shank diameter 8 mm[0.31 in.] shaft) through the plug hole on the left side of the cylinder block to the left counterbalance shaft.
  • Page 128 (2) Align the timing mark on the crankshaft sprocket with that on the front case. Timing mask 6EN0671 (3) Align the timing mark on the oil pump sprocket with its mating mark. Timing mark 6EN0672 (4) Install the timing belt on the crankshaft sprocket, oil pump sprocket camshaft sprocket...
  • Page 129 (8) Apply force to the tensioner in the direction shown by arrow to make the belt engage completely with each sprocket. Tensioner 6EN0017 (9) Tighten the tensioner attaching bolt to the specified torque. Tensioner (10) Tighten the tensioner spacer to the specified torque. spacer NOTE: If the nut is tightened first, the tensioner may also turn together with the nut and loose tension of the belt may result.

  • Page 130: Intake Manifold

    Intake Manifold Removal and Installation 6EN1894 Removal steps 1. Water outlet 4. Engine hanger 2. Gasket 5. Intake manifold 3. Thermostat 6. Gasket G424 Service Manual Base Engine Service Procedure...

  • Page 131: Exhaust Manifold And Water Pump

    Exhaust Manifold and Water Pump Gasoline/LPG Engine Removal and Installation 6EN1895 Removal steps 1. Oil level gauge 7. Exhaust manifold 2. Oil level gauge guide 8. Gasket 3. O-ring 9. Water inlet pipe 4. Heat protector A 10.O-ring 5. Heat protector B 11.
  • Page 132 O-ring and water pipe installation Replace the water inlet pipe O-ring with a new one. Apply water to the outer circumference of the O-ring for easier insertion into the water pump and thermostat housing. Caution: 1) Never apply engine oil or any other oil or grease to the O- ring.
  • Page 133 LPG Engine (Low Emission Version) Removal and Installation T=4.5(32.5)[45] Removal steps 8. Exhaust manifold 1. Oil level gauge 9. Gasket 2. Oil level gauge guide 10. Water inlet pipe 3. O-ring 11.O-ring 4. Heat protector A 12. Water hose 5. Heat protector B 13.

  • Page 134: Rocker Arms And Camshaft

    Rocker Arms And Camshaft Removal and Installation 6EN1896 Removal steps 1. Breather hose 12. Bearing cap No. 4 2. P.C.V. hose 13. Rocker arm C 3. P.C.V. valve 14. Bearing cap No. 3 4. Oil filler cap 15. Bearing cap No. 2 5.
  • Page 135 Removal Service Points MD998443 Rocker arm and rocker shaft removal Caution: If the lash adjuster is re-used, clean the lash adjuster. (1) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit. Special tool MD998443 to prevent the lash adjuster coming free and falling to the 6EN0569 floor.
  • Page 136 (2) Place the lash adjuster in container A and clean its outside surface. NOTE: Use a nylon brush if deposits are hard to remove. Diesel fuel 6EN1699 (3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through five to ten strokes until it slides smoothly.
  • Page 137 (6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. MD998442 Diesel fuel 6EN1809 (7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442.
  • Page 138 Installation Service Points Camshaft installation Apply engine oil to the journals and cams of the camshafts. Install the camshaft on the cylinder head. Rocker shaft installation Notch Insert the rocker shafts into the front bearing cap so that the notches on the shafts face up, and insert the installation bolts without tightening them.
  • Page 139 Lash adjuster installation MD998443 Caution: If the lash adjuster is re-used, clean the lash adjuster. (1) Set special tool MD998443 to prevent the lash adjuster coming free and falling to the floor. 6EN0569 Camshaft oil seal installation (1) Apply engine oil to the lip area of the oil seal and the MD998713 camshaft front end outer diameter.

  • Page 140: Cylinder Head And Valves

    Cylinder Head And Valves Removal and Installation 6EN1897 Removal steps 1. Cylinder head bolt 11. Exhaust valve 2. Cylinder head assembly 12. Valve stem seal 3. Cylinder head gasket 13. Valve spring seat 4. Retainer lock 14. Valve stem seal 5.
  • Page 141 Removal Service Points Cylinder head bolt removal MB991654 Using special tool, loosen the cylinder head bolts. Loosen each bolt evenly, little by little, by two or three steps. 6EN0717 Retainer lock removal Store removed valves, springs and other parts, tagged to MD998772 indicate their cylinder No.
  • Page 142 2. Valve (1) Check the valve face for correct contact. If incorrect, reface. Valve seat contact should be maintained uniform at the center of valve face. Valve seat (2) If the margin exceeds the service limit, replace the valve: contact Standard value: Margin Intake 1.2 mm (0.047 in.)
  • Page 143 5. Valve Seats Valve stem end (1) Assemble the valve, than measure the valve stem projection between the end of the valve stem and the Valve Projection spring seating surface. If the measurement exceeds the specified limit, replace the valve seat. Standard value: 42.05 mm (1.6555 in.) Spring seating Limit: 42.55 mm (1.6752 in.)
  • Page 144 Valve Guide Replacement Procedure (1) Using a press, remove the valve guide toward the cylinder block side. (2) Rebore the valve guide hole to the new oversize valve guide outside diameter. NOTE: Do not install a valve guide of the same size again. Valve guide hole diameter.
  • Page 145 Retainer lock installation The valve spring, if excessively compressed, causes the MD998772 bottom end of the retainer to be in contact. 6EN0652 Cylinder head bolt installation (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit is exceeded, replace the bolt.

  • Page 146: Front Case And Oil Pan

    Front Case And Oil Pan Removal and Installation 6EN1898 Removal steps 1. Oil filter 17. Oil pump case assembly 2. Oil pressure switch 18. Front case gasket 3. Drain plug 19. Oil pump cover 4. Drain plug gasket 20. Oil pump drive gear 5.
  • Page 147 Removal Service Points MD998727 Oil pan removal (1) Remove the all oil pan bolts. (2) Drive in the special tool between the cylinder block and oil pan (3) Side the tool by striking the edge of the special tool to separate the oil pan from the cylinder block.
  • Page 148 Counterbalance shaft front bearing removal (1) Using the special tool, remove the counterbalance shaft front bearing from the cylinder block. NOTE: Be sure to remove the front bearing first. If it has not been removed, the rear bearing puller cannot be used. Front bearing MD998371...
  • Page 149 4. Oil Pump (1) Assemble the oil pump to the front case and rotate it to ensure smooth rotation with no looseness. (2) Check the side clearance using a thickness gauge. (3) Check the side clearance Standard value: 0.08 to 0.14 mm (0.0031 to 0.0055 in.) Drive gear 0.06 to 0.12 mm (0.0024 to 0.0047 in.) Driven gear...
  • Page 150 Left counterbalance shaft rear bearing installation MB991603 (1) Install the special tool (Guide Plate) to cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block. (3) Using the special tool, install the rear bearing. NOTE: The left rear bearing has no oil holes.
  • Page 151 Counterbalance shaft oil seal installation (1) Using a suitable socket wrench, install the Socket wrench counterbalance shaft oil into the front case. Front case Oil seal 6EN0580 Oil pump oil seal installation (1) Using a suitable socket wrench, install the oil pump oil Socket seal into the front case.
  • Page 152 Front case installation (1) Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case. MD998285 6EN0746 (2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts(other than those for tightening the filter bracket).
  • Page 153 Plug installation MD998162 (1) Install a new o-ring to the groove of the front case. (2) Install a plug to the front case. (3) Fit the special tool MD998162 on the plug, and then hold in position with special tool MD998783. (4) Tighten the plug to the special tool MD998783.
  • Page 154 Oil pressure switch installation Specified sealant: 3M AAD Part No. 8672 or equivalent Sealant Caution: 1) Keep the end of threaded portion clear of sealant. 2) Avoid an over tightening. 9EN0094 Oil filter installation Bracket side (1) Clean the installation surfaces of the filter bracket. (2) Apply engine oil to the o-ring of oil filter.

  • Page 155: Piston And Connecting Rod

    Piston And Connecting Rod Removal and Installation 6EN1899 Removal steps 1. Nut 7. Piston ring No. 2 2. Connecting rod cap 8. Oil ring 3. Connecting rod bearing 9. Piston pin 4. Piston and connecting rod assembly 10. Piston 5. Connecting rod bearing 11.
  • Page 156 Removal Service Points Connecting rod cap removal Cylinder Mark the cylinder number on the side of the connecting rod number big end for correct reassembly. DEN0050 unit:mm(in) Piston pin removal Guide A Guide B Push rod 17.9(0.705) The special tool, Piston Pin Setting Tool (MD998780), consists of the parts shown in the illustration at the left.
  • Page 157 Inspection 1. Piston Ring (1) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or both piston and ring. (2) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall.
  • Page 158 Installation Service Points Piston Piston pin installation (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod (2) Obtain dimension L (to be used later) from the above measurements by using by following formula.
  • Page 159 Oil ring installation (1) Fit the oil ring spacer into the piston ring groove. First, Side install the upper side rail, and then install the lower side rail rail. Spacer NOTE: 1) The side rails and spacer may be installed in either direction.
  • Page 160 (2) Using piston ring expander, fit No.2 and then No.1 piston ring into position. NOTE: Install piston ring with identification mark facing up, to the piston crown (3) Install the No.1 piston ring in the same manner as step 2. 7EN0452 Piston and connecting rod installation Upper...
  • Page 161 Connecting rod bearing installation No.1 When the bearings are replaced, select and install them No.4 according to the identification colors on the crankshaft and identification marks stamped on the connecting rod bearing. Crankshaft Connecting rod bearing Pin O.D. Identification Thickness, No.2 identification mm (in.) mark or color...
  • Page 162 Connecting rod cap nut installation (1) Since the connecting rod bolts and nuts are torque using a plastic area tightening method, they should be examined BEFORE reuse. If the bolt threads are “necked down”, the bolts should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt’s thread.

  • Page 163: Crankshaft And Cylinder Block

    Crankshaft And Cylinder Block Removal and Installation 6EN1900 Removal steps 1. Flywheel bolt 8. Crankshaft bearing cap 2. Flywheel 9. Crankshaft bearing lower 3. F/W Housing 10. Crankshaft 4. Cover - F/W Housing 11. Crankshaft bearing upper 5. Oil seal case 12.
  • Page 164 Inspection Plastic gauge 1. Crankshaft Oil Clearance (Plastic Gauge Method) Use of the plastic gauge can facilitate the oil clearance measurement work. To use the plastic gauge, proceed as follows: (1) Remove oil from the crankshaft journal and crankshaft bearing. 6EN0703 (2) Install the crankshaft.
  • Page 165 3. Cylinder Boring (1) Oversize pistons to be used should be determined on the basis of largest bore cylinder. (2) Oversize pistons are available in four size 0.50 mm Thrust direction (0.0197 in.), and 1.00 mm (0.0394 in.). Rebore the cylinder to a diameter that matches the selected piston outside diameter that matches the selected piston outside diameter with the specified clearance.
  • Page 166 Crankshaft bearing installation (1) From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter. Cylinder Crankshaft Identification Crankshaft journal bearing for mark or block bearing outside diameter No.3 color bore Identification Size Identification Identification Identification color mm (in.) mark...
  • Page 167 Crankshaft journal Cylinder block bearing support section Crankshaft bearing Identification O.D. mm (in.) Identification I.D. mm (in.) Identification Thickness mm(in.) color mark mark Yellow 61.000 to 61.006 1.988 to 1.991 (2.40157 to 2.40181) (0.07827 to 0.07839) 56.994 to 57.000 61.006 to 61.012 1.991 to 1.994 (2.24385 to 2.24409) (2.40181 to 2.40204)
  • Page 168 Bearing cap/bearing cap bolt installation (1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt.
  • Page 169 Sealant application to oil seal case. Specified sealant: Silicone RTV sealant or equivalent. Seal ant NOTE: 1) Be sure to install the case quickly while the sealant is wet(within 15 minutes). 2) After installation, keep the sealant area away front the oil and coolant for approx.

  • Page 170: Adjustment And Troubleshooting

    ADJUSTING AND TROUBLESHOOTING Adjustment The following is the method of adjustment of the Gasoline carburetor and pneumatic governor on a reassembled engine. Rubber cap Caution : (1) The pneumatic governor hss been properly adjusted and sealed in the factory before shipping. Never break the seal unless it is necessary during engine overhaul.
  • Page 171 NOTE Engine timing can be measured at not only engine crankshaft pulley but also flywheel assy. The measurement of engine timing at crankshaft pulley is exact but it is difficult and dangerous. The measurement of engine timing at flywheel side is safe, but it is need to adjust zero position of timing plate like the followings brfore measurement of engine timing.

  • Page 172: Idle Speed Adjustment

    3. Idling Speed Adjustment (3) While holding the adjust screw to prevent it from turning, rotate the adjusting nut either clockwise or Gasoline Carburetor counterclockwise to make the engine run at 2700 L 50 rpm. Adjusting nut: Clockwise rotation Increases the engine speed (increases the installed load of spring).

  • Page 173: 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 174: 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 175: Engine Noise

    Engine Noise No definite rule or test will positively determine the 4. Try to isolate the noise to location in engine, front source of engine noise. Therefore, use the following to back, top to bottom. This can help determine information only as a general guide to engine noise which components are at fault.
  • Page 176 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. Valve lifter. (rear of engine). B. Cam bearings. 7. Noise in crankshaft area A. Loss of oil pressure. (throughout engine).

  • Page 177: 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 178: 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 179: 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 180: 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 181: Lp Fuel System

    LP Fuel System (Standard and/or Low Emission Version) 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 •...
  • Page 182 Problem Probable Cause Probable Solution Difficult to Start 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 •...
  • Page 183 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 •...
  • Page 184 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...
  • Page 185 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 •...
  • Page 186 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 187 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 •...

  • Page 188: General

    Troubleshooting Flow Chart General Loose connection in ignition system wiring –Check connections and retighten. Abnormal Ignition system combustion Defective spark plug –Replace spark plug. Incorrect ignition timing –Adjust ignition timing. Carburetion related Defective carburetor –Repair or replace carburetor. components Contaminated or clogged fuel filter element –Clean fuel filter element and pipe.
  • Page 189 Loose fan belt tension –Adjust or replace. Insufficient Overheating output Worm or damaged fan belt –Replace. Oil on fan belt –Clean. Thermostat not functioning properly –Replace. Water pump not functioning properly –Replace. Clogged radiator –Clean radiator and coolant passages. Incorrect ignition timing –Adjust ignition timing.

  • Page 190: Engine

    Base Engine Incorrect valve clearance –Cleaned or replace auto-lash adjuster. Valves and Poor idling related Valve not in close contact with valve seat –Reface seat surface. components Excessive clearance between valve stem –Replace valve and valve guide. and valve guide Incorrect valve clearance –Cleaned or replace auto-lash adjuster.
  • Page 191 Oil working its way up Engine Excessive oil Piston ring gaps in improper positions –Adjust ring gap positions. consumption Piston rings or ring grooves worn or rings –Replace piston or rings. seized in grooves Carbon deposit in oil return hole of oil ring –Replace rings.
  • Page 192 Carburetor Needle valve and valve seat not seating –Clean or replace Poor engine properly startability Incorrect float level –Adjust Worn float lip –Replace Worn float level pin and related components –Replace level pin and its related parts Malfunction choke valve –Repair Idle rpm set out of adjustment –Adjust idling speed...

  • Page 193: Electrical Components

    Electrical components Cracked distributor cap and burnt or –Clean or replace. Distributor Poor engine starting contaminated cord insertion hole Poor engine Centrifugal and vacuum advance device –Repair or replace. acceleration malfunction Insufficient engine output Excessive fuel consumption Improper spark plug gap –Adjust or replace.
  • Page 194 Brush holder not properly insulated –Clean brush or replace holder. Starter Starter does not rotate. Worn bearing bushing –Replace bushing. Starter rotates but slowly and Wires of armature coil about to be –Rewind or replace. irregularly. shortcircuited or grounded Field coil not properly connected or –Repair connections.
  • Page 195 Drive belt slipping –Adjust belt. Battery Run-down battery Alternator Stator coil grounded or open-circuited –Replace or repair. Rotor coil open-circuited –Replace. Brush and slip ring not properly connected –Replace brush if worn. (Clean holder.) (Brush does not properly come down) –Polish slip ring.

  • Page 196: Special Tools

    SPECIAL TOOLS Style Tool No. Tool name MD998781 Flywheel stopper Holding flywheel MD998785 Sprocket stopper Holding counterbalance shaft sprocket MD998778 Crankshaft spocket puller Removal of crankshaft sprocket MB990767 End yoke holder Holding camshaft sprocket (Use with MD998719) MD998719 Pulley holding pins Holding camshaft sprocket when loosening or torquing bolt (Use with MB990767)
  • Page 197 Style Tool No. Tool name MD998772 Valve spring compressor Compression of valve spring MD998729 Valve stem seal installer Installation of valve stem seal MD998727 Oil pan remover Removal of the oil pan MD998162 Plug wrench Removal and installation of front case cap plug MD998783 Plug wrench retainer...
  • Page 198 Style Tool No. Tool name Removal of counterbalance shaft rear MD998372 Silent shaft bearing puller bearing Removal and installation of piston pin MD998780 Piston pin setting tool Crankshaft rear oil seal MD998776 Installation of crankshaft rear oil seal installer MB990938 Handle Installation of crankshaft rear oil sear (Use with MD998776)
  • Page 199 ITK-1 Pressure Gauge Kit FSA-1000 Fuel System Analyzer The IMPCO ITK-1 pressure gauge kit is designed See instructions for proper usage to check air/fuel for testing and troubleshooting IMPCO gaseous mixture. fuel systems. The kit contains the following: 0-160 psi gauge - For measuring fuel container pressure or on dual fuel systems it may be used to measure gasoline fuel system pressure.

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