Engine distributors DSG-423 Manuals

Manuals and User Guides for Engine distributors DSG-423. We have 1 Engine distributors DSG-423 manual available for free PDF download: Service Manual

Engine distributors DSG-423 Service Manual (240 pages)

INDUSTRIAL ENGINE 2.3 LITER

Brand: Engine distributors | Category: Engine | Size: 7 MB

Dsg-423 General Information Index 01

4
- Table of Contents
  4
- Safety Notice
  6
- General Information
  6
- Notes, Cautions, and Warnings
  6
- Battery Handling and Charging
  7
- Engine Identification
  8
- Parts and Service
  8
- Description and Operation
  8
- Special Tools
  9
- Inspection and Verification
  10
- Pcv System Malfunction
  13
- Engine Oil Leaks
  13
- Compression Tests
  15
- Cylinder Leakage Detection
  16
- Intake Manifold Vacuum Test
  16
- Excessive Engine Oil Consumption
  18
- Oil Pressure Test
  19
  - Valve Train Analysis – Static
    20
  - Valve Train Analysis – Dynamic
    20
- Hydraulic Valve Lash Adjuster
  23
- Camshaft Runout
  25
- Camshaft End Play
  25
- Crankshaft Main Bearing Journal Diameter
  26
- Crankshaft Main Bearing Journal Taper
  26
- Crankshaft Main Bearing Journal Clearance
  27
- Crankshaft End Play
  28
- Crankshaft Runout
  28
- Cylinder Bore Taper
  28
- Cylinder Bore Out-Of-Round
  29
- Piston Inspection
  29
- Piston Diameter
  29
- Piston to Cylinder Bore Clearance
  29
- Piston Ring End Gap
  30
- Crankshaft Connecting Rod Journal Diameter
  31
- Connecting Rod Cleaning
  31
- Connecting Rod Twist
  32
- Connecting Rod Larger End Bore
  32
- Piston Pin Diameter
  32
- Connecting Rod Bushing Diameter
  32
- Connecting Rod Bend
  32
- Connecting Rod Piston Pin Side Clearance
  33
- Connecting Rod Journal Clearance
  33
- Roller Follower Inspection
  34
- Hydraulic Lash Adjuster Inspection
  34
- Valve Stem Diameter
  35
- Valve Stem-To-Valve Guide Clearance
  35
- Valve Inspection
  35
- Valve Guide Inner Diameter
  36
- Valve Guide Reaming
  36
- Valve Spring Installed Length
  36
- Valve Spring Free Length
  36
- Valve Spring Out-Of-Square
  36
- Valve Spring Compression Pressure
  37
- Valve and Seat Refacing Measurements
  37
- Valve Seat Width
  37
- Valve Seat Runout
  37
- Flywheel Inspection
  38
- Oil Pump Gear Radial Clearance
  38
- Oil Pump Rotor Inspection
  38
- Oil Pump Side Clearance
  38
- Cylinder Bore Honing
  39
- Cylinder Bore Cleaning
  39
- Cylinder Block Core Plug Replacement
  40
- Cylinder Head - Distortion
  40
- Spark Plug Thread Repair
  42
- Exhaust Manifold Straightness
  43
  - Specifications
    44
Section 2

45
- Engine Cooling System
  47
- Positive Crankcase Ventilation System
  47
- Drive Belt System
  49
- Ignition System
  49
  - Fuel System
    49
- Lubrication System
  49
- Camshaft Cover - Removal
  50
- Intake Manifold - Installation
  50
- Intake Manifold - Removal
  50
- Camshaft Cover - Installation
  51
- Crankshaft Pulley - Removal
  52
- Crankshaft Pulley - Installation
  53
- Crankshaft Front Seal - Installation
  54
- Crankshaft Front Seal - Removal
  54
- Engine Front Cover - Removal
  55
- Engine Front Cover - Installation
  56
- Timing Drive Components - Removal
  58
- Timing Drive Components - Installation
  59
- Valve Spring - Installation
  60
- Valve Spring - Removal
  60
- Valve Seal - Installation
  61
- Valve Seal - Removal
  61
- Camshafts - Installation
  62
- Camshafts - Removal
  62
- Valve Tappet - Replacement
  62
- Exhaust Manifold - Installation
  63
- Exhaust Manifold - Removal
  63
- Cylinder Head - Installation
  64
- Cylinder Head - Removal
  64
- Oil Filter Adapter - Installation
  67
  - Oil Level Indicator & Tube - Replacement
    68
- Oil Filter Adapter - Removal
  67
- Oil Pressure Sender - Replacement
  67
- Oil Pan - Removal
  68
- Oil Pan - Installation
  69
- Oil Pickup Tube - Replacement
  69
- Oil Pump - Installation
  70
- Oil Pump - Removal
  70
- Crankshaft Rear Seal/Retainer - Installation
  71
- Crankshaft Rear Seal/Retainer - Removal
  71
- Flywheel/Flexplate - Replacement
  71
- Engine Disassembly
  72
  - Disassembly & Assembly
    72
- Cylinder Head Disassembly
  77
- Engine Cleaning
  78
- Cylinder Head Assembly
  79
- Engine Assembly
  80
- Valve Clearance Check
  89
- Removal and Installation
  99
Section 3

101
- Cautions & Warnings
  
  103
- General Information - Gasoline
  
  103
  - Fuel System Requirements
    104
  - Wiring Diagrams
    105
- General Information - Dry Fuel
  
  107
- Diagnosis and Testing - NG
  
  110
- Diagnosis and Testing - Lpg
  
  110
  - Preliminary Test
    111
  - Diagnostic Charts
    112
    
    Engine Backfires
    122
    
    Engine Overheats
    127
  - Visual Inspection
    130
- Diagnosis and Testing - Gasoline
  
  130
  - Fuel Pressure Check
    130
- General Service Procedures
  
  131
- Removal and Installation
  
  136
  - Actuator - Removal
    136
  - Actuator - Installation
    136
Section 4

138
- Diagnosis and Testing
  
  142
  - Coolant Inspection
    142
  - Coolant Range Check
    142
  - Drive Belt Inspection
    143
  - Cooling System Pressure Test
    145
  - Radiator Cap Pressure Test
    145
  - Thermostat Operational Check
    145
- General Service Procedures
  
  146
  - Draining the Cooling System
    146
  - Filling the Cooling System
    146
  - Flushing the Cooling System
    146
- Removal and Installation
  
  147
  - Belt Tensioner - Replacement
    147
  - Drive Belt - Installation
    147
  - Drive Belt - Removal
    147
  - Idler Pulley - Replacement
    147
  - Radiator Hose - Installation
    148
    
    Thermostat & Housing - Replacement
    149
  - Radiator Hose - Removal
    148
  - Coolant Pump - Replacement
    150
  - Block Heater - Replacement
    151
  - Outlet Pipe - Replacement
    151
  - Coolant Bypass - Replacement
    152
Section 5

154
- Wiring Diagram
  157
- Diagnosis and Testing
  
  158
  - Preliminary Checks
    158
  - Warning Indicator Check
    158
  - Battery Drain Test
    160
  - Battery Load Test
    160
  - Generator Output Test
    161
  - Generator Voltage Test
    161
- General Service Procedures
  
  162
  - Battery Cleaning and Inspection
    162
  - Battery Tools
    162
- Removal and Installation
  
  164
  - Generator - Replacement
    164
  - Voltage Regulator - Replacement
    164
  - Generator Pulley - Replacement
    165
  - Battery - Installation
    166
Dsg-423 Starter Index Subject Page

168
- Motor Feed Circuit - Voltage Drop Test
  174
- Starter Motor - Ground Circuit Check
  174
- Jump Starting
  175
- Starter Motor - Replacement
  176
Subject Page

178
- General Information
  
  179
  - Battery - Removal
    166
  - GCP and Sensors
    179
  - Fuel System Components - Gasoline
    185
  - Coil-On-Plug Ignition
    186
  - Adaptive Learn
    187
  - Electrostatic Discharge Damage
    187
  - GCP Service Precautions
    187
  - Open Loop and Closed Loop Operation
    187
  - Use of Circuit Testing Tools
    187
  - Diagrams and Schematics
    188
  - Engine Component Locator View
    200
- Diagnosis and Testing
  
  201
  - Diagnostic Approach
    201
  - GCP Diagnostic Overview
    201
  - On-Board Diagnostics - GCP
    201
  - Engine Control Module (GCP) Limp Home Mode Strategy
    201
  - Intermittent MIL
    202
  - Malfunction Indicator Lamp (MIL) DTC Retrieval Procedure
    202
  - Diagnosis Using a Personal Computer
    203
  - Visual Inspection
    213
  - Intermittent Problems
    213
  - Symptom Charts
    214
  - Engine Control Module (GCP) - Diagnostic Trouble Codes
    217
- Removal and Installation
  
  220

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Engine distributors DSG-423 Service Manual (240 pages)

Table of Contents

Dsg-423 General Information Index 01

Section 2

Section 3

Cautions & Warnings

General Information - Gasoline

General Information - Dry Fuel

Diagnosis and Testing - NG

Diagnosis and Testing - Lpg

Diagnosis and Testing - Gasoline

General Service Procedures

Removal and Installation

Section 4

Diagnosis and Testing

General Service Procedures

Removal and Installation

Section 5

Diagnosis and Testing

General Service Procedures

Removal and Installation

Dsg-423 Starter Index Subject Page

Subject Page

General Information

Diagnosis and Testing

Removal and Installation

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