Doosan G424 Gasoline Lp Engine G424 Lp Engine G20e 3 G25e 3 G30 Service Manual
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SB2215E01
Oct.2001
Service Manual
G424 Gasoline/LP Engine
G424 LP Engine (Low Emission Version)
G20E-3, G25E-3, G30E-3
GC20E-3, GC25E-3, GC30E-3
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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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. 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.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
1
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 ....................................54
Distributor, disassembly and reassembly ...........56
SPECIFICATIONS ...................................................13
General Specification ..........................................13 GASOLINE FUEL SYSTEM ....................................58
Service Specification ..........................................14 General Description ............................................58
Geasoline Carburetor, Operation........................59
MAINTENANCE ......................................................17 Removal and Installation ....................................64
Test Fuel System for Leaks ................................17 Gasoline Carburetor
Check Engine Oil Level ......................................17 Disassembly and Reassembly............................66
Inspect Engine for Fluid Leaks ...........................17
Change Engine Oil and Filter .............................17 LPG FUEL SYSTEM ...............................................73
Inspect Accessory Drive Belts ............................18 General Description ............................................73
Inspect Electrical System....................................18 Electric Fuelock Model ..................................73
Inspect Vacuum lines and fitting .........................18 Converter .......................................................74
Check Coolant Level...........................................18 Fuel Tank .......................................................75
Inspect Coolant Hoses........................................18 LP Relief Valve ..............................................75
Inspect Ignition System.......................................18 Carburetor .....................................................76
Replace Spark Plug ............................................18 Tests or Adjustments...........................................77
Replace LP fuel filter element.............................19 Carburetor Adjustment ..................................77
Test Fuelock (electric) .........................................19 Fuel System Leak Check ..............................79
Replace Gasoline Fuel filter ...............................20 Recommendation for LP Fuel System ..........80
Inspect Gasoline Carburetor ...............................20 LP Converter - Check, Clean ........................81
Inspect Pressure Regulator/Vaporizer ................20 Disassembly and Assembly ................................82
Inspect LP Mixer (Standard LP Truck)................20 LPG Carburetor .............................................82
Inspect Variable Venturi Air/Fuel Mxer LP Gas Fuelock.............................................84
(Low Emission LP Truck) ....................................20 LP Gas Converter..........................................85
Inspect Complete Exhaust System for
Leaks,damage ....................................................20 LPG FUEL SYSTEM (LOW EMISSION VERSION)..87
Engine Control Unit (ECU) and others General Description ............................................87
(Low Emission LP Truck) ....................................20 LP Carburetor ................................................89
Maintenance Schedule .......................................21 Vacuum switch (MAP) ...................................90
Vacuum switch ..............................................90
ENGINE SYSTEM ...................................................22 LP Converter .................................................91
Engine Overview .................................................22 Fuel Control Valve .........................................92
Timing System ....................................................25 Fuelock Valve ................................................92
Silent Shaft Mechanism ......................................26 Engine Control Unit (ECU) ............................93
Auto Lash Adjuster..............................................27 Oxygen Sensor..............................................94
Intake and Exhaust System ................................28 Catalytic Muffler.............................................95
Electrical System ................................................30 Tests or Adjustments...........................................96
LP Carburetor - Check, Clean.......................97
STARTING SYSTEM ...............................................32 LP Converter-Check,Clean ...........................97
General Description ............................................32 Inspection of Fuelock Valve ..........................97
Start Relay Test ..................................................35 Inspection of Fuel Control Valve ...................97
Start Motor ..........................................................36 Inspection of Vacuum switch.........................97
Operation .......................................................36 Inspection of Vacuum switch (MAP)..............97
Removal and Installation ...............................39 Inspection of Oxygen sensor.........................98
Disassembly and Reassembly ......................42 Disassembly and Assembly ................................99
LPG Carburetor .............................................99
CHARGING SYSTEM..............................................47
LP Gas Converter........................................101
General Description ............................................47
G424 Service Manual 2 Index
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 ........................................107
Engine Oil...............................................107
Lubrication System Problem ..................107
Oil Pressure Check ................................109
COOLING SYSTEM ...............................................110
General Description ..........................................110
Testing and Adjusting ........................................111
Cooling System Visual Inspection ...............111
Cooling System Tests ..................................111
Thermostat...................................................113
Cooling system Heat Problem .....................114
Cooling System Recommendation ..............114
Belt Adjustment............................................116
V-belt Diagnosis...........................................116
Serivce Procedure ............................................117
Draining and Filling Cooling System ...........117
Flushing the Cooling System.......................118
Radiator Service ..........................................118
Removal & Install Water Temperature Sender ..119
BASE ENGINE SERVICE PROCEDURE .............120
Timing Belt ........................................................120
Intake Manifold .................................................129
Exhaust Manifold and Water Pump ..................130
Rocker Arms and Camshaft ..............................133
Cylinder Head and Valves ................................139
Front Case and Oil Pan ....................................145
Piston and Connecting Rod ..............................154
Crankshaft and Cylinder Block .........................162
ADJUSTMENT AND TROUBLESHOOTING ........169
Adjustment ........................................................169
Valve Clearnce Adjustment .........................169
Ignition Timing Adjustment ..........................169
Idle Speed Adjustment ................................171
Air Governor Adjustment .............................171
Anti-Hunting Adjustment ..............................171
Troubleshooting ................................................172
Engine Performance....................................172
Engine Starting Problems ...........................172
Charging System Problems ........................173
Instrument Problems ...................................173
Engine Noise ...............................................174
Oil Pressure Diagnostics .............................176
Oil Pressure Problems ................................177
Water in Engine ...........................................178
Engine Overheting.......................................179
LP Fuel System
(Standard and/or Low Emission Version)....180
Troubleshooting Flow Chart ........................187
G424 Service Manual 3 Index
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
(1) A diagram of the component parts is provided • Removal steps:
near the front each section in order to give the The part designation number corresponds to the
reader a better understanding of the installed number in the illustration to indicate removal steps.
condition of component parts.
• Installation steps:
(2) The numbers provided within the diagram Specified in case installation impossible in reverse
indicate the sequence for maintenance and order of removal steps. Omitted if installation is
servicing procedures; the symbol N indicates a possible in reverse order of removal steps.
non-reusable part; the tightening torque is
provided where applicable. • Disassembly steps:
The part designation number corresponds to the number
in the illustration to indicates disassembly steps.
• Reassembly steps.
Specified in case reassembly is impossible in
reverse order of disassembly steps. Omitted if
reassembly is possible in reverse order of
disassembly steps.
Classification of Major Maintenance/Service points
When there are major points relative to maintenance and servicing procedures (such as essential
maintenance and service points, maintenance and service standard values, information regarding the
use of special tools, etc.), these are arranged together as major maintenance and service points and
explained in detail.
A : Indicates that there are essential points for removal or disassembly.
B : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and following the component parts page, and
Adhesives explained.
Information concerning the locations for
lubrication and for application of sealants and .... Sealant or adhesive
adhesives if provided, by using symbols, in the
diagram of component parts, or on the page .... Engine oil or gear oil
Inspection
Only the inspections to be performed by using special tools or measuring instruments are covered. General
service procedures not covered in this manual, such as visual inspections and cleaning of parts, however, should
always be performed during actual service operations.
G424 Service Manual 4 General Information
FRONT CASE AND OIL PAN
REMOVAL AND INSTALLATION
6EN1898
Removal steps
N 1. Oil filter H 17. Oil pump case assembly
M 2. Oil pressure switch 18. Front case gasket
3. Drain plug G 19. Oil pump cover
L 4. Drain plug gasket G 20. Oil pump drive gear
A K 5. Oil pan G 21. Oil pump driven gear
6. Oil screen F 22. Crankshaft front oil seal
7. Oil screen gasket E 23. Oil pump oil seal
B J 8. Plug D 24. Counterbalance shaft oil seal
9. O-ring 25. Front case
C I 10. Flang bolt 26. Counterbalance shaft, left
11. Relief plug 27. Counterbalance shaft, right
12. Gasket D C 28. Counterbalance shaft, front bearing
13. Relief spring E B 29. Counterbalance shaft, rear bearing, left
14. Relief plunger E A 30. Counterbalance shaft, rear bearing, right
15. Oil filter bracket
16. Oil filter bracket gasket
REMOVAL SERVICE POINTS
MD998727 A 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.
6EN0698
This alphabetical letter corresponds to the one assigned Operating procedures, cautions, etc.
to a part in the removal, installation, disassembly or on removal, installation, disassembly
reassembly steps that are indicated in the drawing on the and reassembly are described
first page of each section.
G424 Service Manual 5 General Information
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.
Use of substitute tools will result in malfunction of the part
or damage it.
1EN0019
Tightening Torque
Tighten the part properly to specified torque.
1EN0020
Sealant
T
Use specified brand of sealant.
AN
AL
Use of sealant other than specified sealant may cause
SE
water or oil leaks.
1EN0021
G424 Service Manual 6 General Information
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.
1EN0023
Oil and Grease
Before reassembly, apply specified oil to the rotating and
sliding parts.
1EN0024
Genuine Part
When the part is to be replaced, be sure to use genuine
part.
For selection of appropriate parts, refer to the Parts
Catalog.
1EN0025
G424 Service Manual 7 General Information
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
6EN1916
G424 Service Manual 8 General Information
Doosan G424 Gasoline Lp Engine G424 Lp Engine G20e 3 G25e 3 G30 Service Manual
Full download: http://manualplace.com/download/doosan-g424-gasoline-lp-engine-g424-lp-engine-g20e-3-g25e-3-g30-service
Tightening Torque
Major Bolts and Nuts
Torque
Item Remarks
kg•m lb•ft N•m
Water pump pulley bolt 0.9 6.5 9
Crankshaft pulley bolt 2.5 18.1 25
Ignition system Spark plug 2.5 18.1 25
Distributor nut 1.2 8.7 12
Timing belt cover bolt 1.1 8.0 11
0.9 6.5 9
Tensioner spring spacer 4.9 35.4 48
Tensioner belt Tensioner bolt 4.9 35.4 48
Oil pump sprocket nut 5.5 39.8 54
Crankshaft bolt 12.0 86.8 118
Tensioner B bolt 1.9 13.7 19
Counterbalance shaft 4.6 33.3 45
Engine support bracket bolt 3.6 26.0 35
Camshaft sprocket bolt 9.0 65.1 88
Timing belt rear bolt 1.4 10.1 14
Fuel system Carburetor nut 1.2 8.7 12
carburetor Air horn nut 1.2 8.7 12
Stud 1.2 8.7 12
Fuel pump 1.1 8.0 11
Fuel system LPG carburetor nut 1.2 8.7 12
LPG carburetor Fuel pump cover 1.1 8.0 11
Intake manifold Water outlet bolt 1.4 10.1 14
Intake manifold bolt/nut 1.8 13.0 18
Exhaust Oil level gauge guide bolt 1.4 10.1 14
manifold Heat protector bolt 0.9 6.5 9
Exhaust manifold nut 3.5 25.3 34
Water inlet pipe bolt 1.4 10.1 14
Water pump bolt 1.4 10.1 14
Rocker cover bolt 0.6 4.3 6
Rocker arm
M8 B 25 2.4 17.4 24
and camshaft Bearing cap bolt
M6 B 65 2.0 14.5 20
Cylinder head,
8.0 kgf•m(57.9 lb•ft)[78 N•m]+ 0 +
valve Cylinder head bolt 2.0 kgf•m(14.5 lb•ft)[20 N•m]+
1/4 turn + 1/4 turn
G424 Service Manual 9 General Information
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