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Daewoo G424 LP User Manual

Daewoo G424 LP
199 pages
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Service Manual
G424 Gasoline/LP Engine
G424 LP Engine (Low Emission Version)
G20E-3, G25E-3, G30E-3
GC20E-3, GC25E-3, GC30E-3
SB2215E01
Oct.2001

Table of Contents

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Daewoo G424 LP Specifications

General IconGeneral
BrandDaewoo
ModelG424 LP
CategoryEngine
LanguageEnglish

Summary

Important Safety Information

GENERAL INFORMATION

How To Read This Manual

Explains how to understand the service procedures, component diagrams, and symbols used in the manual.

Tightening Torque

Major Bolts and Nuts

Provides a list of major bolts and nuts with their specified tightening torques in various units.

SPECIFICATIONS

General Specifications

Details engine specifications including type, displacement, bore, stroke, weight, compression, and timing.

MAINTENANCE

Test Fuel System for Leaks

Procedure to check for leaks in the fuel system using a soap solution.

ENGINE SYSTEM

Engine Overview

Provides a general description of the engine's construction and key features.

Electrical System

Wiring Diagram (Gasoline Engine)

Illustrates the electrical circuit for the gasoline engine model.

STARTING SYSTEM

General Description

Explains the function and operation of the starting motor and its components.

Starter Motor

Operation

Details the operational sequence of the starter motor when the ignition key is turned.

CHARGING SYSTEM

General Description

Describes the function and components of the alternator system.

IGNITION SYSTEM

Breakerless Ignition System

Explains the breakerless ignition system, its components, and operation.

Distributor

Vacuum advance mechanism

GASOLINE FUEL SYSTEM

General Description

Provides an overview of the gasoline fuel system components and their functions.

Gasoline Carburetor (Disassembly and Reassembly)

Service Points of Disassembly

Highlights specific parts of the carburetor that should not be disassembled.

LP FUEL SYSTEM

General Description

Overview of the LP fuel system components and their roles.

LP FUEL SYSTEM (Tests or Adjustments)

Carburetor Adjustment

Details the procedures for adjusting the carburetor's idle speed and mixture.

LP Converter (Check, Clean)

Inspect Converter for Oil Accumulation

Procedure to inspect the converter for oil accumulation and clean it.

LPG Carburetor (Disassembly & Assembly)

Remove & Install LP Gas Carburetor

Step-by-step guide for removing and installing the LP gas carburetor.

LPG FUEL SYSTEM (LOW EMISSION VERSION)

General Description

Explains the low emission LPG system with closed-loop carburetion.

LP Carburetor (Variable Venturi)

Vacuum Switch (MAP)

LP Converter

Fuel Control Valve

Describes the function and operation of the fuel control valve.

Engine Control Unit (ECU)

Catalytic Muffler

LPG Fuel System (Tests or Adjustments)

LP Carburetor-Check, Clean

Procedure for periodic inspection and cleaning of the LP carburetor.

DUAL FUEL SYSTEM

Dual Fuel Basic Schematic

Diagram illustrating the basic components of the dual fuel system.

GOVERNING SYSTEM

General Description

Explains the function of the air governor in controlling engine speed.

LUBRICATION SYSTEM

General Description

Overview of the engine's full-flow filtered pressure-feed lubrication system.

LUBRICATION SYSTEM (Testing & Adjusting)

Engine Oil

Provides recommendations for selecting engine oil based on specifications.

Oil Pressure Check

COOLING SYSTEM

General Description

Explains the operation and components of the engine's cooling system.

COOLING SYSTEM (Testing & Adjusting)

Cooling System Visual Inspection

Procedure for visually inspecting the cooling system for potential issues.

COOLING SYSTEM (Pressure Cap Test)

Thermostat

Operation

Describes how the thermostat controls coolant circulation based on temperature.

COOLING SYSTEM (Cooling System Heat Problems)

Cooling System Recommendation

Provides recommendations for coolant mixture, protection, and system cleaning.

COOLING SYSTEM (Belt Adjustment)

V-Belt Diagnosis

Information on diagnosing V-belt wear, failure causes, and types of belt damage.

COOLING SYSTEM (Service Procedures)

Draining and Filling the Cooling System

Step-by-step guide for draining and refilling the engine's cooling system.

BASE ENGINE SERVICE PROCEDURE

Timing Belt

Details the removal and installation procedures for the timing belt.

BASE ENGINE SERVICE PROCEDURE (Timing Belt B)

Timing belt “B” removal

Instructions for removing the timing belt 'B'.

Intake Manifold

Removal and Installation

Procedure for removing and installing the intake manifold.

Exhaust Manifold and Water Pump

Removal and Installation

Steps for removing and installing the exhaust manifold and water pump.

Rocker Arms And Camshaft

Removal and Installation

Procedure for removing and installing rocker arms and camshaft.

Rocker Arms And Camshaft (Inspection)

Camshaft

Instructions for inspecting the camshaft for wear and dimensions.

Cylinder Head And Valves

Removal and Installation

Steps for removing and installing cylinder head and valves.

Cylinder Head And Valves (Inspection)

Cylinder Head

Inspection of the cylinder head for leaks, damage, and flatness.

Cylinder Head And Valves (Valve)

Valve

Instructions for inspecting valves, springs, and guides.

Cylinder Head And Valves (Valve Seats)

Valve Seats

Details on measuring and reconditioning/replacing valve seats.

Cylinder Head And Valves (Valve Guide Replacement)

Valve Guide Replacement Procedure

Procedure for removing and installing valve guides.

Front Case And Oil Pan

Removal and Installation

Guide for removing and installing the front case and oil pan.

Front Case And Oil Pan (Inspection)

Front Case

Inspection of the front case for clogging, wear, and damage.

Piston And Connecting Rod

Removal and Installation

Steps for removing and installing pistons and connecting rods.

Piston And Connecting Rod (Inspection)

Piston Ring

Instructions for checking piston ring groove clearance and end gap.

Crankshaft And Cylinder Block

Removal and Installation

Procedure for removing and installing the crankshaft and cylinder block.

Crankshaft And Cylinder Block (Inspection)

Crankshaft Oil Clearance (Plastic Gauge Method)

Method for measuring crankshaft oil clearance using plastic gauge.

ADJUSTING AND TROUBLESHOOTING

Adjustment

Details adjustment procedures for carburetor and pneumatic governor.

ADJUSTMENT AND TROUBLESHOOTING (Troubleshooting)

Engine Performance

Troubleshooting guide for poor engine idle and acceleration.

Engine Noise

Oil Pressure Diagnostics

Oil Pressure Problems

Water in Engine

Engine Overheating

LP Fuel System (Standard and/or Low Emission Version)

Will Not Start/FCV Staying On

Troubleshooting steps for when the engine will not start or FCV stays on.

LP Fuel System (Won’t Run Continuously)

Won’t Run Continuously

Troubleshooting for engine stalling or running continuously.

LP Fuel System (Rough Idle)

Rough Idle/Weak Ignition/Lean Condition

Guide for diagnosing rough idle, weak ignition, or lean conditions.

LP Fuel System (Poor High Speed)

Poor High Speed Performance/Lean Condition

Troubleshooting for poor high speed performance or lean conditions.

ADJUSTMENT AND TROUBLESHOOTING (Troubleshooting Flow Chart)

General

A general troubleshooting flow chart for various engine issues.

SPECIAL TOOLS

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