Doosan G420F - Front Case and Oil Pump

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G420F(FE) Service Manual Chapter 3. Engine Mechanical System 78

Front Case and Oil Pump

COMPONENTS

1. Filter 7.Relief plunger

2. Front case 8.Oil seal

3. Gasket 9.Inner rotor

4. Oil screen 10.Outer rotor

5. Plug 11.Pump cover

6.Relief spring

Main Page

Default Chapter2
- Important Safety Information2
- Table of Contents4
Chapter 1. General Information8
Precautions before Service8
- Electrical System9
Tightening Torque11
Recommended Lubricants and Capacities12
Engine Model and Engine Serial Number13
General Specification14
Engine Power and Torque16
Chapter 2 . RECOMMENDED17
General Maintenance17
- Engine Oil Classification18
- Checking Engine Oil Level19
- Replacing Engine Oil and Filter19
- Checking Compressed Pressure20
- Adjusting Timing Belt Tension21
Cooling System Maintenance22
- Coolant Recommendation22
- Check Coolant Level22
- Inspect Coolant Hoses22
- Checking Coolant Leaks23
- Specific Gravity Test23
- Checking and Adjusting Drive Belt24
- Adjusting25
- Checking Belt for Damage25
- Ignition System Maintenance26
- Inspect Battery System26
- Inspect Ignition System26
- Inspection of Spark Plug27
Fuel System Maintenance29
- Replace Lp Fuel Filter Element29
- Testing Fuel Lock-Off Operation30
- Inspect Air/Fuel Valve Mixer Assembly31
- Exhaust System Maintenance31
- Inspect Engine for Exhaust Leaks31
- Inspect for Intake Leaks31
- Inspect Throttle Assembly31
- Checking the Tmap Sensor31
Maintenance Schedule32
Chapter 5 . ENGINE MANAGEMENT34
General Information34
- Specifications36
Chapter 3 . ENGINE MECHANICAL39
- Torque Specification39
Special Tools40
- Troubleshooting42
Timing Belt System43
- Removal44
- Inspection45
- Assembly47
PCV Valve49
- Outline and Operation Principle49
- Service Procedure50
Intake and Exhaust System51
- Exhaust Manifold53
- Cooling System55
- Testing and Adjusting56
- Cooling System Recommendation59
- Coolant Pipe and Hose61
- Water Pump62
- Thermostat64
Cylinder Head Assembly66
Lubrication System75
- Testing and Adjusting76
- Oil Pressure Switch78
- Front Case and Oil Pump79
CAM Shaft, HLA, Timing Chain84
- Removal85
- Inspection86
Crankshaft91
Flywheel and Housing95
Piston and Connection Rod96
- Engine Block102
Cylinder Block111
- Specifications119
- Coil-On-Plug Ignition System120
- Cop Components120
- Ignition System120
- Inspection of Ignition Timing123
- Inspection of Ignition Coil124
- Inspection of Spark Plug125
Charging System127
- Troubleshooting129
- Troubleshooting Procedure130
- Disassembly and Installation135
Starting System140
- Diagnosis Procedure141
- Start Relay Tests143
- Starter145
  - Removal and Installation146
  - General Information151
- Service Standard156
- Component Location157
- G420FE EMS (Engine Management System Overview161
- LPG Fuel System Operation164
- MPI Gasoline System Operation171
- Electronic Throttle System172
Chapter 4 . ENGINE ELECTRICAL173
Ignition System173
- Exhaust System174
- Secm176
  - SECM Wiring Diagrams for G420FE179
  - G420F EMS (Engine Management System Overview181
- LPG Fuel System Operation184
- MPI Gasoline System Operation188
- SECM Wiring Diagrams for G420F189
EMS Inspection and Repair190
- Engine Control Module (Secm)190
- Camshaft Position Sensor192
- Crank Shaft Position Sensor193
- MAP (Manifold Absolute Pressure) Sensor194
- Iat (Intake Air Temperature)195
- Oxygen Sensor (Pre-Catalyst)196
- Oxygen Sensor (Post-Catalyst)197
- ECT (Engine Coolant Temperature) Sensor198
- LP Fuel Temperature Sensor200
- Angle Sensor-Accelerator201
- Transmission Oil Temperature Switch202
- Ground Speed Limit Switch (Optional)203
- Electronic Throttle Body204
Chapter 6 . LPG FUEL DELIVERY205
G420FE LP System Inspection and Repair205
- Hose Connections206
- Removal and Installation of207
- Removal and Installation of CA100 Mixer for G420FE208
- Tests and Adjustments210
- Parts Description217
G420F LPG System Inspection and Repair221
- G420F Fuel System Connections222
  - Removal and Installation of N-2001 LP Regulator/Converter223
  - Removal and Installation of CA100 Mixer for G420F224
- Tests and Adjustments226
  - AVV (Air Valve Vacuum) Testing228
- Idle Mixture Adjustment229
- Parts Description231
Chapter 7 . MPI GASOLINE FUEL240
Specification240
Components Location241
Fuel Pressure Test242
Injector244
Injector Inspection246
Fuel Pump248
Chapter 8. Basic Troubleshooting249
- Visual/Physical Check249
- Before Starting249
Preliminary Checks249
Basic Troubleshooting Guide250
- Customer Problem Analysis Sheet250
- Basic Inspection Procedure251
- Connector Inspection Procedure252
- Symptom Troubleshooting Guide Chart256
Basic Troubleshooting262
- Surges And/Or Stumbles263
  - Engine Cranking but will Not Start / Difficult to Start264
  - Speed Performance / Hesitation During Acceleration266
- Detonation / Spark Knock268
- Backfire269
- Dieseling, Run-On269
- Rough, Unstable, Incorrect Idle, or Stalling270
- Cuts Out, Misses272
- Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell273
- High Idle Speed274
- Excessive Exhaust Emissions or Odors275
- Diagnostic Aids for Rich / Lean Operation276
- Chart T-1 Restricted Exhaust System Check277
- Displaying Fault Codes (DFC) from SECM Memory278
Chapter 9. Advanced Diagnostics278
Reading Diagnostic Fault Codes278
Clearing Fault (Dfc) Codes278
Fault Action Descriptions279
Fault List Definitions279
- Table 1. Fault List Definitions280
Dfc Probable Fault Action290
- Table 2. Diagnostic Fault Codes (Flash Codes)290
Appendix Service Tool Software (Motoview)308
- Service Tool Connection to SECM309
- Service Tool Display310
- SECM Field Update with Service Tool315
Ground Speed Limits (Option)319
LPG and LPG Fuel Tanks321
- Lpg Fuel Tank Components322
- Lpg Fuel Tanks322
Regulatory Compliance325
Special Conditions for Safe Use325
Abbreviations326

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