Doosan G424FE - Chapter 3. ENGINE MECHANICAL SYSTEM

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G424F(FE) Service Manual Chapter 3. Engine Mechanical System 30

Chapter 3. ENGINE MECHANICAL SYSTEM

General Information

Engine Outline

Main Page

Default Chapter3
- Important Safety Information3
- Table of Contents5
Index6
Chapter 1. GENERAL INFORMATION9
Precautions before Service9
- Electrical System10
Tightening Torque12
Recommended Lubricants and Capacities13
Engine Model and Engine Serial Number14
General Specification15
G424F/G424FE Engine Power and Torque17
Chapter 2. RECOMMENDED MAINTENANCE18
General Maintenance18
- Test Fuel System for Leaks18
- Inspect Engine for Fluid Leaks18
- Inspect Vacuum Lines and Fittings18
- Inspect Electrical System18
- Inspect Foot Pedal Operation18
- Engine Oil Classification19
- Checking Engine Oil Level20
- Replacing Engine Oil and Filter20
- Checking Compressed Pressure21
Cooling System Maintenance22
- Coolant Recommendation22
- Check Coolant Level22
- Inspect Coolant Hoses22
- Checking Coolant Leaks23
- Specific Gravity Test23
- Relation between Coolant Concentration and Specific Gravity23
- Checking and Adjusting Drive Belt24
- Adjusting24
- Checking Belt for Damage24
Ignition System Maintenance25
- Inspect Battery System25
- Inspect Ignition System25
- Inspection of Ignition Timing25
- Inspection of Spark Plug26
Fuel System Maintenance28
- Replace LP Fuel Filter Element28
- Testing Fuel Lock-Off Operation28
- Pressure Regulator/Converter Inspection29
- Inspect Air/Fuel Valve Mixer Assembly29
- Inspect for Intake Leaks29
- Inspect Throttle Assembly29
- Checking the TMAP Sensor29
Exhaust System Maintenance29
- Inspect Engine for Exhaust Leaks29
Maintenance Schedule30
Chapter 3. ENGINE MECHANICAL SYSTEM32
General Information32
- Engine Outline32
- Technical Specifications33
- Shells Selection Table35
- Recommended Torque Values38
- Troubleshooting40
Engine Exploded View41
Intake Manifold and Gasket43
Exhaust Manifold and Gasket47
Timing Belt49
Timing Belt Tensioner53
PCV Valve54
- Crankcase Ventilation55
- Service Procedure56
Camshaft Timing Pulley And/Or Seal57
Crankshaft Timing Pulley57
Crankshaft Front Seal58
Crankshaft Accessory Pulley59
Timing Belt Rear Cover59
Camshaft Case Cover and Gasket59
Rocker Arms, Linkage, Valve Lifters with61
Cylinder Head and Eegine61
Cooling System62
- Testing and Adjusting64
- Cooling System Recommendation67
Thermostat Housing68
Water Pump69
Lubrication System70
Oil Pan73
Oil Pump74
Oil Pump Assembly75
Camshaft Case Assembly76
Cylinder Head80
Valve, Spring or Seal81
Engine Disassembly83
Engine Assembly87
Cylinder Block92
Crankshaft93
Pistons And/Or Connecting Rods99
Rings101
Chapter 4. ENGINE ELECTRICAL SYSTEM103
Specifications103
Ignition System104
- Wasted Spark DIS Ignition System104
- Inspection of Ignition Coil105
- Spark Plug Wire Inspection106
- Spark Plug Wire Replacement106
- Spark Plug Replacement107
- Spark Plug Inspection107
Charging System109
- General Description109
- Troubleshooting Procedure112
Starting System117
- General Description117
- Diagnosis Procedure118
- Start Relay Tests120
- Troubleshooting121
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)123
General Information123
- Specifications123
- Service Standard128
- Component Location129
G424FE EMS (Engine Management System) Overview133
- General Description133
- LPG Fuel System Operation136
- MPI Gasoline System Operation143
- Electronic Throttle System144
- Ignition System145
- Exhaust System146
- Secm148
- SECM Wiring Diagrams for G424FE151
G424F EMS (Engine Management System) Overview154
- General Description154
- LPG Fuel System Operation157
- Electronic Throttle System161
- Ignition System161
- Secm161
- SECM Wiring Diagrams for G424F LP Engine162
EMS Inspection and Repair163
- Engine Control Module (SECM)163
- Camshaft Position Sensor165
- IAT (Intake Air Temperature) Sensor169
- Oxygen Sensor (Pre-Catalyst)170
- Oxygen Sensor (Post-Catalyst)171
- ECT (Engine Coolant Temperature) Sensor172
- LP Fuel Temperature Sensor174
- Angle Sensor-Accelerator175
- Transmission Oil Temperature Switch176
- Ground Speed Limit Switch (Optional)177
- Electronic Throttle Body178
Chapter 6. LPG FUEL DELIVERY SYSTEM179
G424FE LP System Inspection and Repair179
- Removal and Installation179
- Tests and Adjustments185
- Parts Description191
  - CA100 Mixer for G424FE Engine191
  - N-2007 Regulator for G424FE Engine193
G424F LPG System Inspection and Repair195
- Removal and Installation195
- Tests and Adjustments200
- Parts Description205
Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM214
Specification214
Components Location215
Fuel Pressure Test216
Injector218
- Injector Inspection219
Fuel Pump221
Chapter 8. BASIC TROUBLESHOOTING222
Preliminary Checks222
- Before Starting222
- Visual/Physical Check222
Basic Troubleshooting Guide223
- Customer Problem Analysis Sheet223
- Basic Inspection Procedure224
- Connector Inspection Procedure225
- Symptom Troubleshooting Guide Chart229
Basic Troubleshooting235
- Intermittents235
- Surges And/Or Stumbles236
- Engine Cranking but will Not Start / Difficult to Start237
- Lack of Power, Slow to Respond / Poor High239
- Acceleration239
- Detonation / Spark Knock241
- Backfire242
- Dieseling, Run-On242
- Rough, Unstable, Incorrect Idle, or Stalling243
- Cuts Out, Misses245
- Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell246
- High Idle Speed247
- Excessive Exhaust Emissions or Odors248
- Diagnostic Aids for Rich / Lean Operation249
- Chart T-1 Restricted Exhaust System Check250
Chapter 9. ADVANCED DIAGNOSTICS251
Reading Diagnostic Fault Codes251
Displaying Fault Codes (DFC) from SECM Memory251
Clearing Fault (DFC) Codes251
Fault Action Descriptions252
Fault List Definitions252
- Table 1. Fault List Definitions253
Dfc Probable Fault Action263
- Table 2. Diagnostic Fault Codes (Flash Codes)263
Appendix281
Service Tool Software (Motoview)281
- Introduction281
- Connection of the Service Tool282
- Motoview Display Screens283
- SECM Field Update with Service Tool295
Ground Speed Limits (Option)299
LPG and LPG Fuel Tanks301
- Lpg Fuel Tanks302
- Lpg Fuel Tank Components302
Regulatory Compliance305
Special Conditions for Safe Use305
Abbreviations306

Doosan G424FE - Chapter 3. ENGINE MECHANICAL SYSTEM

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