Daewoo Doosan Forklift D15S-2 to G20SC-2 Service Manual SB4048E00 - PDF DOWNLOAD by www.heydownloads.com

For use in service manual form SB4047E SB4048E00 Oct. 2000

SERVICE MANUAL CONTENTS NOTICE This form lists the contents of the complete Service Manual for this product. The items listed with form numbers are available and included in the manual. If form numbers listed with mark (*) are, they are not available for the initial release of the manual. When items are updated, or supplements added, they will be announced in preview and should be ordered as they become available.

TITLE Service Manual Contents Safety Torque Specifications

FORM NUMBER SB4048E00 SB2003E00 SB2004E00

ENGINE G420 LP/Gasoline Engine DC24 Diesel Engine Delco Remy CS-121 Series Alternator CS-105D Series Alternator

SB4008E01 SB2012E02 SB2007E01 SB4050E00

POWER TRAIN Power Train

SB4018E01

VEHICLE SYSTEMS Vehicle Systems Vehicle Systems D & A Mast Systems Hydraulic System Schematic Electric System Schematic D15/18/20S(C)-2 Electric System Schematic G15/18/20S(C)-2

SB4019E01 SB4020E01 SB2143E01 SB4021E01 SB4049E00 SB4022E00

OPERATION & MAINTENANCE Operation & Maintenance Manual

Models ; D15S-2, D18S-2, D20SC-2 G15S-2, G18S-2, G20SC-2

SB2309E01

SB2003E00 O c t. 1 9 9 6

WARNING

SAFETY WARNING

WARNING

Do not operate this machine unless you have read and understand the instructions in the OPERATOR'S GUIDE. Improper machine operation is dangerous and could result in injury or death.

The proper and safe lubrication and maintenance for this machine, recommended by DAEWOO, are outlined in the OPERATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE GUIDE before performing any lubrication or maintenance.

5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this Manual, Use proper lifting procedures when removing any components.

7. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

Following is a list of basic precautions that should always be observed.

8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

1. Read and understand all Warning plates and decals on the machine before operating, lubricating or repairing the product. 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.

9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. 10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly.

11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.

4. Lower the forks or other implements to the ground before performing any work on the machine. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

12. If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine.

1 of 2

WARNING 21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on machine. Hang "Do Not Operate" tag in the Operator's Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

22. On LP equipped lift trucks, be sure to close the valve on the LP tank before service work is performed. Always close the valve on the LP tank when the lift truck is being stored. Do not check for LP leaks with an open flame. 23. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in DAEWOO products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated.

15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

If dust which may contain asbestos is present, there are several common sense guidelines that should be followed.

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

a. Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials.

18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d. Use exhaust ventilation on permanent machining jobs. e. Wear an approved respirator if there is no other way to control the dust. f. Comply with applicable rules and regulations for the work place (for example in the U.S.A., OSHA requirements as set forth in 29 CFR 1910. 1001).

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

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SB2004E00 Dec. 1998

Specifications TORQUE SPECIFICATIONS

STANDARD TORQUE FOR METRIC FASTENERS

NOTE : Take care to avoid mixing metric and inch dimensioned fasteners. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible injury. Exceptions to these torques are given in the Service Manual where needed. NOTE : Prior to installation of any hardware, be sure components are in near new condition. Bolt and nut threads must not be worn or damaged. Hardware must be free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply engine oil to threads and bearing face. If thread lock or other compounds are to be applied, do not apply engine oil.

METRIC NUTS AND BOLTS THREAD SIZE (mm)

STANDARD TORQUE (N i m)

12 ± 3

(lb i ft)

28 ± 7

20 ± 5

M10

55 ± 10

40 ± 7

M12

100 ± 20

75 ± 15

M14

160 ± 30

120 ± 22

M16

240 ± 40

175 ± 30

M20

460 ± 60

340 ± 44

M24

800 ± 100

600 ± 75

M30

1600 ± 200

1200 ± 150

M36

2700 ± 300

2000 ± 225

9 ± 2

METRIC TAPERLOCK STUDS THREAD SIZE (mm)

STANDARD TORQUE (N i m)

8± 3

(lb i ft)

17 ± 5

13 ± 4

M10

35 ± 5

26 ± 4

M12

65 ± 10

48 ± 7

M16

110 ± 20

80 ± 15

M20

170 ± 30

125 ± 22

M24

400 ± 60

300 ± 45

M30

650 ± 80

480 ± 60

M36

870 ± 100

640 ± 75

1 of 7

6 ± 2

STANDARD TORQUE FOR INCH FASTENERS Exceptions to these torques are given in the Service Manual where needed.

INCH NUTS AND BOLTS THREAD SIZE inch

STANDARD TORQUE (N i m)

(lb i ft)

1/4

12 ± 3

5/16

25 ± 6

18.0 ± 4.5

3/8

47 ± 9

35 ± 7

7/16

70 ± 15

50 ± 11

1/2

105 ± 20

75 ± 15

9/16

160 ± 30

120 ± 20

5/8

215 ± 40

160 ± 30

3/4

370 ± 50

275 ± 35

7/8

620 ± 80

460 ± 60

900 ± 100

660 ± 75

1-1/8

1300 ± 150

950 ± 100

1-1/4

1800 ± 200

1325 ± 150

1-3/8

2400 ± 300

1800 ± 225

1-1/2

3100 ± 350

2300 ± 250

9 ± 2

INCH TAPERLOCK STUDS THREAD SIZE inch

STANDARD TORQUE (N i m)

1/4

8 ± 3

(lb i ft)

5/16

17 ± 5

13 ± 4

3/8

35 ± 5

26 ± 4

7/16

45 ± 10

33 ± 7

1/2

65 ± 10

48 ± 7

5/8

110 ± 20

80 ± 15

3/4

170 ± 30

125 ± 22

7/8

260 ± 40

190 ± 30

400 ± 60

300 ± 45

1-1/8

500 ± 70

370 ± 50

1-1/4

650 ± 80

480 ± 60

1-3/8

750 ± 90

550 ± 65

1-1/2

870 ± 100

640 ± 75

2 of 7

6± 2

O-RING FACE SEAL FITTINGS O-RING FACE SEAL FITTING

O-RING GROOVE

O-RING FACE SEAL NUT

O-RING

IDAS001B

STRAIGHT THREAD O-RING FITTING (FOR O-RING FACE SEAL FITTING ONLY) THREAD SIZE inch

STANDARD TORQUE (lb i ft) (N i m)

45±15 lb i in

5/16-24

5.0 ± 1.5

3/8-24

12 ± 2

7/16-20

20 ± 4

1/2-20

30 ± 5

22 ± 4

9/16-18

40 ± 5

30 ± 4

3/4-16

100 ± 15

75 ± 10

7/8-14

135 ± 15

100 ± 10

1 1/16-12

200 ± 25

150 ± 20

1 3/16-12

250 ± 25

185 ± 20

1 5/16-12

300 ± 40

225 ± 30

1 5/8-12

300 ± 40

225 ± 30

1 7/8-12

300 ± 40

225 ± 30

2 1/2-12

300 ± 40

225 ± 30

110±20 lb i in 15 ± 3

O-RING FACE SEAL FITTING NUT THREAD SIZE inch

STANDARD TORQUE (N i m)

(lb i ft)

9/16-18

16 ± 3

12 ± 2

11/16-16

30 ± 4

22 ± 3

13/16-16

50 ± 7

37 ± 5

1-14

90 ± 10

65 ± 7

1 3/16-12

120 ± 15

90 ± 10

1 7/16-12

160 ± 20

120 ± 15

1 11/16-12

190 ± 20

140 ± 15

2-12

215 ± 25

160 ± 20

3 of 7

STRAIGHT THREAD O-RING PORT FITTING END

FITTING INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting into the part it is used on until backup washer (4) just makes contact with the face of the part it is used on.

HYDRAULIC LINE INSTALLATION 1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight. 2. Tighten the bolts at the rigid end.

2.To put the fitting assembly in its correct position, turn the fitting body (2) out (counterclockwise) a maximum of 359û. Tighten locknut (3) to the torque shown in the correct chart for the fitting used.

3. Install the hose and tighten all bolts finger tight. 4. Put the hose in a position so that it does not make contact with the machine or another hose.

NOTE: If the fitting is a connector (straight fitting), the hex on the body takes the place of the locknut. To install this type fitting, tighten the hex against the face of the part it goes into.

5. Tighten the bolts on both connections. 6. Start the engine. 7. Move the implement control levers to all positions. 8. Look at the hose during movement of the implement. Make sure hose is not in contact with the machine or other hoses.

TORQUES FOR FLARED AND O-RING FITTINGS The torques shown in the charts that follow are to be used on the nut part of 37û Flared, 45û Flared and Inverted Flared fittings (when used with steel tubing), O-ring plugs, O-ring fittings and swivel nuts when used in applications to 3000 psi (20 700 kPa).

9. Shut off the engine. 10. If necessary, put the hose in a new position where it will not make contact when the implement is moved.

ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS

HOSE CLAMP-BAND TYPE

This type of fitting is used in many applications. The tube end of the fitting will be different in design so that it can be used in many different applications. However, the installation procedure of the fitting is the same. If the tube end of the fitting body is the same as in the illustration (either an elbow or a straight body) it will be necessary to assemble the sleeve on the tube before connecting the tube to the end.

2 1

IDAS003B

CLAMP WIDTH 7.9 mm (.312 in) 13.5 mm (.531 in) 15.9 mm (.625 in)

3 5 6

IDAS002B

ELBOW BODY ASSEMBLY (1) End of fitting body (connects to tube). (2) Fitting body. (3) Lock-nut. (4) Backup washer. (5) O-ring seal. (6) End of fitting that goes into other part.

4 of 7

TORQUE ON NEW HOSE 0.9 ± 0.2 N i m 8 ± 2 lb i in

RETIGHTENING TORQUE 0.7 ± 0.2 N i m 6 ± 2 lb i in

7.5 ± 0.5 N i m 65 ± 5 lb i in

4.5 ± 0.5 N i m 40 ± 5 lb i in

3.0 ± 0.5 N i m 25 ± 5 lb i in

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

37û FLARED

O-RING FITTING-PLUG

SWIVEL NUTS

IDAS004B

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS (EXCEPT O-RING FACE SEAL FITTINGS)

METRIC

INCH

THREAD SIZE inch

3.18

.125

4.76

NOMINAL TUBE O.D.

STANDARD TORQUE (N i m)

5/16

5.0 ± 1.5

(lb i ft)

.188

3/8

11.0 ± 1.5

8 ± 1

6.35

.250

7/16

16 ± 2

12 ± 1

7.94

.312

1/2

20 ± 5

15 ± 4

9.52

.375

9/16

25 ± 5

18 ± 4

9.52

.375

5/8

35 ± 5

26 ± 4

12.70

.500

3/4

50 ± 7

37 ± 5

15.88

.625

7/8

65 ± 7

48 ± 5

19.05

.750

1-1/16

100 ± 10

75 ± 7

22.22

.875

1-3/16

120 ± 10

90 ± 7

25.40

1.000

1-5/16

135 ± 15

100 ± 11

31.75

1.250

1-5/8

180 ± 15

135 ± 11

38.10

1.500

1-7/8

225 ± 15

165 ± 11

50.80

2.000

2-1/2

320 ± 30

240 ± 22

TIGHTENING OTHER FITTINGS Hi Duty (Shear sleeve) Tube Fittings After tube has been put through the nut and makes contact against the tube shoulder in the fitting body, turn the nut with a wrench until a small decrease in torque is felt. This is an indication that the sleeve has been broken off the nut. Hold the tube to prevent turning and tighten the nut 1-1/2 turns.

IDAS005B

Hi Seal Fittings Put nut and sleeve over the tubing with the short heavy end of the sleeve facing the end of tubing. Put the tube end against the counterbore in the body of the fitting and tighten until nut is over the last thread on the body. The remainder of space is used whenever the fitting is removed and installed again.

IDAS006B

5 of 7

4 ± 1

45û FLARED AND 45û INVERTED FLARE FITTINGS

INVERTED 45û FLARED

45û FLARED

IDAS007B

45û FLARED AND 45û INVERTED FLARE FITTINGS

METRIC

INCH

THREAD SIZE inch

3.18

.125

4.76

NOMINAL TUBE O.D.

STANDARD TORQUE (N i m)

5/16

5.0 ± 1.5

(lb i ft)

.188

3/8

8.0 ± 1.5

6 ± 1

6.35

.250

7/16

11 ± 2

8 ± 1

7.94

.312

1/2

17 ± 3

13 ± 2

9.52

.375

5/8

30 ± 3

22 ± 2

11.11

.438

11/16

30 ± 3

22 ± 2

12.70

.500

3/4

38 ± 4

28 ± 3

15.88

.625

7/8

50 ± 5

37 ± 4

19.05

.750

1-1/16

90 ± 8

65 ± 6

22.22

.875

1-1/4

100 ± 10

75 ± 7

TIGHTENING OTHER FITTINGS Ermeto Tube Fittings Put nut and sleeve over the tube with head or shoulder end of sleeve next to nut. Push tube into counterbore of fitting body as far as possible. Turn nut clockwise until sleeve holds tube and prevents movement. Tighten the nut 1-1/4 turns more to seat sleeve and give a locking action. When necessary to assemble again, put sleeve over tube and tighten nut until a sudden increase in torque is felt. Then tighten 1/6 to 1/3 turn more to seat the sleeve.

IDAS008B

Flex Fittings Put nut and sleeve over the tubing and push tube in to counterbore of fitting body as far as possible. Tighten the nut until it is against the hex part of the fitting body.

IDAS009B

6 of 7

4 ± 1

AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS

O-RING

45û FLARE

IDAS010B

AIR CONDITIONING FITTINGS 45û FLARE FITTING END

O-RING FITTING END

STEEL TUBES

ALUMINUM TUBES

STANDARD TORQUE

THREAD SIZE inch

STANDARD TORQUE

5/8-18

18 ± 4

13 ± 3

30 ± 3

22 ± 2

23 ± 3

17 ± 2

3/4-16

37 ± 4

27 ± 3

52 ± 5

38 ± 4

33 ± 4

24 ± 3

7/8-14

40 ± 4

30 ± 3

60 ± 7

44 ± 5

38 ± 4

28 ± 3

1 1/16-14

45 ± 5

33 ± 4

75 ± 8

55 ± 6

50 ± 5

37 ± 4

N im

(lb i ft)

N im

(lb i ft)

N im

TAPERED PIPE THREAD FITTINGS STANDARD TORQUE

PIPE THREAD SIZE inch

THREADS WITH 1E2200E SEALANT

THREADS WITHOUT SEALANT

Nim

(lb i ft)

Nim

(lb i ft)

1/16-27

1/8-27

1/4-18

3/8-18

1/2-14

3/4-14

1-11 1/2

1 1/4-11 1/2

110

1 1/2-11 1/2

110

130

2-11 1/2

130

160

120

7 of 7

(lb i ft)

SB4008E01 May 2000

Service Manual G420 LP/Gasoline Engine

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 ÒSafetyÓ section of the Service or Technical Manual. Additional safety precautions are listed in the ÒSafetyÓ 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.

Index General Information General ......................................................................8 How To Read This Manual.........................................4 Precautions Before Servce ........................................6 Sealant .....................................................................12 Tightening Torque ......................................................9

Specifications General Specifications .............................................13 Service Specifications..............................................14

Removal And Installation Air Governor.............................................................78 Carburetor ................................................................71 Crankshaft And Cylinder Block ................................64 Cylinder Head And Valves .......................................41 Distributor.................................................................88 Exhaust Manifold and Water Pump .........................33 Front Case And Oil Pan ...........................................47 Fuel System .............................................................28 Ignition System ........................................................17 Intake Manifold.........................................................31 Piston And Connecting Rod.....................................56 Rocker Arms And Camshaft.....................................35 Starter Motor ............................................................80 Timing Belt ...............................................................19

System Operation Engine ......................................................................90 Lubricating System ..................................................95 Fuel System .............................................................96 Cooling System......................................................105 Intake and Exhaush System ..................................106 Electrical System ...................................................107

Adjust And Trouble Shooting Engine Adjustment .................................................113 Troubleshooting......................................................115

Special Tools Special Tools ..........................................................123

G420 LP/Gasoline Engine

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 near the front each section in order to give the reader a better understanding of the installed condition of component parts. (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures; the symbol N indicates a non-reusable part; the tightening torque is provided where applicable.

¥ Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. ¥ Installation steps: Specified in case installation impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. ¥ 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 Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives if provided, by using symbols, in the diagram of component parts, or on the page

following the component parts page, and explained. .... Sealant or adhesive .... 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.

G420 LP/Gasoline Engine

General Information

FRONT CASE AND OIL PAN REMOVAL AND INSTALLATION

6EN1898 Removal steps N M

L K

1. Oil filter 2. Oil pressure switch 3. Drain plug 4. Drain plug gasket 5. Oil pan 6. Oil screen 7. Oil screen gasket 8. Plug 9. O-ring 10. Flang bolt 11. Relief plug 12. Gasket 13. Relief spring 14. Relief plunger 15. Oil filter bracket 16. Oil filter bracket gasket

MD998727

G G G F E D

D E E

C B A

17. Oil pump case assembly 18. Front case gasket 19. Oil pump cover 20. Oil pump drive gear 21. Oil pump driven gear 22. Crankshaft front oil seal 23. Oil pump oil seal 24. Counterbalance shaft oil seal 25. Front case 26. Counterbalance shaft, left 27. Counterbalance shaft, right 28. Counterbalance shaft, front bearing 29. Counterbalance shaft, rear bearing, left 30. Counterbalance shaft, rear bearing, right

REMOVAL SERVICE POINTS 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 to a part in the removal, installation, disassembly or reassembly steps that are indicated in the drawing on the first page of each section.

G420 LP/Gasoline Engine

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described

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

SE AL AN T

Sealant Use specified brand of sealant. Use of sealant other than specified sealant may cause water or oil leaks.

1EN0021

G420 LP/Gasoline Engine

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

G420 LP/Gasoline Engine

General Information

General Engine models and numbers Engine model

Fuel type

G420

L. P. G./ Gasoline

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

4G63

AA0001 to YY9999

6EN1916

G420 LP/Gasoline Engine

General Information

Tightening Torque Major Bolts and Nuts Torque

Item

Remarks

kg¥m

lb¥ft

N¥m

Water pump pulley bolt

0.9

6.5

Crankshaft pulley bolt

2.5

18.1

Spark plug

2.5

18.1

Distributor nut

1.2

8.7

Timing belt cover bolt

1.1

8.0

0.9

6.5

Tensioner spring spacer

4.9

35.4

Tensioner bolt

4.9

35.4

Oil pump sprocket nut

5.5

39.8

Crankshaft bolt

12.0

86.8

118

Tensioner B bolt

1.9

13.7

Counterbalance shaft

4.6

33.3

Engine support bracket bolt

3.6

26.0

Camshaft sprocket bolt

9.0

65.1

Timing belt rear bolt

1.4

10.1

Fuel system

Carburetor nut

1.2

8.7

carburetor

Air horn nut

1.2

8.7

Stud

1.2

8.7

Fuel pump

1.1

8.0

LPG carburetor nut

1.2

8.7

LPG carburetor Fuel pump cover

1.1

8.0

Intake manifold Water outlet bolt

1.4

10.1

Intake manifold bolt/nut

1.8

13.0

Exhaust

Oil level gauge guide bolt

1.4

10.1

manifold

Heat protector bolt

0.9

6.5

Exhaust manifold nut

3.5

25.3

Water inlet pipe bolt

1.4

10.1

Water pump bolt

1.4

10.1

Rocker cover bolt

0.6

4.3

M8 B 25

2.4

17.4

M6 B 65

2.0

14.5

Ignition system

Tensioner belt

Fuel system

Rocker arm and camshaft

Bearing cap bolt

Cylinder head, valve

Cylinder head bolt

G420 LP/Gasoline Engine

8.0 kgf¥m(57.9 lb¥ft)[78 N¥m]+ 0 + 2.0 kgf¥m(14.5 lb¥ft)[20 N¥m]+ 1/4 turn + 1/4 turn

General Information

Torque

Item

Remarks

kg¥m

lb¥ft

N¥m

Drain plug

4.0

28.9

Oil pan bolt

0.7

5.1

Oil screen bolt/nut

1.9

13.7

Oil pressure switch

1.0

7.2

Front case,

Plug

2.4

17.4

doil pan

Flange bolt

3.7

26.8

Relief plug

32.5

Oil filter bracket

1.9

13.7

Oil pump cover bolt

1.7

12.3

Oil pump cover screw

1.0

7.2

Front case bolt

2.4

17.4

Piston, Connecting rod bearing nut connecting rod. Flywheel bolt

Crankshaft, cylinder block

13.5

97.6

132

0.9

6.5

6.0

43.4

Rear plate cover

1.1

8.0

Oil seal case bolt

1.1

8.0

Rear plate bolt

Bearing cap bolt Starter motor

2.0 kg¥m(14.5 lb¥ft) [20 N¥m]+ 1/4 turn

Starter motor bolt

G420 LP/Gasoline Engine

2.0 kg¥m(14.5 lb¥ft) [20 N¥m]+ 1/4 turn 2.7

19.5

General Information

General Bolts and Nuts Tightening Torque Standard Bolts and Nuts Torque, kg¥m (lb¥ft) [N¥m] Nominal diameter

Pitch

Bolt, stud, nut (with spring washer)

Flange bolt, flange nut

Head mark 4

Head mark 7

Head mark 10

Head mark 4

Head mark 7

0.5 (0.5) [3.6]

0.6 (4.3) [5.9]

0.9 (6.5) [8.8]

1.2 (8.7) [12]

1.0 (7.2) [9.8]

1.2 (8.7) [12]

2.2 (15.9) [22]

3.0 (21.7) [29]

1.3 (9.4) [13]

2.4 (17.4) [24]

2.5 (18.1) [25]

4.5 (32.5) [44]

6.0 (43.4) [59]

2.6 (18.8) [25]

5.0 (36.2) [49]

4.2 (30.4) [41]

8.6 (60.0) [81]

10.7 (77.4) [105]

4.7 (34.0) [46]

9.5 (68.7) [93]

M10

7.3 (52.8) [72]

14.0 (101.3) [137]

14.5 (104.9) [142]

Tapered Threads Torque, kg¥m (lb¥ft) [N¥m] Size

Material of internal threads:

Aluminum alloy

Cast iron or steel

NPTF 1/16

0.5 to 0.8 (3.6 to 5.8) [5 to 8]

0.8 to 1.2 (5.8 to 8.7) [8 to 11]

PT 1/8

0.8 to 1.2 (5.8 to 8.7) [8 to 11]

1.5 to 2.2 (10.8 to 15.9) [15 to 21]

PT 1/4

2.0 to 3.0 (14.5 to 21.7) [20 to 29]

3.5 to 4.5 (25.3 to 32.5) [34 to 44]

NPTF 1/4

2.0 to 3.0 (14.5 to 21.7) [20 to 29]

3.5 to 4.5 (25.3 to 32.5) [34 to 44]

PT 3/8

4.0 to 5.5 (28.9 to 39.8) [39 to 59]

5.5 to 7.5 (39.8 to 54.2) [54 to 73]

PT 1/2

7.0 to 10.0 (50.6 to 72.3) [69 to 98]

12.0 to 16.0 (86.8 to 115.7) [118 to 156]

New Tightening Method-By Use of Bolts to be Tightened in Plastic Area A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. where the bolts are in use: ¥Area (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts method ¥Tightening After tightening the bolts to the specified torque, tighten them another 90¡ or 180¡ (twice 90¡). The tightening method varies on different areas. Observe the tightening method described in the text.

G420 LP/Gasoline Engine

General Information

Sealant Part to be Applied

Brand

Semi circular packing

3MTM AAD Part No.8672 or equivalent

Rocker cover

3MTM AAD Part No.8672 or equivalent

Oil pressure switch

3MTM AAD Part No.8672 or equivalent

Oil pan

Silicone RTV sealant or eguivalent

Rear oil seal case

Silicone RTV sealant or eguivalent

Rear plate bolt

3MTM AAD Part No.8672 or equivalent

Oil seal case bolt

3MTM AAD Part No.8672 or equivalent

From in Place Gasket (FIPG)

Surface preparation

The engine has several areas where the from-inplace gasket(FIPG) is in use. To ensure that gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size.

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old FIPG remaining in the bolt holes. From-in-place gasket Application Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only.

Since the FIPG used in the engine hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool ÒOil Pan RemoverÓ (MD998727) is available. Be sure to use the special tool to remove the oil pan.

G420 LP/Gasoline Engine

The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.

General Information

Specifications General Specifications Engine model Item

G420

Type

Water-cooled, 4-cycle, gasoline-powered and L.P.G.-powered

No. of cylinders and arrangement

4, in-line

Combustion chamber type

Semi-spherical

Valve mechanism

OHC

Total displacement, cm3(cc) [cu in.]

1997 (1997) [122]

Bore x stroke, mm (in.)

85 B 88 (3.35 B 3.46)

Dry weight, kg (lb)

143 (315)

Compression ratio

8.5

Compression pressure, kPa (kgf/cm2) [psi]

Valve timing

1128 (11.5) [163.5]

Intake

Open

12¡ BTDC

valve

40¡ ABDC

Exhaust

Open

54¡ BBDC

valve

6¡ ATDC

Firing order

1-3-4-2

Ignition timing, BTDC/rpm

4¡/740 (gasoline), 9¡/740 (L.P.G.)

Fuel pump

Gasoline

Mechanical (diaphragm type)

Carburetor

Down-draft type

Governor

Air flow type

Lubrication system

Pressure feed, full-flow filtration type

Oil pump

Gear, driven by timing belt

Oil filter

Filter paper, cartridge type

Cooling system

Water-cooled, forced circulation

Water pump

Centrifugal, driven by V-belt

Thermostat

Wax type

Electrical system

12V DC, negative ground

Alternator, (12V-50A)

Alternator current, built-in fan and regulator

Starter motor, (12V-1.2kW)

Reduction drive

Distributor

Equipped with automatic timing controller, breaker less type

Spark plug (NGK)

Gasoline

BPR4ES

L. P. G.

BPR5ES

Quantity of lubricating oil, cm (liter) [U.S.gal]

4000(4.0) [1.06 ]( including 300 cm3(0.3 liter)[0.08 U.S.gal ]in oil filter

Quantity of coolant, cm3 (liter) [U.S.gal] IDLE RPM

3100 (3.1) [0.82] (in engine proper)

LOW (RPM)

750 L 25

HIGH (RPM)

2450 L 50

G420 LP/Gasoline Engine

Specifications

Service Specifications Unit : mm(in.) Standard value

Item Flatness of gasket surface

0.2 (0.008)

Total resurfacing depth of both cylinder head and cylinder block

89.9 to 90.1 (3.539 to 3.547)

Oversize rework dimensions of valve guide hole

0.05 (0.0020)

13.05 to 13.07 (0.5138 to 0.5146)

0.25 (0.0098)

13.25 to 13.27 (0.5217 to 0.5224)

0.50 (0.0197)

13.50 to 13.57 (0.5315 to 0.5343)

Oversize rework dimensions of valve seat ring hole

Cylinder head Camshaft

Overall height

0.30 (0.0118)

44.30 to 44.33 (1.7441 to 1.7453)

0.60 (0.0236)

44.60 to 44.63 (1.7559 to 1.7571)

0.30 (0.0118)

38.30 to 38.33 (1.5079 to 1.5091)

0.60 (0.0236)

38.60 to 38.63 (1.5197 to 1.5209)

Intake Exhaust

Cam height

Intake

41.62 (1.6386)

41.12 (1.6189)

Exhaust

41.62 (1.6386)

41.12 (1.6189)

Journal diameter

33.935 to 33.950 (1.33602 to 1.33661)

Oil clearance Overall length

0.05 to 0.09 (0.0020 to 0.0035) Intake

109.8 (4.328)

109.3 (4.3031)

Exhaust

106.6 (4.197)

106.1 (4.126)

42.05 (1.6555)

42.55 (1.6752)

Intake

7.960 to 7.975 (0.31339 to 0.31398)

Exhaust

7.930 to 7.950 (0.31220 to 0.31299)

Valve stem projection Stem diameter Valve

Remarks

0.03 (0.0012)

Grinding limit

Piston Valve seat Valve guide Valve spring

Limit

Face angle

45¡ to 45.5¡

Thickness of valve

Intake

1.2 (0.047)

head (margin)

Exhaust

2.0 (0.079)

Stem-to-guide

Intake

0.025 to 0.058 (0.00098 to 0.00228)

clearance

Exhaust

0.050 to 0.088 (0.00197 to 0.00346)

Free height

48.0 (1.89)

Load/installed height

176.5N (18kg) [39.7lbf]/40.4 (1.591)

Out-of-squareness

2¡ or less Intake

Overall length Inner diameter Valve contact width

4¡

47 (1.85)

Exhaust

52 (2.05) 8.000 to 8.018 (0.31496 to 0.31567) 0.9 to 1.3 (0.035 to 0.051)

Sinkage

0.2 (0.008)

Outside diameter

84.97 to 85.00 (3.3453 to 3.3465)

Piston clearance

0.02 to 0.04 (0.0008 to 0.0016)

G420 LP/Gasoline Engine

47.0 (1.85)

Specifications

Unit : mm(in.) Item No. 1 ring

0.25 to 0.40 (0.0098 to 0.0157)

0.8 (0.031)

0.45 to 0.60 (0.0177 to 0.0236)

0.8 (0.031)

Oil ring

0.20 to 0.60 (0.0079 to 0.0236)

1.0 (0.039)

Ring-to-ring groove

No. 1

0.02 to 0.06 (0.0008 to 0.0024)

clearance

No. 2

0.02 to 0.06 (0.0008 to 0.0024)

Piston ring Piston pin Connecting rod Crankshaft Cylinder block

Outside diameter

Oil pump

Remarks

22.002 to 22.005 (0.86622 to 0.86634)

Press-in load

7350 to 17160

(at room temperature),

(750 to 1750)

N (kg) [lbf]

[1650 to 3860]

Big end center-to small end center

149.9 to 150.0 (5.902 to 5.906)

length Bend

0.05 (0.0020)

Twist

0.10 (0.0039)

Big end thrust clearance

0.10 to 0.25 (0.0039 to 0.0098)

End play

0.05 to 0.18 (0.0020 to 0.0071)

Journal outside diameter

56.982 to 57.000 (2.24338 to 2.24409)

Pin Outside diameter

44.985 to 45.000 (1.77106 to 1.77165)

Out-of-roundness and taper of journal and pin Concentricity journal and pin

0.005 (0.00020) 0.03 (0.0012)

Oil clearance of journal

0.02 to 0.04 (0.0008 to 0.0016)

Oil clearance of pin

0.02 to 0.05 (0.0008 to 0.0020)

Cylinder inner diameter

85.00 to 85.03 (3.3465 to 3.3476)

Flatness of gasket surface

0.05 (0.0020) Total resurfacing depth of both 0.2 (0.008) cylinder head and cylinder block

Grinding limit Overall height

Drive belt

Limit

No. 2 ring

End gap

Carburetor

Standard value

Side clearance Deflection

283.9 to 284.1 (11.177 to 11.185) Drive gear

0.08 to 0.14 (0.031 to 0.0055)

Drive gear

0.06 to 0.12 (0.0024 to 0.0047)

New belt

7.0 to 10.0 (0.28 to 0.39)

Used belt

10 (0.39)

Throttle bore diameter

32 (1.26)

Outer venturi diameter

24 (0.94)

Inner venturi diameter

9 to 12 (0.35 to 0.47)

Main jet size symbol

130

Main air jet diameter

0.9 (0.035)

Pilot jet diameter

0.55 (0.0217)

Pilot air jet diameter

1.6 (0.063)

Primary throttle valve to throttle bore clearance

1.1(0.043)

G420 LP/Gasoline Engine

Specifications

Unit : mm(in.) Item

Standard value

Starter motor

Nominal output, kW No-load characterstics

Commutator

11.0

Current, A

90 or less

Speed, rpm

3000

Outer diameter

29.4 (1.16)

28.8 (1.13)

Runout

0.05 (0.0020)

0.1 (0.0039)

Undercut

0.5 (0.020)

0.2 (0.008)

0.5 to 2.0 (0.020 to 0.079)

Tahermostat Spark plug Ignitio n coil Distributor

Brush length

Wear limit line

Centrifugal advance crank

Start

0¡/1000

angle/engine speed, ¡/rpm

End

20¡/5000

Vacuum advance crank

End

0¡/80

angle/vacuum, ¡/mmHg

Start

23¡/280

Primary coil resistance, ½

1.08 to 1.32

Secondary coil resistance, ½

22.1 to 29.9

Plug gap

0.7 to 0.8 (0.028 to 0.031)

Valve opening temperature, ¡C (ûF)

82 (180)

Fully opening temperature, ûC (ûF)

95 (203)

G420 LP/Gasoline Engine

Remarks

1.2 Voltage, V

Pinion gap

Valve lift

Limit

8 (0.31) or more

Specifications

Removal and Installation Ignition System Removal and Installation

6EN1891

Removal steps 1. Drive belt 2. Water pump pulley 3. Crankshaft pulley 4. Spark plug cable 5. Spark plug 6. High tension cable

G420 LP/Gasoline Engine

7. Vacuum hose 8. Ignition coil 9. Harness 10. Distributor

Removal And Installation

Inspection High voltage terminal

Ignition Coil Perform the following measurements. Replace the ignition coil if the standard values are not met.

1EN0393

(1) Measure the resistance values of the primary and secondary coils and of the external resistor with a tester. If the readings are within the standard limits, it follows that there is no short or open circuit in the ignition coil. Standard value: Primary coil resistance value: 1.08 to 1.32 ½ Secondary coil resistance value: 22.1 to 29.9½

Spark Plug Cable/High Tension Cable (1) Check the caps and covering for cracks. (2) Measure the resistance values: Standard value: 16 k½/m

Installation Service Points A Gear mating mark Housings mating mark

Distributor installation

(1) Turn the crankshaft so that the No.1 cylinder is at top dead center. (2) Align the distributor housing and gear mating marks.

6EN0598

(3) Install the distributor to the engine while aligning the fine cut (groove or projection) of the distributorÕs installation flange with the center of the distributor installation stud.

Stud HousingÕs mating mark

6EN0599

G420 LP/Gasoline Engine

Removal And Installation

Timing Belt Removal and Installation

B C D

H G G G F E

Removal steps 1. Timing belt front cover upper 2. Timing belt front cover lower 3. Timing belt 4. Tensioner spacer 5. Tensioner spring 6. Tensioner pulley 7. Oil pump sprocket 8. Crankshaft bolt 9. Crankshaft washer 10. Crankshaft sprocket 11. Flang

G420 LP/Gasoline Engine

E F

D C

G B H

12. Tensioner B 13. Timing belt B 14. Counterbalance shaft sprocket 15. Spacer 16. Crankshaft sprocket B 17. Crankshaft key 18. Engine support bracket 19. Camshaft sprocket bolt 20. Camshaft sprocket 21. Timing belt rear cover

Removal And Installation

Removal Service Points A

Timing belt removal

(1) When the timing belt is to be re-used, make an arrow mark on the back surface on the belt to indicate the rotating direction with a chalk or the like so that the belt can be installed in the same direction. (2) Move the timing belt tensioner upward and temporarily tighten the tensioner lock bolt. (3) Remove the timing belt. 6EN0716

6EN0884

Screw driver

Oil pump sprocket removal

(1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm[0.31 in.]) to block the counterbalance shaft. (3) Remove the nut. (4) Remove the oil pump sprocket.

6EN0663

Crankshaft bolt removal

(1) Hold the flywheel with the special tool as shown. (2) Remove the crankshaft bolt.

MD998781

6EN0868

G420 LP/Gasoline Engine

Removal And Installation

D MD998778

Crankshaft sprocket removal

(1) If it is difficult to remove the sprocket, use the special tool.

6EN0642

Timing belt ÒBÓ removal

(1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. NOTE: Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace part if seriously contaminated. 6EN1322

(2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.

Counterbalance shaft sprocket removal

(1) Set the special tool as shown to prevent the counterbalance shaft sprocket from turning together. (2) Loosen the bolt and remove the sprocket. MD998785

6EN0636

G MD998778

Crankshaft sprocket ÒBÓ removal

(1) If it is difficult to remove the sprocket, use the special tool.

6EN0637

G420 LP/Gasoline Engine

Removal And Installation

H MB990767

Crankshaft sprocket removal

(1) Using the special tool show in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft sprocket bolt.

MD998719 6EN0668

Inspection 1. Timing Belt Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail. 8EN0066

Cracks

Peeling

Cracks

(2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks on belt sides.

Cracks

8EN0044

(6) Abnormal wear of belt sides. NOTE: The sides are normal if they are sharp as if cut by a knife.

Rounded edge

Abuormal wear (Flutty strand) 8EN0067

G420 LP/Gasoline Engine

Removal And Installation

(7) Abnormal wear on teeth Earlier stage: Canvas worn (canvas fibers napped, rubber lost, discolored whitish, and unclear canvas texture) Latter stage: Canvas lost, rubber exposed (tooth width thinner) (8) Missing tooth

Rubber exposed

Tooth missing

8EN0068

Installation Service Points A

Camshaft sprocket installation

(1) Using the special tools show in the illustration, lock the camshaft sprocket in position. (2) Tighten the camshaft sprocket bolt to the specified torque.

MB990767

MD998719 6EN0669

Engine support bracket installation

(1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3MTM AAD Part No. 8762 or equivalent

6EN0739

MD998785

Counterbalance shaft sprocket installation

(1) Install the counterbalance shaft sprocket and screw the bolt. (2) Install special tool as shown in the illustration to lock the counterbalance shaft. (3) Tighten the bolt, and then remove the special tool.

6EN0636

G420 LP/Gasoline Engine

Removal And Installation

D Timing marks (on fron case)

timing marks

Timing belt ÒBÓ installation

(1) Align timing mark on the crankshaft sprocket ÒBÓ and counterbalance shaft sprocket with the marks on the front case respectively. (2) Install the timing belt ÒBÓ on the crankshaft sprocket ÒBÓ and counterbalance shaft sprocket. There should be no slack on the tension side.

DEN0602

(3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.

Tensioner ÒBÓ

Center of tensioner paller

Center of bolt 6EN0571

(4) Move the tensioner ÒBÓ in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten bolt to secure tensioner ÒBÓ. When the bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be over tensioned.

6EN0572

Timing marks

(5) Check to ensure that timing marks on sprockets and front case are in alignment. (6) Press with index finger the center of span on the tension side of timing belt ÒBÓ. The belt must deflect 5 to 7 mm. [0.196 to 0.276 in].

Belt deflection

timing marks

6EN0573

G420 LP/Gasoline Engine

Removal And Installation

Crankshaft bolt installation

(1) Using the special tool, hold the flywheel. (2) Install the crankshaft pulley in position.

MD998781 6EN0634

Oil pump sprocket installation

(1) Insert a phillips screwdriver (shank diameter 8 mm[0.31 in.] shaft) through the plug hole on the left side of the cylinder block to the left counterbalance shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts. (4) Tighten the nuts to the specified torque. Screw driver

6EN0564

G Spring end Tensioner spring Spring end

Crankshaft bolt installation

(1) Hook the tensioner spring end to the water pump body projection and tensioner bracket. (2) Move the tensioner fully toward the water pump and tighten the bolt and tensioner spacer.

Bolt Water pump

Tensioner

6EN0555

Timing belt installation

(1) Align the timing mark on the camshaft sprocket with that on the cylinder head. Timing mark

6EN0670

G420 LP/Gasoline Engine

Removal And Installation

(2) Align the timing mark on the crankshaft sprocket with that on the front case. Timing mask

6EN0671

(3) Align the timing mark on the oil pump sprocket with its mating mark.

Timing mark

6EN0672

Tensioner spacer

6EN0015

Timing mark

(4) Install the timing belt on the crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order. There should be no slack on the tension side. (5) Apply a reverse direction (counterclockwise) force to the camshaft sprocket to make the tension side of the belt ÒtightÓ. In that state, recheck that all the timing marks are in alignment. (6) Loosen a turn or two the tensioner bolt and nut that were temporarily tightened to hold the tensioner on the water pump side. This gives tension to the belt by the action of the tensioner spring. (7) Rotate the crankshaft by the amount equivalent to two camshaft sprocket teeth in the forward (clockwise) direction. Since this step is intended for giving the timing belt proper tension, do not attempt rotate the crankshaft in the reverse (counterclockwise) direction or press the belt to check the tension.

Two teeth

Timing mark Timing belt

G420 LP/Gasoline Engine

6EN0562

Removal And Installation

(8) Apply force to the tensioner in the direction shown by arrow to make the belt engage completely with each sprocket.

Tensioner

6EN0017

(9) Tighten the tensioner attaching bolt to the specified torque. (10) Tighten the tensioner spacer to the specified torque.

Tensioner spacer

NOTE: If the nut is tightened first, the tensioner may also turn together with the nut and loose tension of the belt may result. Always tighten the bolt (at the bottom of the tensioner) first and then tighten the nut (at the top of the tensioner). Tensioner

6EN0015

(11) Hold the center of the tension side span of the timing belt (between the camshaft and oil pump sprockets) between your thumb and index finger as shown. Then, make sure that the clearance between the belt back surface and cover meets the standard value. Standard value: 14 mm (0.55 in.)

14mm (0.55in)

6EN0616

G420 LP/Gasoline Engine

Removal And Installation

Fuel System Removal and Installation Carburetor

6EN1893

G420 LP/Gasoline Engine

Removal steps 1. Return set hose assembly 2. Oil seal 3. Air horn 4. Gasket 5. Carburetor 6. Air governor 7. Gasket

8. Fuel pipe 9. Fuel hose 10. Fuel pipe 11. Fuel pump 12. Gasket 13. Insulator 14. Push rod

Removal And Installation

Removal Service Points A

Carburetor removal

(1) Hold the carburetor in a level position while using care not to let fuel spill, remove it from the intake manifold. (2) Turn the carburetor upside down on a pan to drain fuel.

Fuel pump removal

Placing the piston in No.1 cylinder at TDC on the compression stroke makes the fuel pump stroke lift the smallest, allowing easy removal of the pump.

Installation Service Points

Arm pin Arm

Rod spring Rod

Cam shaft Push rod

Breather hose Diaphragm spring Diaphragm

Pump body Pump cover

OUT 6EN0841

G420 LP/Gasoline Engine

Fuel pump installation

(1) Bring the piston in No.1 cylinder to TDC on the compression stroke. This provides the smallest lift of the eccentric cam, allowing easy installation of the fuel pump. (2) Apply engine oil to the surface of the push rod and insert it into the hole in the cylinder head. Make sure that the push rod sides smoothly. (3) Install the fuel pump on the cylinder head with the insulator and a new gasket in between, and tighten the bolts completely.

Removal And Installation

Removal and Installation LPG Carburetor

6EN1890

Removal steps 1. Throttle return spring 2. Accel wire assembly 3. Return spring support 4. LPG carburetor 5. Throttle chamber gasket

G420 LP/Gasoline Engine

6. Throttle body 7. Carburetor gasket 8. Air governor 9. Air governor gasket 10. Fuel pump cover

Removal And Installation

Intake Manifold Removal and Installation

6EN1894

Removal steps 1. Water outlet 2. Gasket 3. Thermostat

G420 LP/Gasoline Engine

4. Engine hanger 5. Intake manifold 6. Gasket

Removal And Installation

Intentional blank

G420 LP/Gasoline Engine

Removal And Installation

Exhaust Manifold and Water Pump Removal and Installation

6EN1895

Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector A 5. Heat protector B 6. Engine hanger

G420 LP/Gasoline Engine

A A

7. Exhaust manifold 8. Gasket 9. Water inlet pipe 10.O-ring 11. Water hose 12. Water pump 13. Gasket

Removal And Installation

O-ring and water pipe installation

Replace the water inlet pipe O-ring with a new one. Apply water to the outer circumference of the O-ring for easier insertion into the water pump and thermostat housing. Caution: 1) Never apply engine oil or any other oil or grease to the O-ring. 2) Fasten the water pipe after the thermostat housing has been installed.

G420 LP/Gasoline Engine

Removal And Installation

Rocker Arms And Camshaft Removal and Installation

6EN1896

G A

G420 LP/Gasoline Engine

Removal steps 1. Breather hose 2. P.C.V. hose 3. P.C.V. valve 4. Oil filler cap 5. Rocker cover 6. Gasket 7. Semi-circular packing 8. Rocker arms and rocker shafts 9. Rear bearing cap 10. Rear arm D 11. Spring

D D D C B B E F A

12. Bearing cap No. 4 13. Rocker arm C 14. Bearing cap No. 3 15. Bearing cap No. 2 16. Wave washer 17. Right rocker shaft 18. Left rocker shaft 19. Front bearing cap 20. Lash adjuster 21. Oil seal 22. Camshaft

Removal And Installation

Removal Service Points

MD998443

Rocker arm and rocker shaft removal

Caution: If the lash adjuster is re-used, clean the lash adjuster.

6EN0569

(1) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit. Special tool MD998443 to prevent the lash adjuster coming free and falling to the floor.

Inspection 1. Camshaft Measure the cam height and if the limit is exceeded, replace. Standard value: 41.62 mm (1.6386 in.) Limit: 41.12 mm (1.6189 in.)

9EN0058

2. Lash Adjuster Caution: ¥The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. ¥Do not attempt to disassemble the lash adjusters. ¥Use only fresh diesel fuel to clean the lash adjusters

Cutside cleaning

Inside cleaning

Filling with diesel fuel

(1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.

6EN1698

G420 LP/Gasoline Engine

Removal And Installation

(2) Place the lash adjuster in container A and clean its outside surface. NOTE: Use a nylon brush if deposits are hard to remove.

Diesel fuel 6EN1699

(3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through five to ten strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil. Caution: The steel ball spring is extremely weak, so the lash adjusterÕs functionality may be lost if the air bleed wire is pushed in hard.

Diesel fuel MD998442 6EN1808

NOTE: If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.

(4) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442 Diesel fuel

6EN1809

(5) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through five to ten strokes until it slides smoothly. This operation will clean the lash adjusterÕs pressure chamber.

MD998442

Caution: The steel ball spring is extremely weak, so the lash adjusterÕs functionality may be lost if the air bleed wire is pushed in hard.

Diesel fuel 6EN1808

G420 LP/Gasoline Engine

Removal And Installation

(6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.

MD998442 Diesel fuel

6EN1809

(7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442.

MD998442

Caution: Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel. Diesel fuel 6EN1810

(8) Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.

MD998442

Diesel fuel 6EN1811

(9) Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. NOTE: If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

6EN1704

G420 LP/Gasoline Engine

(10) Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.

Removal And Installation

Installation Service Points A

Camshaft installation

Apply engine oil to the journals and cams of the camshafts. Install the camshaft on the cylinder head.

Notch

Rocker shaft installation

Insert the rocker shafts into the front bearing cap so that the notches on the shafts face up, and insert the installation bolts without tightening them.

Frout bearing cap

6EN0575

Wave washer

Wave washer installation

Install the wave washer in correct direction as shown.

Front bearing cap

No.1 intake side rocker arm

6EN0576

D Rocker cover

Mounting bolt hole

Bearing cap

(1) No.3 bearing cap looks very similar to No.2 and No.4 bearing caps. NOTE: No.2 bearing cap is the same as No.4 bearing cap.

Front mark No.2

Indentification No.3

G420 LP/Gasoline Engine

Mark No.4

(2) Install the bearing caps with their front marks pointing to the camshaft sprocket side. 6EN0024

Removal And Installation

MD998443

Lash adjuster installation

Caution: If the lash adjuster is re-used, clean the lash adjuster. (1) Set special tool MD998443 to prevent the lash adjuster coming free and falling to the floor.

6EN0569

Camshaft oil seal installation

(1) Apply engine oil to the lip area of the oil seal and the camshaft front end outer diameter. (2) Using special tool, install the camshaft oil seal.

MD998713

6EN0650

G Apply sealant

Semi-circular packing installation

(1) Apply sealant to the location shown in the illustration. Specified sealant: 3MTM AAD Part No. 8672 or equivalent.

DEN0053

G420 LP/Gasoline Engine

Removal And Installation

Cylinder Head And Valves Removal and Installation

6EN1897

C B

G420 LP/Gasoline Engine

Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring

11. Exhaust valve 12. Valve stem seal 13. Valve spring seat 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19. Exhaust valve seat 20. Cylinder head

Removal And Installation

Removal Service Points A

MB991654

Cylinder head bolt removal

Using special tool, loosen the cylinder head bolts. Loosen each bolt evenly, little by little, by two or three steps.

6EN0717

B MD998772

Retainer lock removal

Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.

6EN0652

Valve stem seal removal

Caution: Do not reuse removed valve stem seal.

Inspection 1. Cylinder Head 6EN0718

6EN0719

G420 LP/Gasoline Engine

(1) Check the cylinder head for water leaks, gas leaks, damage or cracks before cleaning. (2) Thoroughly remove oil, water scale, sealant, carbon deposit, etc. After the oil passages have been cleaned, blow air to make sure that they are clean. (3) Check the cylinder head gasket surface for flatness by using straightedge and thickness gauge. If the service limit is exceeded, correct to meet the specification. Standard valve: 0.03 mm (0.0012 in.) or less. Limit: 0.2 mm (0.008 in.) Grinding limit: 0.2 mm (0.008 in.) Cylinder head height (when new): 89.9 to 90.1 mm (3.539 to 3.547 in.) NOTE: Grinding the cylinder head is permitted as long as the total thickness of the metal removed from the cylinder head and the cylinder block does not exceed 0.2 mm (0.008 in.). 42

Removal And Installation

2. Valve

Valve seat contact Margin

6EN0542

(1) Check the valve face for correct contact. If incorrect, reface. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve: Standard value: Intake 1.2 mm (0.047 in.) Exhaust 2.0 mm (0.079 in.) Limit: Intake 0.7 mm (0.028 in.) Exhaust 1.5 mm (0.059 in.) (3) Measure the valveÕs total length. If the measurement is less than specified, replace the valve. Standard value: 4G63 Intake 109.8 mm (4.328 in.) Exhaust 108.7 mm (4.280 in.) 4G64 Intake 106.6 mm (4.197 in.) Exhaust 105.2 mm (4.142 in.) Limit: 4G63 Intake 109.3 mm (4.3031 in.) Exhaust 108.2 mm (4.260 in.) 4G64 Intake 106.1 mm (4.177 in.) Exhaust 104.7 mm (4.122 in.)

3. Valve Spring Out of squareness

Free height

(1) Measure the free height of spring and, if it is smaller than the limit, replace. Standard value: 48.0 mm (1.89 in.) Limit: 47.0 mm (1.85 in.) (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: 2 degrees or less Limit: 4 degrees

1EN0264

4. Valve Guide Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.

Valve guide

Guide I.D.

Stem I.D.

G420 LP/Gasoline Engine

1EN0279

Removal And Installation

Valve stem end

Valve Projection

Spring seating surface

5. Valve Seats (1) Assemble the valve, than measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat. Standard value: 42.05 mm (1.6555 in.) Limit: 42.55 mm (1.6752 in.)

DEN0212

0.9 (0.0 to 1.3 35 t o 0. 05

Unit : mm(in)

60û

Valve Seat Reconditioning Procedure

) o 1.3 .051 0.9 0t 35 to 0 (0.

60û

25û 43.5û to 44û

(1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Correct to obtain the specified seat width and angle. (3) After correction, valve and valve seat should be lapped with a lapping compound.

43.5û to 44û 25û 1EN0105

0.5 to 1.0 Unit : mm(in) (0.020 to 0.039)

Valve Seat Replacement Procedure (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.

Cut away

0.5 to 1.0 (0.020 to 0.030)

1EN0274

(2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. (3) Before fitting the valve seat, cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling. (4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See ÒValve Seat Reconditioning ProcedureÓ.

Height of valve seat

Over size I.D 1EN0275

G420 LP/Gasoline Engine

Removal And Installation

Valve Guide Replacement Procedure (1) Using a press, remove the valve guide toward the cylinder block side. (2) Rebore the valve guide hole to the new oversize valve guide outside diameter. NOTE: Do not install a valve guide of the same size again. Valve guide hole diameter. 0.05 O.S. 13.05 to 13.07 mm (0.5138 to 0.5146 in.) 0.25 O.S. 13.25 to 13.27 mm (0.5217 to 0.5224 in.) 0.50 O.S. 13.50 to 13.52 mm (0.5315 to 0.5323 in.)

Press

(3) Press in the valve guide to the position shown in the illustration. Standard value: 11.5 mm (0.453 in.)

Press

11.5mm (0.453 in)

Push rod Valve guide Removal

Valve guide

Installation 6EN0543

NOTE: 1) Press-fit the valve guide, working from the cylinder head top surface. 2) Note that the intake and exhaust side valve guides are different in length. 3) After installing valve guides, insert new valves in them to check for sliding condition.

Installation Service Points

MD998729

Valve stem seal installation

(1) Install the valve spring seat. (2) Using special tool, install the new valve stem seat to the valve guide.

6EN0743

Caution: 1) Do not reuse removed valve stem seal. 2) The special tool must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.

B Indentification color

Spring retainer

Valve spring installation

Direct the valve spring end with identification color toward the rocker arm.

Stem seal Spring seat 6EN0437

G420 LP/Gasoline Engine

Removal And Installation

C MD998772

Retainer lock installation

The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact.

6EN0652

Cylinder head bolt installation

(1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit is exceeded, replace the bolt. Standard value: 120.4 mm (4.740 in.) (2) Apply engine oil to the bolt threads and washers.

Shank length

6EN0782

7 6EN0694

G420 LP/Gasoline Engine

(3) According to the tightening sequence, tighten the bolts to 8.0 kg¥m (57.9 lb¥ft)[80 N¥m]. (4) Loosen the bolts completely. (5) Torque the bolts to 2.0 kg¥m (14.5 lb¥ft)[20 N¥m]. (6) Tighten the bolts 1/4 turns (90¡) more. (7) Tighten the bolts 1/4 turns (90¡) additionally. Caution: 1) If the bolt is turned less than 90¡, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. 2) If the bolt is over tightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).

Removal And Installation

Front Case And Oil Pan Removal and Installation

6EN1898

N M

L K

G420 LP/Gasoline Engine

Removal steps 1. Oil filter 2. Oil pressure switch 3. Drain plug 4. Drain plug gasket 5. Oil pan 6. Oil screen 7. Oil screen gasket 8. Plug 9. O-ring 10. Flange bolt 11. Relief plug 12. Gasket 13. Relief spring 14. Relief plunger 15. Oil filter bracket 16. Oil filter bracket gasket

H G G G F E D

D E E

C B A

Removal And Installation

Removal Service Points MD998727

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

B MD998162

Plug removal

(1) Fit special tool MD998162 on the plug, then hold it in position with special tool MD998783. (2) Loose the plug.

MD998783 6EN0909

Oil pump oil seal installation

(1) Remove the plug on the side of cylinder block. (2) Insert a phillips screwdriver(shank diameter 8mm[0.31 in.]) into the plug hole to lock the counterbalance shaft.

Screw driver Plug 6EN1026

(3) Loosen the flange bolt.

6EN0565

G420 LP/Gasoline Engine

Removal And Installation

Counterbalance shaft front bearing removal

(1) Using the special tool, remove the counterbalance shaft front bearing from the cylinder block. NOTE: Be sure to remove the front bearing first. If it has not been removed, the rear bearing puller cannot be used.

MD998371

Front bearing 3EN0166

E MB991603

Counterbalance shaft rear bearing removal

(1) Using the special tool, remove the counterbalance shaft rear bearing from the cylinder block. NOTE: When removing the left counterbalance shaft bearing, install the special tool (MB991603) in front of the cylinder block.

MD998372 6EM0207

Inspection 1. Front Case (1) Check oil holes for clogging and clean if necessary. (2) Check the left counterbalance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case. (3) Check the front case for cracks and other damage. Replace cracked or damaged front case. 2. Oil Seal (1) Check the oil seal lip for wear and Replace oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace oil seal if necessary. 3. Counterbalance Shaft (1) Check oil hole for clogging. (2) Check journals for seizure, damaged and contact with bearing. If there is anything wrong with the journal assembly.

DEN0711

G420 LP/Gasoline Engine

Removal And Installation

4. Oil Pump

6LU0013

(1) Assemble the oil pump to the front case and rotate it to ensure smooth rotation with no looseness. (2) Check the side clearance using a thickness gauge. (3) Check the side clearance Standard value: 0.08 to 0.14 mm (0.0031 to 0.0055 in.) Drive gear 0.06 to 0.12 mm (0.0024 to 0.0047 in.) Driven gear

Installation Service Points A

Right counterbalance shaft rear bearing installation

(1) Apply engine oil to the outer surface of bearing. (2) Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block.

MD998705

Cylinder block 6EN1034

G420 LP/Gasoline Engine

Removal And Installation

B MB991603

Left counterbalance shaft rear bearing installation

(1) Install the special tool (Guide Plate) to cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block. (3) Using the special tool, install the rear bearing. NOTE: The left rear bearing has no oil holes.

MD998705

6EN0208

Rear bearing

MB991603

MD998705 6EN0557

Counterbalance shaft front bearing installation

(1) Using the special tool, install the rear bearing.

MD998705

Bearing

Cylinder block 6EN1035

G420 LP/Gasoline Engine

Removal And Installation

D Socket wrench

Oil seal

Counterbalance shaft oil seal installation

(1) Using a suitable socket wrench, install the counterbalance shaft oil into the front case.

Front case

6EN0580

Oil pump oil seal installation

(1) Using a suitable socket wrench, install the oil pump oil seal into the front case.

Socket

Oil seal Front case

6EN0494

MD998375

Crank shaft front oil seal installation

(1) Using the special tool, install the crankshaft front oil seal into the front case.

Oil seal Front case

6EN0579

Alignment mark

Oil pump driven gear/oil pump drive gear installation

(1) Apply engine oil amply to the gears and line up the alignment marks.

6LU0015

G420 LP/Gasoline Engine

Removal And Installation

Front case installation

(1) Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.

MD998285

6EN0746

(2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts(other than those for tightening the filter bracket).

MD998285

6EN0747

Flange bolt installation

(1) Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the counterbalance shaft.

Screw driver

6EN0564

(2) Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to specified torque.

6EN0565

G420 LP/Gasoline Engine

Removal And Installation

J MD998162

Plug installation

(1) Install a new o-ring to the groove of the front case. (2) Install a plug to the front case. (3) Fit the special tool MD998162 on the plug, and then hold in position with special tool MD998783. (4) Tighten the plug to the special tool MD998783. (5) Remove the special tools MD998783 and MD998162.

MD998783 6EN0909

FIPG

Oil pan installation

(1) Clean both mating surface of the oil pan and cylinder block. (2) Apply a 4 mm (0.16 in.) wide bead of FIPG to the entire circumference of the oil pan flange. The oil pan should be installed in 15 minutes after the application of FIPG. Specified FIPG: 3MTM AAD Part No.8672 or equivalent

Groove portion

Bolt hole portion

6EN0213

(3) Note the difference in bolt lengths at the location shown. Crank pulley side

8mm bolts

Oil pan viewed from lower side

6EN0449

Drain plug

Drain plug gasket installation

(1) Install the drain plug gasket in the direction shown. Caution: Fitting the gasket in a wrong way will result in oil leakage.

Oil seal Gasket Oil pan side

7EN0179

G420 LP/Gasoline Engine

Removal And Installation

Oil pressure switch installation

Specified sealant: 3MTM AAD Part No. 8672 or equivalent Sealant

Caution: 1) Keep the end of threaded portion clear of sealant. 2) Avoid an over tightening.

9EN0094

N Bracket side

Oil filter installation

(1) Clean the installation surfaces of the filter bracket. (2) Apply engine oil to the o-ring of oil filter. (3) Screw the oil filter in until the o-ring contacts the bracket.

Engine Oil

6EN0591

G420 LP/Gasoline Engine

Removal And Installation

Piston And Connecting Rod Removal and Installation

6EN1899

G F E D E C

Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing 6. Piston ring No. 1

G420 LP/Gasoline Engine

C B A

7. Piston ring No. 2 8. Oil ring 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt

Removal And Installation

Removal Service Points A Cylinder number

Connecting rod cap removal

Mark the cylinder number on the side of the connecting rod big end for correct reassembly.

DEN0050

unit:mm(in)

Push rod

Guide B

Guide C

Base

Guide A 17.9(0.705)

Piston pin removal

The special tool, Piston Pin Setting Tool (MD998780), consists of the parts shown in the illustration at the left.

Guide A 18.9(0.744)

Guide A 20.9(0.823)

Guide A 21.9(0.862) 7EN0431

Push rod

Front mark Front mark

(1) Insert the special tool, Push Rod, into the piston from the side on which the front mark is stamped in the piston head, and attach the guide C to the push rod end. (2) Place the piston and connecting rod assembly on the special tool, Piston Pin Setting Base, with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE: Keep the disassembled piston, piston pins and connecting rods in order according to the cylinder number.

Guide C

Base

7EN0390

G420 LP/Gasoline Engine

Removal And Installation

Inspection 1. Piston Ring

7EN0475

Press down ring with piston

Piston ring

End gap

(1) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or both piston and ring. (2) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring gap is excessive, replace the piston ring. Standard value: No.1 0.25 to 0.40 mm (0.0098 to 0.0157 in.) No.2 0.45 to 0.60 mm (0.0177 to 0.0236 in.) Oil 0.20 to 0.60 mm (0.0079 to 0.0236 in.) Limit: No.1, No.2 0.8 mm(0.031 in.) Oil 1.0 mm (0.039 in.)

7EN0476

2. Crankshaft Pin Oil Clearance (Plastic Gauge Method)

1EN0246

G420 LP/Gasoline Engine

(1) Remove oil from the crankshaft pin and the connecting rod bearing. (2) Cut the plastic gauge to the same length as the width of the bearing and place it on the crankshaft pin in parallel with its axis. (3) Install the connecting rod cap carefully and tighten the bolts to the specified torque. (4) Remove the bolt and carefully remove the connecting rod cap. (5) Measure the width of the plastic gauge at its widest part by using the scale printed on the plastic gauge package. Standard value: 0.02 to 0.05 mm (0.0008 to 0.0020 in.) Limit: 0.1 mm (0.004 in.)

Removal And Installation

Piston

Installation Service Points A

Connecting rod Piston pin

A7EN0432

Piston pin installation

(1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod (2) Obtain dimension L (to be used later) from the above measurements by using by following formula. (A - C) - (B - D) L= 2 (3) Insert the special tool, Push Rod, into the piston pin and attach the guide A to the push rod end. (4) Assemble the connecting rod in the piston with their front marks facing the same direction. (5) Apply engine oil to the entire periphery of the piston pin. (6) Insert the piston pin, push rod and guide A assembly having assembled in stop (3) from the guide A side into the piston pin hole on the front marked side. (7) Screw the guide B into the guide A until the gap between both guides amounts to the value L obtained in step (2) plus 3 mm (0.12 in.)

3mm (0.12in) +L2

Guide B

Guide A 7EN0433

Push rod Piston pin Front mark Front mark

(8) Place the piston onto the piston setting base with the front marks directed upward. (9) Press-fit the piston pin using a press. If the press-fitting force required is less than the standard value, replace the piston and piston pin set or/and the connecting rod. Standard value: 750 to 1750 kgf (1654 to 3859 lbf) [7350 to 17160 N]

Guide A

Base

Guide B

7EN0391

G420 LP/Gasoline Engine

Removal And Installation

B Side rail

Spacer

6EN0585

Oil ring installation

(1) Fit the oil ring spacer into the piston ring groove. First, install the upper side rail, and then install the lower side rail. NOTE: 1) The side rails and spacer may be installed in either direction. 2) The new spacers and side rails are painted in the following colors to identify their sizes. Size

Identification color

STD

No color

0.50 mm (0.020 in.) O.S.

Blue

1.00 mm (0.040 in.) O.S.

Yellow

(2) To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration.

Side rail gap

Caution: The side rail could be broken if it is expanded with a piston ring expander in the same way as with a compression ring. (3) Make sure that the side rails move smoothly in either direction. 7EN0451

Identification Identification Size mark mark

Piston ring No.2/piston ring No.1 installation

(1) To prevent wrong installation, check the identification mark of each piston ring. The installation mark is stamped near the ring gap. NOTE: Size mark on piston ring are as follows.

9EN0524

G420 LP/Gasoline Engine

Size

Size mark

STD

Paint red

0.50 mm (0.020 in.) O.S.

1.00 mm (0.040 in.) O.S.

100

Removal And Installation

(2) Using piston ring expander, fit No.2 and then No.1 piston ring into position. NOTE: Install piston ring with identification mark facing up, to the piston crown (3) Install the No.1 piston ring in the same manner as step 2.

7EN0452

D Upper side rail

No.1

Piston pin

No.2 ring gap and space gap

Lower side ral 6EN0549

Piston and connecting rod installation

(1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. (3) Insert the piston and connecting rod assembly from above the cylinder in such a way that the front mark(arrow) on the top of the piston will be directed toward the camshaft sprocket.

(4) Insert the piston and connecting rod assembly with the piston rings held firmly with a ring band. Forcing it by pounding should be avoided because damage to the piston rings or crank pin could result.

9EN0072

G420 LP/Gasoline Engine

Removal And Installation

No.1 No.4

Connecting rod bearing installation

When the bearings are replaced, select and install them according to the identification colors on the crankshaft and identification marks stamped on the connecting rod bearing. Crankshaft Pin

No.2 No.3 6EN0700

Pin O.D.

Identification

Thickness,

identification mm (in.)

mark or color

mm (in.)

color

Yellow

44.995 to 45.000 (1.77145 to 1.77165)

1 or Yellow

None

44.985 to 44.995 (1.77106 to 1.77145)

2 or None

White

44.980 to 44.985 (1.77086 to 1.77106)

3 or Blue

Identfication mark 6AE0115

1.487 to 1.491 (0.05854 to 0.05870) 1.491 to 1.495 (0.05870 to 0.05886) 1.495 to 1.499 (0.05886 to 0.05902)

Connecting rod inside diameter: 48.000 to 48.015 mm (1.88976 to 1.89035 in.)

Cylinder No.

Connecting rod bearing

Connecting rod cap installation

(1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches come on the same side as shown.

Notches DEN0051

(2) Make sure that connecting rod big end side clearance meets the specification. Standard value: 0.10 to 0.25 mm (0.0039 to 0.0098 in.) Limit: 0.4 mm (0.016 in.)

6EN0621

G420 LP/Gasoline Engine

Removal And Installation

Connecting rod cap nut installation

(1) Since the connecting rod bolts and nuts are torque using a plastic area tightening method, they should be examined BEFORE reuse. If the bolt threads are Ònecked downÓ, the bolts should be replaced. Necking can be checked by running a nut with fingers to the full length of the boltÕs thread. If the nut does not run down smoothly, the bolt should replaced. (2) Before installing the nuts, the threads should be oiled with engine oil. (3) Install both nuts on the bolts finger tight, then alternately torque each nut to assemble the cap properly. (4) Tighten the nuts to 2.0 kg¥m (14.5 lb¥ft) [20 N¥m] and plus 1/4 (90¡) turn. Caution: 1) If the nut is turned less than 90¡, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it. 2) If the nut is over tightened (exceeding 100¡), loosen the nut completely and then retighten it by repeating the tightening procedure from step (1).

G420 LP/Gasoline Engine

Removal And Installation

Crankshaft And Cylinder Block Removal and Installation

6EN1900

F E D C

Removal steps 1. Flywheel bolt 2. Flywheel 3. Rear plate 4. Rear plate cover 5. Oil seal case 6. Oil seal 7. Crankshaft bearing cap bolt

G420 LP/Gasoline Engine

C B B B

8. Crankshaft bearing cap 9. Crankshaft bearing lower 10. Crankshaft 11. Crankshaft bearing upper 12. Thrust bearing 13. Cylinder block

Removal And Installation

Inspection

Plastic gauge

1. Crankshaft Oil Clearance (Plastic Gauge Method) Use of the plastic gauge can facilitate the oil clearance measurement work. To use the plastic gauge, proceed as follows:

6EN0703

(1) Remove oil from the crankshaft journal and crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to specified torque. (5) Remove the bolt, and carefully remove the crankshaft bearing cap. (6) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 to 0.04 mm (0.0008 to 0.0016 in.) Limit: 0.1 mm (0.004 in.)

6EN0623

2. Cylinder Block (1) Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. (2) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm (0.0020 in.) Limit: 0.1 mm (0.004 in.) 9EN0074

6EN0553

G420 LP/Gasoline Engine

(3) Check the cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace. (4) Using a cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, rebore all cylinders to an oversize and replace piston rings. Measure at the points shown in the illustration. Standard value: Cylinder I.D. 4G63 85.00 to 85.03 mm (3.3465 to 3.3476 in.) 4G64 86.50 to 86.53 mm (3.4055 to 3.4067 in.) Cylindricity 0.1 mm (0.004 in.) 65

Removal And Installation

3. Cylinder Boring

Thrust direction

Piston O.D 6En0554

(1) Oversize pistons to be used should be determined on the basis of largest bore cylinder. (2) Oversize pistons are available in four size 0.50 mm (0.0197 in.), and 1.00 mm (0.0394 in.). Rebore the cylinder to a diameter that matches the selected piston outside diameter that matches the selected piston outside diameter with the specified clearance. The reference piston outside diameter measuring point is shown in the illustration. (3) Based on the measured piston O.D. calculate the boring finish dimension. Boring finish dimension = Piston O.D. + 0.02 to 0.04 mm (0.0008 to 0.0016 in.) (clearance between piston O.D. and cylinder ) - 0.02 mm (0.0008 in.) (honing margin) (4) Bore all cylinders to the calculated boring finish dimension. Caution: To prevent distortion that may result from temperature rise during boring, bore cylinders, working from No.2 to No.4 to No.1 to No.3. (5) Hone to the final finish dimension (piston O.D. + clearance between piston O.D. and cylinder). (6) Check the clearance between the piston and cylinder. Standard value: Clearance between piston and cylinder 0.02 to 0.04 mm (0.0008 to 0.0016 in.)

Installation Service Points A

Crankshaft thrust bearing installation

(1) Install the two thrust bearing in the No.3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings, this will help fold them in position. (2) The thrust bearings must be installed with their groove side toward the crankshaft web. Groovers 6EN1557

G420 LP/Gasoline Engine

Removal And Installation

Crankshaft bearing installation

(1) From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter.

Crankshaft journal outside diameter

Cylinder Crankshaft block bearing bearing for No.3 bore

Identification mark or color

Identification

Size

Identification Identification Identification

color

mm (in.)

mark

Yellow

56.994 to 57.000 (2.2439 to 2.2241)

None

White

56.988 to 56.994 (2.2436 to 2.2439) 56.982 to 56.988 (2.2434 to 2.2436)

mark or color mark or color 0

1 or Green 0 or Black

2 or Yellow 1 or Green

3 or None 2 or Yellow

2 or Yellow 1 or Green

3 or None 2 or Yellow

4 or Blue

3 or None 2 or Yellow

4 or Blue

3 or None

5 or Red

4 or Blue

3 or None

6EN0705

If the crankshaft journal outside diameter ID color is ÒyellowÓ and the cylinder block bearing bore ID mark is Ò1Ó for example, select a bearing whose ID mark is Ò2Ó or ID color is ÒyellowÓ for No. 1, 2, 4 and 5, and a bearing whose ID mark is Ò1Ó or ID color is ÒgreenÓ for No. 3. Bearing bore identification mark

If there is no ID color paint on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured value.

Cylinder inner diameter size mark

Bottom of cylinder block

Rear face of cylinder block

6EN1632

G420 LP/Gasoline Engine

Removal And Installation

Crankshaft journal Identification color

Cylinder block bearing support section

O.D. mm (in.)

Yellow

Crankshaft bearing

Identification mark

I.D. mm (in.)

Identification mark

Thickness mm(in.)

61.000 to 61.006

1.988 to 1.991

(2.40157 to 2.40181) 56.994 to 57.000

(2.24385 to 2.24409)

61.006 to 61.012

(0.07827 to 0.07839) 2

(2.40181 to 2.40204) 2

61.012 to 61.018

(0.07839 to 0.07850) 3

(2.40204 to 2.40228) None

61.000 to 61.006

(2.24362 to 2.24189)

61.006 to 61.012

61.012 to 61.018

61.000 to 61.006

(2.24338 to 2.24362)

61.006 to 61.012

61.012 to 61.018 (2.40204 to 2.40228)

1.994 to 1.997 (0.07850 to 0.07862)

(2.40181 to 2.40204) 2

1.997 to 2.000 (0.07862 to 0.07874)

(2.40157 to 2.40181) 56.982 to 56.988

1.994 to 1.997 (0.07850 to 0.07862)

(2.40204 to 2.40228) White

1.991 to 1.994 (0.07839 to 0.07850)

(2.40181 to 2.40204) 2

1.994 to 1.997 (0.07850 to 0.07862)

(2.40157 to 2.40181) 56.988 to 56.944

1.991 to 1.994

1.997 to 2.000 (0.07862 to 0.07874)

2.000 to 2.003 (0.07874 to 0.07886)

Identification mark of color 6EN1096

Groove

(2) Install the bearing having an oil groove to the cylinder block. (3) Install the bearing having no oil groove to the bearing caps.

for upper for lower 6EN1558

G420 LP/Gasoline Engine

Removal And Installation

6EN0624

Bearing cap/bearing cap bolt installation

(1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Limit: Max. 71.1 mm (2.799 in.) (3) Torque the bearing cap bolts to 2.5 kgf¥m (18.1 lb¥ft)[25 N¥m] and, from that position, retighten them 1/4 (90¡) turns more. Caution: 1) If the bolt is turned less than 90¡, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. 2) If the bolt is over tightened (exceeding 100¡), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).

(4) After installing the bearing caps, make sure that the end play is correct. If the end play exceeds the limit, replace the crankshaft bearings. Standard value: 0.05 to 0.25 mm (0.0020 to 0.0098 in.) Limit: 0.4 mm (.016 in.)

6EN0625

D MB990938

Oil seal installation

(1) Using the special tool, knock, the oil seal into the oil seal case.

MD998776

6EN0709

G420 LP/Gasoline Engine

Removal And Installation

Sealant application to oil seal case

Specified sealant: Silicone RTV sealant or equivalent. Seal ant

NOTE: 1) Be sure to install the case quickly while the sealant is wet(within 15 minutes). 2) After installation, keep the sealant area away front the oil and coolant for approx. one hour. 6EN0626

Rear plate installation

(1) Be sure install the spring washers and special washers in correct position. Spring washer

Special washer 6EN1919

G420 LP/Gasoline Engine

Removal And Installation

Carburetor Disassembly and Reassembly

A A B

C C

C C D

B B A

Disassembly steps 1. Throttle return spring 2. Damper spring 3. Choke rod 4. Screw 5. Float chamber cover 6. Float chamber cover gasket 7. Cover 8. Packing 9. Bimetal 10. O-ring 11. Accelerator wire bracket 12. Float pin 13. Float 14. Needle valve assembly 15. Packing 16. Filter 17. Weight 18. Ball 19. Main jet 20. Screw 21. Screw 22. Accelerator pump cover 23. Diaphragm 24. Spring 25. Fuel cut solenoid 26. O-ring 27. Enrichment 28. Enrichment jet 29. Speed adjust screw 30. Pilot jet 31. Choke lever 32. Spring 33. Main body 34. Insulator gasket 35. Throttle lever 36. Throttle control lever 37. Mixture adjusting screw 38. Throttle body

G420 LP/Gasoline Engine

6En0850

Removal And Installation

Service Points of Disassembly The following parts must not be disassembled at the time of disassembly. (1) Choke valve and choke shaft (2) Inner venturi (3) Throttle valve and throttle shaft

Return spring/choke rod removal

(1) When the spring is removed, avoid prying it with undue force or any other attempt that can cause damage to it. (2) Press the end of the choke rod to force the rod out. Avoid applying a strong force to the plastic grommet of the rod fit-in hole.

Float chamber cover removal

(1) Since the screws require great force to loosen, use a Phillips screwdriver that exactly fits in the cross recess in the screw heads. (2) To remove the float chamber cover, slowly lift it, while using care not to give damage to the float. DonÕt tilt the main body, as the pump discharge weight and the related parts may come out and could be lost. 6EN0851

Pump weight/ball

Turn the main body upside down to remove the weight and ball.

Main jet

Main jet removal

To remove the main jet, be sure to use a screwdriver whose tip exactly fits in the slot of the jet.

6EN0852

G420 LP/Gasoline Engine

Removal And Installation

Inspection 1. General Inspection Check the following and repair or replace parts if faulty. (1) Check fuel passages (jets) and air passages (jets or orifices) for clogging. If clogged, wash thoroughly with cleaning solvent or detergent and remove dirt by compressed air. Do not use wire or other metal pieces. (2) Check diaphragms, O-rings and springs for damage and cracks. (3) Check that needle valve operates lightly. If the valve is hard to operate or is binding, repair or replace. If there is overflow, poor valve to seat contact is suspected. Check thoroughly. (4) Check the fuel inlet filter (located above the needle valve) for clogging and damage. (5) Check the float operation. Check float and lever for deformation and damage and replace if necessary. (6) Check operation of the throttle valve, choke valve and link. If they do not operate lightly, wash well and apply engine oil sparelingly to their shaft. (7) Check the float chamber cover and main body for damage and cracks.

2. Fuel Cut Solenoid Valve Operation Check (1) Connect the battery directly to the body and terminal of the fuel cut solenoid valve to apply the voltage. Caution: Use care not to short-circuit the battery. (2) Listen to a click which should be heard when the valve operates normally at the moment the battery is connected.

12V

6EN0853

3. Fuel Cut Solenoid Valve Resistance Check Measure the resistance between the body and the terminal of the fuel cut solenoid valve with a tester. Standard value: Approx. 90½ [at 20¡C (68¡F)]

6EN0854

G420 LP/Gasoline Engine

Removal And Installation

4. Inspection of Mixture Adjusting Screw (MAS) Check tapered end of mixture adjusting screw (MAS) for damage from over tightening, etc.

Check for damage 6EN1888

5. Throttle Body Check Make sure that the throttle shaft moves smoothly. If any sticky movement is found, thoroughly clean the shaft, and then coat it with a small amount of engine oil. Do not disassemble the shaft unnecessarily.

6EN0855

Service Points of Reassembly For reassembly, reverse the order of disassembly while paying much attention to the following: (1) Clean every parts with clear cleaning oil before reassembly. Check all passages for clogging. (2) Replace all the removed packings and gaskets. (3) Make sure the throttle and choke linkage operates smoothly. If any sticky movement is found, clean or replace the linkage, and make sure that the carburetor operates without any problem.

Main jet

Installation of main jets

(1) When replacing a main jet, the oil jet and the new jet must be of the same size, because the jet is selected after exact flow measurement by factory. (A size symbol is stamped on each jet.)

6EN0852

G420 LP/Gasoline Engine

Removal And Installation

(2) Main jets have size symbols stamped on their ends for identification. Size symbols G420 130

130 Size symbol

6EN0869

Weight Check ball

Check ball/weight installation

Install the acceleration check ball and weight.

Float/float pin installation

After the float and float pin have been installed, make sure that the float is in a level position.

6EN0856

Hole A 3rd Stage 2nd stage

¥ Strangler spring setting positions Spring Setting Positions Hole B

If the strangler spring of the choke valve shaft is out of position, set it correctly in the positions shown in the illustration.

1st stage Hole C

6EN0858

G420 LP/Gasoline Engine

Removal And Installation

Choke shaft

Inspection and Adjustment After Reassembly

Choke lever

1. Fast Idle Opening (1) Move the choke lever to place the choke valve in fully closed position.

6EN0859

(2) Measure the clearance ÒAÓ (primary throttle valve to throttle bore).

Primary throttle valve

NOTE: Refer to the table in SERVICE SPECIFICATIONS for the clearance.

Clearance ÒAÓ (drill bit diameter) 6EN1889

Fastidle adjusting screw

(3) If the clearance ÒAÓ is out of specifications, adjust to the standard value by the fast idle adjusting screw. Screw direction of rotation

Clearance

Remarks

Clockwise

Increases

Fast idle speed increases

Counterclockwise Decreases

Fast idle speed decreases

6E0860

2. Choke valve Operation (1) With the choke valve lever set to its full position, move the choke valve with a finger to make sure that the choke valve shaft has not an excessive play and the valve moves smoothly without sticking. (2) If the choke valve can not be moved smoothly, clean the choke valve and the area around it. (3) If the play of the choke valve shaft is excessive, replace the float chamber cover.

G420 LP/Gasoline Engine

Removal And Installation

3. Ports (1) Connect a hand vacuum pump and check each port for clogging. (2) If clogged, clean the port and then blow air into it.

6EN0861

G420 LP/Gasoline Engine

Removal And Installation

Air Governor Disassembly and Reassembly

6EN0862

A A

A B

Disassembly steps 1. Ventilation hose 2. Gasket 3. Sealing cap 4. Cover plate assembly 5. Gasket 6. Adjusting nut 7. Adjusting screw 8. Plate assembly 9. Valve assembly 10. Valve shaft assembly 11. Piston cover 12. Gasket 13. Stabilizer piston 14. Piston shaft 15. Governor body

G420 LP/Gasoline Engine

Disassembly Service Points Caution: Since the air governor has been adjusted and sealed in the manufacturerÕs factory to conform to the specifications, it should not be disassembled in general cases. Like any other sealed components, the air governor should not be disassembled anywhere except the locations where a warranty claim decision is authorized. In addition, the cam on the throttle valve shaft should never be removed. 78

Removal And Installation

Inspection

Piston shaft

Stabilizer piston

Valve

1. Check the plate assembly (9) composed of a ribbon spring and coil spring for cracks and any other damage. 2. Check the valve shaft for wear, and also make sure that it rotates smoothly when mounted in the body. 3. Check the piston for damage. Check also the valve fit-in section of the shaft for damage. 4. Grease packed needle bearings are press-fitted at both ends of the valve shaft hole of the governor body. Avoid cleaning the body in gasoline or any other solvent.

Section A-A Valve

Shaft

Screw

Adjusting nut

Reassembly Service Points Caution: Thoroughly clean all component parts before installation. Do not apply grease or oil anywhere in the body except the needle bearings (grease packed) in the throttle valve shaft hole.

Adjusting screw and nut setting

When assembling the air governor separately from the engine, temporarily assemble it so that the throttle valve will be in the fully opened position.

G420 LP/Gasoline Engine

Removal And Installation

Starter Motor Removal and Installation

Removal steps 1. Bolt 2. Starter

6EN0867

Inspection Pinion Gap Adjustment (1) Disconnect the field coil wire from terminal M of the magnetic switch. (2) Connect a 12 V battery between terminal S and starter motor body (positive terminal to terminal S).

Stopper Pinion gap Pinion

6EN1918

Caution: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning out. (3) Set switch to ÒONÓ, and pinion will move out. (4) Check pinion to stopper clearance (pinion gap) with a thickness gauge. Pinion gap: 0.5 to 2.0 mm (0.0197 to 0.0787 in.)

(5) If the pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket.

1EN0301

G420 LP/Gasoline Engine

Removal And Installation

Pull-in Test of Magnetic Switch S

(1) Disconnect field coil wire from terminal M of magnetic switch. (2) Connect a 12V battery between terminal S and terminal M.

Battery 12V

Caution: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

Disconnect connector

6EN0871

(3) If pinion moves out, then pull-in coil is good. If it doesnÕt. replace magnetic switch.

Hold-in Test of Magnetic Switch (1) Disconnect field coil wire from terminal M of magnetic switch. (2) Connect a 12V battery between terminal S and body.

S Battery 12V

Caution: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. Disconnect connector 6EN0872

(3) Manually pull out the pinion as far as the pinion stopper position. (4) If pinion remains out, everything is in order. If pinion moves in, hold-in circuit is open. Replace magnetic switch. Return Test of Magnetic Switch (1) Disconnect field coil wire from terminal M of magnetic switch. (2) Connect a 12V battery between terminal S and body.

M Battery 12V

Caution: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. Disconnect connector 6EN0873

(3) Pull pinion out and release. If pinion quickly returns to its original position, everything is in order. If it doesnÕt, replace magnetic switch. Caution: Be careful not to get your fingers caught when pulling out the pinion.

G420 LP/Gasoline Engine

Removal And Installation

Free Running Test Variable resistance M Ammeter Starter motor

Battery 12 Voltmeter 6EN0874

(1) Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows: (2) Connect a ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter motor terminal. (3) Connect a voltmeter (15-volt scale) across starter motor. (4) Rotate carbon pile to full-resistance position. (5) Connect battery cable from battery negative post to starter motor body. (6) Adjust the rheostat until the battery voltage shown by the voltmeter is 11V. (7) Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: max. 60 amps

Symptom

Possible cause

Current is too large, and starter motor rotates at too low speeds. ( Motor output torque is insufficient.)

¥Contaminated or oil stained metal ¥Friction between armature core and pole piece ¥Armature coil and/or field coil not properly grounded ¥Armature coil short-circuited

Current is too large, and motor does not rotate at all.

¥Electromagnetic switch not properly grounded ¥Armature coil and/or field coil not properly grounded ¥Seizure of metal

No current is available, and motor does not rotate.

¥Armature coil and/or field coil open-circuited ¥Brush and/or pigtail open-circuited ¥Poor contact of brush and commutator due to contaminated commutator, high mica, etc.

Current is too small, and motor rotates at low speed. (Motor output torque is insufficient.)

Loose field coil connections (If the shunt coil alone is open-circuited or loosely connected, the motor will rotate at a high speed.)

Current is too large, and motor rotates at too high speeds. (Motor output torque is insufficient.)

Field coil short-circuited

G420 LP/Gasoline Engine

Removal And Installation

Disassembly And Reassembly

6EN1917

B B

Disassembly steps 1. Screw 2. Magnetic switch 3. Screw 4. Screw 5. Rear bracket 6. Brush holder 7. Brush 8. Rear bearing 9. Armature 10. Yoke assembly 11. Ball

G420 LP/Gasoline Engine

C C

A A

12. Packing A 13. Packing B 14. Plate 15. Planetary gear 16. Lever 17. Snap ring 18. Stop ring 19. Overrunning clutch 20. Internal gear 21. Planetary gear holder 22. Front bracket

Removal And Installation

Maguetic switch

Disassembly Service Points

ÒSÓ teminal

A ÒBÓ terminal

ÒMÓ terminal Fieldcoid wire 6EN0610

Disconnect the field coil wire from terminal M of the magnetic switch

Armature/ball removal

Caution: When removing the armature, take care not to lose the ball (Which is used as a bearing) in the armature end.

Socket

Magnetic switch removal

Snap ring/stop ring removal

(1) Press stop ring off snap ring with a suitable socket. Stop ring Pinion gear

Armature

Overrunning clutch

6EN0611

(2) Remove snap ring with snap ring pliers and then remove stop ring and overrunning clutch.

Snap ring Pinion gear Overrunning clutch

Snap ring pliersa

Armature 6EN0612

Cleaning of Starter Motor Parts Do not immerse the parts in cleaning solvent. Immersion of the yoke, field coil assembly and/or armature will damage to insulation. Do not immerse the drive unit cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will wash lubricant form clutch. The drive may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

G420 LP/Gasoline Engine

Removal And Installation

Inspection 1. Commutator (1) Place the armature on a pair of V-blocks and check the runout using a dial gauge. Standard value: 0.5 mm (0.020 in.) Limit: 0.1 mm (0.004 in.)

1EN0298

(2) Check the outer diameter of the commutator. Standard value: 29.4 mm (1.16 in.) Limited: 28.8 mm (1.13 in.)

1EN0302

(3) Check depth of the undercuts between the segments. Standard value: 0.5 mm (0.020 in.) Limited: 0.2 mm (0.008 in.)

Under cut Segment

Mica 1EN0296

2. Overrunning Clutch Check (1) While holing clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly. (2) Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is damaged, also inspect ring gear for wear or burrs.

Free

3. Front And Rear Bracket Bushing Check

Lock 1EN0293

G420 LP/Gasoline Engine

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket assembly.

Removal And Installation

4. Brush

Wear limit line

(1) Brushes that are worn beyond wear limit line, or oil soaked, should be replaced. (2) When replacing ground brush, side the brush from brush holder by prying retainer spring back.

1EN0292

5. Armature Coil Short Circuit Test (1) Place armature on a growler. (2) Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature.

6EN0600

6. Armature Coil Ground Test Check the insulation between ground commutator segment and the armature coil core. If there should be no continuity.

6EN0601

7. Armature Coil Open Circuit Check Check the continuity between segments. If there should be continuity.

1EN0299

G420 LP/Gasoline Engine

Removal And Installation

Reassembly Service Points A Stop ring

Stop ring/snap ring Installation

Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring.

Overrunning Stop ring clutch

Snap ring

G420 LP/Gasoline Engine

1EN0316

Removal And Installation

Distributor Disassembly and Reassembly

Disassembly steps 1. Distributor cap 2. Rotor 3. Cover 4. Signal rotor 5. Pickup coil assembly 6. Ignitor 7. Heat sink

G420 LP/Gasoline Engine

8. Breaker assembly 9. Snap ring 10. Vacuum control 11. Connector assembly 12. O-ring 13. Distributor housing

Removal And Installation

Inspection Pickup Coil (1) Using a tester, check the resistance of the pickup coil. Standard value: 420 to 540½

1EL0052

(2) Check to make sure the pointer of the tester oscillates when the tip of a screwdriver is moved past by the core of the pickup col assembly.

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Signal rotor

Reassembly Procedure A

Pickup coil assembly installation

Check the air gap between the signal rotor and pickup assembly. Standard value: 0.35 to 0.45 mm (0.0138 to 0.0177 in.)

Air gap

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1EL0054

Removal And Installation

System Operation Engine

The cylinder blocks are made of the special cast iron and employ 5-bearing, deep skirt system. The cylinder heads have hemisphere combustion chambers, are of cross flow type arranged with Vtype valves and high efficient combustion is intended.

G420 LP/Gasoline Engine

The camshaft is located on the top of the cylinder heads and driven by cog type timing belt. Dual type exhaust manifold is employed in order to reduce output loss by exhaust interference.

System Operation

G420 LP/Gasoline Engine

System Operation

Timing System

The timing belt is meshed with the sprockets, the crankshaft sprocket becomes the drive sprocket, and thus functions to drive the camshaft and oil pump.

Timing belt The timing belt is the cogged type, using rubber as its basic material, and it employs a high-strength glass fiber core which does not expand or contract. The features of the cogged-type belt compared to a chin are no expansion/contraction, low noise level, no necessity for lubrication, light weight, etc.

G420 LP/Gasoline Engine

System Operation

Silent Shaft Mechanism

The silent shaft mechanism function mainly to eliminate, by the action of the silent shafts incorporated at both sides of the cylinder block, the vertical vibromotive force of the engine as well as the vibromotive moment in the rolling direction, thus making possible quieter operation of the vehicle. The two silent shafts are arranged as shown in the

G420 LP/Gasoline Engine

figure below. The right silent shaft rotates in the same direction as the crankshaft, and the left silent shaft rotates in the opposites direction. Both of these silent shafts rotate at speed twice that of the crankshaft. Right silent shaft is driven by timing belt B, and the left silent shaft is driven by drive gear.

System Operation

Auto Lash Adjuster Construction

These engines have auto lash adjusters that eliminate the need for valve clearance adjustment and reduce noises of the valve system. The auto lash adjuster automatically absorbs change in the valve clearance caused by engine temperature change or wear of parts and adjusts the valve clearance always to zero. Operation of Auto Lash Adjuster (1) At Start of Valve Lift When the cam lifts up the rocker arm, the hydraulic pressure immediately forces the ball in the high pressure chamber against the seat, closing the high pressure chamber.

(2) During Valve Lift A small amount of oil leaks from the high pressure chamber through a clearance between the body inside and the plunger outside.

(3) At end of Valve Lift The plunger spring forces the body back to the initial position and oil is supplied to the high pressure chamber to make up for the leaked oil.

G420 LP/Gasoline Engine

System Operation

Lubrication System

Lubricating system is the full-flow filtered pressurefeed oil system and the oil reserved in the oil pan is fed with pressure to each part of engine. After the oil pressure is adjusted through the relief valve, the oil is fed to the cylinder blocks and cylinder head. In the cylinder head the oil is forcibly fed to the camshaft journals, rocker arm pivots and further cam surfaces.

G420 LP/Gasoline Engine

System Operation

Oil Filter

Fuel System Gasolin

G420 LP/Gasoline Engine

System Operation

Construction of Carburetor (1) Float. (2) Front chamber cover. (3) Primary inner venturi. (4) Choke valve. (5) Accelerator pump nozzle. (6) Idle compensator. (7) Membrane cover. (8) Enrichment jet. (9) Plug. (10) Throttle body. (11) Primary throttle valve. (12) Mixture adjusting screw. (13) Bypass screw. (14) Primary main jet. (15) Body. (16) Pump inlet ball. (17) Pump lever. (18) Fuel cutoff solenoid. (19) Pump outlet ball. (20) Primary pilot jet. (21) Valve weight. (22) Needle valve. (23) Fuel screen.

The carburetor is of the two-barrel, downdraft type which performs well in every engine operation ranging from slow idle to full speed.

G420 LP/Gasoline Engine

System Operation

1. Air system Air passed through the air cleaner flows through the choke bore and venturi into the clearance of the throttle valve and supports idle running of the engine. When engine speed increases to off-idle and more, intake air is metered by the venturi. Air flow to be fed to the cylinders is controlled by the throttle valve.

Float System

G420 LP/Gasoline Engine

2. Float system The float maintains a constant fuel level in the float chamber. Fuel from the fuel tank is pumped out by the fuel pump and filtered by the strainer. Then, fuel enters the float chamber through a needle valve. With entrance of fuel in the float chamber, the float moves up gradually. At last, the float pushes the needle valve to shut off the fuel inlet. When the fuel level lowers, the float moves down and releases the needle so that the fuel inlet is opened. With repetition of up-and-down movement of the float, fuel in the float chamber is kept at an almost constant level during engine operation.

System Operation

3. Idle system

This system provides adequate air-fuel-mixture richness for smooth engine running ranging from slow-idle to light-load operation. Fuel from the float chamber is sent through the main jet to the pilot jet where metering of fuel is made. On the other hand, air entering the venturi air leak and that entering the pilot air jet No.2 join at the pilot air jet No.1 where metering of air is made. As a result of metering, fuel mixes with air and flows through the air-fuel-mixture passage to the pilot outlet. The flow of air-fuel-mixture is adjusted properly by the bypass screw and enters the air horn through the bypass hole or the pilot outlet. It mixes with the small amount of air that gets past the closed or slightly opened throttle valve. The final mixture flows into the engine cylinders.

G420 LP/Gasoline Engine

The mixture adjusting screw is used for adjusting the richness of air-fuel-mixture necessary for good idling. The bypass screw is for the purpose of adjusting the flow of primary air-fuel-mixture to the bypass hole so as to provide sufficient mixture richness mainly for engine operation ranging from Òoff idlingÓ to a part of medium-load operation. The fuel cutoff solenoid in the idle system functions as follows : When the key switch is turned to ON, the solenoid attracts the needle valve to open the fuel feed line. When the key switch is turned to OFF, the needle valve protrudes to cut off the fuel feed line, thus preventing spontaneous running of the engine which is overheated.

System Operation

Idle Compensator

Main Metering System

The idle compensator uses a bimetal. When the carbretor ambient temperature rises during idle or Òoff idleÓ running, the bimetal bends enough to open the compensator valve. Now additional air from the choke bore can flow through the auxiliary air passage to the intake manifold directly. It leans out the mixture enough to make up for the proper richness.

Fuel metered by the main jet is bled by air from the main air jet and enters the bleed pipe through its holes. The fuel is discharged from the main nozzle and sucked by engine cylinders. If percolation of fuel arises along the main well, gasoline vapor can escape from the main air jet through the relatively wide outside of the bleed pipe. This prevents liquid fuel from spurting from the main nozzle, thus assuring stable engine operation and easy restarting. To prevent percolation due to conduction of heat from the engine, sufficient cooling of the float chamber periphery is taken into consideration in design of the carburetor.

4. Main metering system The wider the throttle valve opens, the faster the air flow in the venturi and the greater the vacuum in the inner venturi will be. As the vacuum becomes greater, additional fuel is discharged from the main nozzle. The main metering system is provided with the bleed valve press-fitted to the inner venturi and the main air jet.

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100

System Operation

5. Enrichment system

Enrichment and Accelerator-Pump systems

The enrichment system provides additional fuel feed to the main metering system during highspeed large-torque operation. This system use the membrane (diaphragm) which is actuated by the intake manifold vacuum and membrane spring to open or close the fuel feed line. During partial-throttle operation, a large manifold vacuum is applied to the vacuum chamber through the vacuum line and acts on the membrane to close the valve against the membrane spring force. When the throttle is opened wide, manifold vacuum decreases. This allows the membrane spring to open the valve. Now, more fuel from the float chamber is metered by the enrichment jet and can flow through the valve into the primary main line leading to the main metering system.

When the engine is accelerated quickly, the membrane is pushed by the pump lever linked to the throttle valve and forces fuel to flow under pressure. When the engine is decelerated, the membrane is pushed back by the spring and the pump chamber is refilled with fuel. Pump delivery decreases with engine speed from which acceleration is starred. It does not deliver fuel at all when the angle of throttle valve from the idling position exceeds the preset angle. 7. Stating system The starting system consists of the choke valve, lever assembly, choke connecting rod, and choke operating lever. This system is provided for feeding a very rich air-fuel mixture to the engine when the engine is started (until the engine warms up) or when a temporary increase of output is needed during engine operation. When the engine is cold, some throttle opening must be maintained so that the engine idles faster then it would when warm. This is done with Òfast idle.Ó With the fast idle, the choke valve is closed while the throttle valve is held at a partially opened position most suitable to warming-up run.

6. Accelerator-pump system Rapid opening of the throttle for acceleration allows a sudden inrush of air. Thus there is a sudden demand for additional fuel. To provide this extra fuel, the accelerator-pump system can feed fuel immediately under pressure. Fuel from the inlet check valve is sent to the pump nozzle through the outlet check valve by reciprocating movement of the membrane. The fuel is then injected into the main bore.

G420 LP/Gasoline Engine

101

System Operation

LPG

G420 LP/Gasoline Engine

102

System Operation

Carburetor (1) Cover. (2) Air-gas valve assÕy. (3) Valve spring. (4) Gas-metering valve. (5) Air passage. (6) Diaphragm. (7) Idle screw. (8) Gas regulating valve. (9) Throttle valve. (10) Air governor valve.

The carburetor for LPG engines is a combination of the carburetor upper body and adapter. Like the carburetor on gasoline engines, this carburetor is mounted on the throttle body on the air governor. The carburetor consists of a converter (vaporizer) and a mixer (carburetor). The converter which serves only to vaporize liquefied petroleum does not require external adjustment.

3. Gas metering valve 4, provided in the air-gas valve, varies its opening with movement of air-gas valve diaphragm so that adequate gas flow passes through it and mixes with air.

1. When the cylinder piston is in down stoke, vacuum created over the top of piston connects through air passage 5 in air-gas valve 2 to the cavity over diaphragm 6. Accordingly, atmospheric pressure pushes the diaphragm up against the force of spring 3.

5. Gas regulating valve 8 serves to keep the air-gas ratio suited to the maximum engine output when the engine runs under load. This valve is effective only in nearly full-load condition of the engine.

4. Idle screw 7 serves to meter the air-gas mixture necessary for maintaining slow-idle run of the engine.

2. Degree of vacuum pressure which is imposed on the diaphragm depends upon speed of the engine and degree of opening of throttle valve 9 . The airgas valve acts exactly, in response to variations in speed of the engine and in opening of the throttle valve, so that adequate air flow to the engine can be obtained.

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103

System Operation

Air Governor

Sectional View of Air Governor (1) Body. (2) Stabilizer rod. (3) Stabilizer piston. (4) Throttle plate. (5) Throttle plate shaft. (6) Bearing. (7) Nipple. (8) Spring. (9) Bush nut. (10) Adjusting screw. (11) Plate. (12) Cam

The air governor is located to the underside of the carburetor. It serves to protect the hydraulic pump, to limit the maximum traveling speed of the vehicle, and to prevent excessive increase of engine speed.

2. Auxiliary operation The throttle plate opening angle of this governor is set under the full-open condition of the carburetor. Accordingly, when the carburetor throttle valve is operated in the direction of closing, governor pressure applied to the throttle plate decreases and, therefore, the throttle plate is rotated by the spring in the direction of opening. As a result, engine speed increases. To prevent this, the governor is provided with a stabilizer piston.

1. Governing operation The throttle plate shaft is offset from the center of the governor bore. Also, the full-open position of the throttle plate does not coincide with the truly full-open position, but rather leans to the closing side. Therefore, the pressure of mixture flow acts on the throttle plate to rotate it in direction of closing, causing a torque to its shaft.

The stabilizer piston acts to close the throttle plate when a large vacuum pressure is developed on the upper side of the throttle plate, so that proper opening of the throttle plate can be maintained in combination with the opening of the carburetor throttle valve. With the help of this auxiliary operation, the governing operation can follow up the variations of load quickly.

The torque stretches the return spring attached to the cam on the throttle plate shaft until the torque balances the tension of the spring, and the throttle plate is maintained at that open angle. This is governing operation. That is, a balance between the pressure applied to the throttle plate, which depends on vacuum pressure, and the spring tension keeps the throttle plate at position between the full-open position and the full-close position to control the amount of mixture flowing into the engine. G420 LP/Gasoline Engine

104

System Operation

Cooling System

The cooling system is of the cooling water forcedcirculation type. The water pump, at the center in front of the cylinder block, is driven by the V-belt together with the alternator by the crankshaft pulley. The thermostat which controls coolant temperature is contained in the thermostat housing which is positioned in the inlet manifold.

Thermostat The thermostat is the wax pellet type. A jiggle valve (which improves air bleeding during water supply) is provided on the flange part. When the thermostat is closed, the circulation of coolant is stopped, thereby making warm-up faster.

Operation When the temperature of the coolant is low, the valve is closed by the spring, with the result that the coolant circulates within the engine, without passing through the radiator. When the temperature of the coolant rises and reaches a certain specified temperature, the valve opens and the coolant also circulates through the radiator. When the temperature increases further and reaches a certain specified temperature, the valve opens fully, allowing even more coolant to circulate through the radiator. Thus, in this way the degree of valve opening is varied according to the temperature of the coolant, and the temperature of the coolant is adjusted by varying the amount of coolant caused to circulate through the radiator.

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105

System Operation

Intake and Exhaust System

The intake manifold employs the shape having good intake performance. The exhaust manifold employs a dual type and intend the reduction of output loss due to exhaust interference.

G420 LP/Gasoline Engine

106

System Operation

Electrical System Wiring Diagram

Stating motor is of the gear reduction type. Distributor is of a breakerless type and employs the ignition advancer which uses jointly centrifugal type and vacuum type.

G420 LP/Gasoline Engine

107

System Operation

Starter Motor Planetary Gear Reduction Drive Type

The starter motor is small in size light weight and high-output type. Rotation of the motor are reduced by the reduction gear, and high torque is transmitted to the pinion gear.

Operation 1. When the ignition key (IG-SW) is turned to the ÒSTÓ position, current flows from the S terminal of the magnetic switch to the pull-in coil and the holding coil. Current from the pull-in coil passes through the M terminal, flows to the starterÕs brush, commutator, and armature, and then the armature begins to gently turn.

G420 LP/Gasoline Engine

108

System Operation

2. The plunger of the magnetic switch is then attracted, and the pinion is pushed out by the shift lever, meshing with the ring gear. As a result of the movement of the plunger, the contacts of the magnetic switch close, and, as a result, the starter is turned by the high current from the battery directly to the B terminal, and the engine is activated. When the contacts closes, the current flowing to the pullin coil stops flowing, and the magnetic force decreases. At this time, what prevents the pinion from being returned by the return spring is the magnetic force of the holding coil. When the engine starts and the pinion is caused to rotate by the ring gear, there is a possibility of damage, and for that reason an over-running clutch is provided so that the rotation from the engine is not transmitted.

3. Because the contacts are still closed at the moment when the ignition key is turned to OFF, current from the battery flows in the reverse direction from the M terminal and through the pull-in coil, thus offsetting the magnetic force of the holding coil, with the result that the pinion is returned by the return spring, and the contacts are opened.

Construction of planetary gear type reduction drive This reduction drive consists of a gear on the front end of the armature shaft, three pinion gears, a gear shaft that supports three pinion gears and work as the output shaft and the internal gear that is fixed to the starter motor body. The unit is called the simple planetary gear set.

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109

System Operation

When the internal gear is fixed as in the case of the starter motor, the carrier rotates in the same direction as the sun gear. This may be used to determine the reduction ratio easily. . Namely, the carrier reduction ratio = (43 + 11) / 11 =. 4.9

Permanent magnet pole Conventionally, the field coil wound around the pole is energized to generate magnetic fluxes. This system uses a permanent magnet (ferrite magnet) for the pole, eliminating the field coil and reducing the size and weight. The auxiliary pole helps generation of magnetic fluxes to ensure stable rotation and output characteristics.

Distributor

The distributor is the contactless type and is equipped with a centrifugal advancer and vacuum advancer. The distributor is installed at the front side surface of the cylinder head, and is driven directly by the camshaft. G420 LP/Gasoline Engine

110

System Operation

Governor advance mechanism

In the figure below, pin A rotates together with the shaft. A governor weight is installed to this pin A. There is a pin B on the governor weight which fits into the oblong hole in the cam base. The governor spring is attached to the spring hook of the governor weight, pulling the governor weight to the fully closed position. When the rotation speed increases, the governor weight is subjected to centrifugal force which causes it to open outward. When the centrifugal force becomes stronger than the tensile force of the spring, the weight opens, as shown by (b) in the figure below, thus maintaining a balance with the force of

the spring. Because pin B of the weight is fit into the oblong hole In the cam base, the movement of pin B becomes rotation of the cam in the direction of rotation. In other words, the cam advances in relation to the shaft. When the rotation speed becomes sufficiently high, pin B contacts the outer side of the oblong hole in the cam base, and the weight opens no further. This position is the fully advanced condition. When the rotation speed decreases, the centrifugal force of the weight becomes weaker and the weight is closed by the force of the spring, thus returning to the original condition.

The advance characteristic of the centrifugal-advance device employed by the governor is as shown in the figure at the left. Point A is the beginning of advance, and point B shows the rotation speed at full advance.

G420 LP/Gasoline Engine

111

System Operation

Vacuum advance mechanism

There is a diaphragm within the vacuum controller, with a spring at the negative-pressure (vacuum) side which pressure against the diaphragm. A link is attached to the diaphragm and is connected to the pickup plate. The pickup assy is installed on the pickup plate, and can rotate together with the pickup plate. The negative pressure (vacuum) side of the vacuum controller is connected to the vacuum port of the carburetor by a tube. When the throttle valve of the carburetor is closed, the engine is in the idling condition, and there is no vacuum inside the tube at this time. When the throttle valve is partially open, the air within the tube

is drawn out by the air/fuel mixture flowing near the vacuum port, thus resulting in a negative-pressure (vacuum) condition. Because the tube is connected to the negative-pressure (vacuum) port of the vacuum controller, the diaphragm pressure against the spring, and it moves in the direction of the arrow. Then the link rotates the pickup plate and, because the position of the pickup changes, the timing also changes. The direction is the direction opposite to the direction of signal rotor rotation, so that the projection of signal rotor will pass the pickup quickly. In this way, then, the ignition timing advances.

The figure at the left shows the advance characteristic curve of the vacuum-advance mechanism. Point A is the start of the advance, and point B is the end of the advance. Because the magnitude of the degree of advance determined by balance of the strength of the vacuum and the pressure of the spring, if the spring is weak the degree of advance will be great at a small vacuum.

G420 LP/Gasoline Engine

112

System Operation

Adjusting And Troubleshooting Engine Adjustment Adjustment The following is the method of adjustment of the carburetor and pneumatic governor on a reassembled engine. Caution: (1) The pneumatic governor has been properly adjusted and sealed in the factory before shipping. Never break the seal unless it is necessary during engine overhaul. (2) If the pneumatic governor is readjusted, seal it again and advise your user that he should not break the seal. 1. Valve Clearance Adjustment Being adjusted automatically with a lash adjuster, the valve clearance needs no adjustment.

2. Ignition Timing Adjustment (1) Let the engine warm up until engine coolant temperature rises to 80~95ûC. (2) Set engine speed at 740 rpm. (3) Remove the vacuum hose(from throttle body to distributor) at throttle body side and plug open end of nipple with something like rubber cab. 6EN0870

(4) Check that the ignition timing is as indicated when the engine is running at idling speed. Standard value: Gasoline 4 BTDC/740rpm LPG 9 BTDC/740rpm (5) If the ignition timing does not conform to the standard value, adjust by moving the distributor. (6) Remove rubber cap and connect the vacuum hose as it was. (7) Reconfirm engine speed. 3. Idling Speed Adjustment

SAS

MAS

G420 LP/Gasoline Engine

6EN0834

(1) Let engine warm up until the engine coolant temperature rises to 80 to 95¡C (176 to 203¡F). (2) Back off the mixture adjusting screw (MAS) 3.5 L 0.5 turns (3) Adjust the engine speed to the specified low idling speed with the speed adjusting screw(SAS). (4) Slowly turn down the mixture adjusting screw(MAS) to a point where the engine speed begins to decrease. Standard value: OPS/700 L 25 rpm (5) After racing the engine two or three times (at approx. 2500 rpm), re-adjust the speed adjusting screw to the point at which the engine rust at the specified idling speed.

113

Adjusting And Troubleshooting

4. Air Governor Adjustment High speed adjustment

Screw

Adjusting nut 6EN0835

5. Anti-Hunting Adjustment

Governor Characteristics

Out put (PS)

Larger spring rigidity Smaller spring rigidity

Engine Speed (rpm)

G420 LP/Gasoline Engine

(1) Place all the hydraulic levers in the neutral position. (2) Depress the accelerator pedal all the way. (The carburetor throttle valve will open fully.) (3) While holding the adjust screw to prevent it from turning, rotate the adjusting nut either clockwise or counterclockwise to make the engine run at 2700 L 50 rpm. Adjusting nut: Clockwise rotation Increases the engine speed (increases the installed load of spring). Counterclockwise rotation Decreases the engine speed (decreases the engine installed load of spring).

6EN0836

(1) Place all the hydraulic levers or power train in the neutral position. (2) Depress the accelerator pedal all the way. (The carburetor throttle valve will open fully.) (3) Slowly rotate the adjusting screw clockwise until hunting disappears. Adjusting screw: Clockwise rotation Increases spring tension (reduces the number of active turns of spring). Counterclockwise rotation Reduces spring tension (increases the number of active turns of spring). Increasing the spring tension will eliminate hunting, but an excessively high tension will change the governor characteristics and produce some effects on the output characteristics of the engine. It is, therefore, imperative to limit the movement of the adjusting screw to less than two turns from the standard position. (4) Clockwise rotation of the adjusting screw raises the engine maximum speed. Rotate the push nut counterclockwise to reduce the speed. (5) Repeat anti-hunting adjustment two or three times by alternately adjusting the push nut and the adjusting screw until the best result is obtained. (6) The number of active turns of spring should not be less than 11 when the adjustment is finished.

114

Adjusting And Troubleshooting

Troubleshooting Abnormal combustion

Loose connection in ignition system wiring

ÐCheck connections and retighten.

Defective spark plug

ÐReplace spark plug.

Incorrect ignition timing

ÐAdjust ignition timing.

Defective carburetor

ÐRepair or replace carburetor.

Contaminated or clogged fuel filter element and pipe

ÐClean fuel filter element and pipe.

Entry of air from carburetor or intake manifold

ÐRetighten set bolts or replace heat insulator and/or intake manifold gasket.

Valves and related components

Defective valves and related components

ÐAdjust or repair valves and related components.

Cylinder head

Carbon deposited in combustion chamber

ÐDisassemble and clean.

Clogged cylinder head water tube

ÐClean or replace water tube.

Cylinder gasket blow-by

ÐReplace gasket.

Ignition system out of adjustment

Incorrect ignition timing

ÐAdjust ignition timing.

Defective spark plug

ÐReplace spark plug.

Insufficient fuel

Defective carburetor

ÐRepair or replace carburetor.z

Damaged cylinder head gasket, etc.

ÐReplace gasket.

Clogged fuel pipe

ÐClean pipe.

Clogged fuel filter

ÐClean or replace.

Air in fuel system

ÐCheck connections and retighten.

Damaged fuel pipe

ÐReplace pipe.

Fuel pump not functioning properly

ÐRepair or replace.

Ignition system

Carburetion related components

Insufficient output

Insufficient intake air in carburetor

Overheating

G420 LP/Gasoline Engine

Damaged diaphragm

ÐReplace.

Defective valve

ÐReplace.

Clogged air cleaner element

ÐClean or replace element.

Carburetor choke always in operation

ÐRepair or replace carburetor.

Air governor malfunction

ÐRepair or replace air governor.

Insufficient coolant

ÐAdd coolant and check for leaky points.

Leaks from radiator

ÐRepair or replace radiator.

Loosened or damaged radiator hose connection

ÐRetighten clamp or replace hose.

Leaks from water pump

ÐReplace.

Coolant leaks from cylinder head gasket

ÐRetighten cylinder head bolts or replace gasket.

Cracks in cylinder head or block

ÐReplace.

115

Adjusting And Troubleshooting

Insufficient output

Poor acceleration

Excessive fuel consumption

Excessive engine oil consumption

Loose fan belt tension

ÐAdjust or replace.

Worm or damaged fan belt

ÐReplace.

Oil on fan belt

ÐClean.

Thermostat not functioning properly

ÐReplace.

Water pump not functioning properly

ÐReplace.

Clogged radiator

ÐClean radiator and coolant passages.

Incorrect ignition timing

ÐAdjust ignition timing.

Improper engine oil

ÐRefer to lubrication table and replace oil with a recommended one.

Too lean mixture

ÐRepair or replace carburetor.

Incorrect valve clearance adjustment

ÐMake measurements on or replace autolash adjuster.

Insufficient compression pressure

Engine out of order

ÐRefer to p. 92 and make repairs.

Overcooling (Coolant temperature does not rise.)

Defective thermostat

ÐReplace thermostat.

Extremely low atmospheric temperature

ÐPlace cover or anything proper on the front of radiator.

Engine

Engine out of order

ÐRefer to p. 92 and make repairs.

Carburetor

Carburetor out of order

ÐReplace or replace distributor.

Ignition system

Defective distributor

ÐRepair or replace distributor.

Defective spark plug

ÐReplace spark plug.

Engine

Engine out of order

ÐAdjust of repair valves.

Carburetor

Defective carburetor

ÐRepair or replace carburetor.

Clogged air bleeder

ÐClean or replace.

Damaged gaskets

ÐReplace.

Improper idling speed

ÐAdjust idling speed.

Ignition system

Incorrect ignition timing

ÐAdjust ignition timing.

Excessive engine oil consumption

Engine out of order

ÐRefer to p. 92 and make repairs.

Oil leaks

Engine out of order

ÐRefer to p. 92 and make repairs.

Overheating

G420 LP/Gasoline Engine

116

Adjusting And Troubleshooting

Engine, Carburetor and Electrical Components Troubleshooting Engine

Valves and related components

Poor idling

Abnormal combustion

Insufficient output Excessive fuel consumption

Engine

Poor startability

Poor acceleration

Excessive fuel consumption

Insufficient output

Incorrect valve clearance

ÐCleaned or replace auto-lash adjuster.

Valve not in close contact with valve seat

ÐReface seat surface.

Excessive clearance between valve stem and valve guide

ÐReplace valve and valve guide.

Incorrect valve clearance

ÐCleaned or replace auto-lash adjuster.

Valve binding

ÐDisassemble, correct or replace.

Deteriorated valve spring

ÐReplace spring.

Incorrect valve clearance

ÐCleaned or replace auto-lash adjuster.

Pressure leaks from valve seal

ÐReface.

Valve stem seizure

ÐRepair or replace.

Deteriorated or broken valve spring

ÐReplace spring.

Valve damaged by heat

ÐReface or replace valve.

Intake manifold gasket not tight enough

ÐRetighten set bolts or replace gasket.

Cylinder head gasket blow-by

ÐReplace gasket.

Valve damaged by heat or not properly serviced

ÐAdjust or replace.

Insufficient compression pressure

ÐDisassemble and repair engine.

Cylinder head gasket blow-by

ÐReplace gasket.

Pressure leaks from cylinder head gasket Piston ring binding or worn

ÐRetighten cylinder head bolts and replace gasket. ÐReplace ring.

Piston ring or ring worn

ÐDisassemble and repair engine.

Oil leaks Excessive oil consumption

G420 LP/Gasoline Engine

Loose oil drain plug

ÐRetighten plug.

Loose oil pan set bolts

ÐRetighten set bolts.

Damaged oil pan gasket

ÐReplace gasket.

Loose timing gear cover or damaged gasket

ÐRetighten set bolts or replace gasket.

Defective crankshaft front oil seal

ÐReplace oil seal.

Defective crankshaft rear oil seal

ÐReplace oil seal.

Damaged cylinder head gasket

ÐReplace gasket.

Loose oil filter set bolt.

ÐRetighten set bolts or replace oil filter gasket.

117

Adjusting And Troubleshooting

Oil working its way up Engine

Excessive oil consumption

Piston ring gaps in improper positions

ÐAdjust ring gap positions.

Piston rings or ring grooves worn or rings

ÐReplace piston or rings.

seized in grooves Carbon deposit in oil return hole of oil ring

ÐReplace rings.

Worn piston and cylinder

ÐRebore and hone cylinder and install oversize piston.

Excessive quantity of oil in oil pan

ÐOil quantity: 4.0 liter (1.1 U.S. gal).

Oil working its way down

Excessive engine noise

G420 LP/Gasoline Engine

Worn valve stem and valve guide

ÐReplace valve and guide.

Defective valve stem oil seal

ÐReplace oil seal

Excessive oil clearance due to worn crankshaft bearing

ÐReplace bearing.

Fusion in crankshaft bearing

ÐReplace bearing and check lubrication system.

Worn connecting rod bearing

ÐReplace bearing.

Bent connecting rod

ÐRepair bent connecting rod or replace.

Fusion in connecting rod bearing

ÐReplace bearing and check lubrication system.

Excessive clearance due to worn cylinder

ÐRebore and hone cylinder and install oversize piston.

Worn piston or piston pin

ÐReplace piston and piston pin.

Piston seizure

ÐReplace piston.

Broken piston ring

ÐReplace piston ring.

Excessive camshaft end play

ÐReplace camshaft thrust plate.

Worn crankshaft thrust bearing

ÐReplace bearing.

Worn timing gears

ÐReplace.

Excessive valve clearance

ÐCleaned or replace auto-lash adjuster.

118

Adjusting And Troubleshooting

Poor engine startability

Poor idle

Carburetor

Abnormal combustion

Poor acceleration

Insufficient output

Excessive fuel consumption

G420 LP/Gasoline Engine

Needle valve and valve seat not seating properly

ÐClean or replace

Incorrect float level

ÐAdjust

Worn float lip

ÐReplace

Worn float level pin and related components

ÐReplace level pin and its related parts

Malfunction choke valve

ÐRepair

Idle rpm set out of adjustment

ÐAdjust idling speed

Damaged idle adjust screw

ÐReplace adjust screw

Clogged idle passage or idle port

ÐClean

Clogged bypass screw

ÐClean jet

Worn throttle shaft

ÐReplace shaft

Loose vacuum pipe union

ÐRetighten union

Idling circuit not airtight

ÐClean

Incorrect float level

ÐReplace

Too lean mixture

ÐClean or replace

Inner dirty carburetor

ÐClean carburetor

Defective float level

ÐAdjust float

Defective accelerating pump plunger

ÐDisassemble or replace

Clogged pump jet

ÐClean or replace

Defective accelerating linkage

ÐReplace linkage

Malfunction power piston

ÐReplace power piston

Malfunction power valve

ÐReplace

Clogged power jet

ÐClean or replace

Float level too low

ÐAdjust float

Throttle valve not opening completely

ÐAdjust valve

Clogged main jet

ÐClean

Incorrect float level

ÐAdjust float

Malfunction power piston

ÐReplace power piston

Malfunction power valve

ÐReplace power valve

Worn throttle shaft

ÐReplace shaft

Throttle valve not opening completely

ÐAdjust valve

Choke valve stuck close

ÐRepair or replace

Float level too high

ÐAdjust float

Defective power valve

ÐReplace valve

Choke valve not opening completely

ÐCheck linkage, replace

Improper idling speed

ÐAdjust idling speed

119

Adjusting And Troubleshooting

Electrical components Distributor

Poor engine starting

Cracked distributor cap and burnt or contaminated cord insertion hole

ÐClean or replace.

Poor engine acceleration

Centrifugal and vacuum advance device malfunction

ÐRepair or replace.

Improper spark plug gap

ÐAdjust or replace.

Carbon deposit in spark plug

ÐClean or replace.

Improper heat range of spark plug

ÐReplace spark plug with proper one.

Loose or defective plug cord

ÐRepair or replace.

Defective ignition coil

ÐReplace ignition coil.

Improperly connected terminals

ÐRepair.

Switch contacts in loose contact

ÐReplace switch

Magnet switch contact plate burnt or in loose contact

ÐGrind or replace contact plate.

Magnet switch pull-in coil opencircuited

ÐReplace.

Magnet switch holding coil opencircuited

ÐReplace.

Brush in loose contact with commutator as a result of wear

ÐReface.

Commutator burnt with consequent poor conduction of electricity

ÐExchange or replace commutators.

High mica of commutator

ÐPerform under-cutting

Field coil not properly grounded or short-circuited

ÐReplace.

Field coil not properly soldered

ÐRepair.

Armature not properly grounded

ÐReplace.

Armature short-circuited

ÐRewind or replace.

Brush spring broken or with inadequate tension

ÐReplace spring.

Insufficient engine output

Excessive fuel consumption

Spark plug

Poor engine starting

Abnormal combustion in engine

Poor engine acceleration

Insufficient engine output Ignition coil

Poor engine staring

Poor engine acceleration

Starter

Starter does not rotate

G420 LP/Gasoline Engine

120

Adjusting And Troubleshooting

Starter

Starter does not rotate.

Starter rotates but slowly and irregularly.

Pinion does not engage with ring gear.

Motor continues to rotate and does not stop.

G420 LP/Gasoline Engine

Brush holder not properly insulated

ÐClean brush or replace holder.

Worn bearing bushing

ÐReplace bushing.

Wires of armature coil about to be shortcircuited or grounded

ÐRewind or replace.

Field coil not properly connected or about to be short-circuited

ÐRepair connections.

Commutator heat-damaged with consequent poor conduction

ÐReplace armature.

Brush movement due to damaged or worn commutator

ÐRepair or replace.

Commutator vibrating, causing brush to move

ÐRepair or replace.

Lifted mica between commutator segments causing brush to move

ÐPerform under-cutting

One or two commutator segments lifted causing brush to move

ÐRepair or replace.

Commutator in loose contact due to worn brush

ÐRepair or replace.

Chipped brush

ÐRepair or replace.

Worn starter clutch pinion end

ÐReplace.

Clutch rotates always freely

ÐReplace.

Deteriorated clutch drive spring

ÐReplace.

Does not rotate in overrunning direction

ÐReplace.

Poor sliding of splined section

ÐRub surfaces smooth, clean and repair.

Worn bushing

ÐReplace.

Improper projecting position of magnet switch pinion

ÐAdjust with stud bolt.

Worn bearing bushing

ÐReplace.

Magnet switch coil layer shorted-circuited

ÐReplace.

Magnet switch contact plate seizure

ÐReplace.

Starter switch does not return properly

ÐReplace switch.

121

Adjusting And Troubleshooting

Battery

Run-down battery

Drive belt slipping

ÐAdjust belt.

Alternator Stator coil grounded or open-circuited

ÐReplace or repair.

Rotor coil open-circuited

ÐReplace.

Brush and slip ring not properly connected (Brush does not properly come down)

ÐReplace brush if worn. (Clean holder.) ÐPolish slip ring.

Diode short-or open-circuited

ÐReplace rectifier assembly.

Battery Short or improper electrolyte

ÐAdd electrolyte and adjust specific gravity.

Defective plates (internal short circuit)

ÐReplace.

Terminals in loose contact

ÐClean and then retighten.

Wiring

Overcharged battery

G420 LP/Gasoline Engine

Open circuit or loose contact between key switch and alternator terminals L and R

ÐRepair.

Burnt fuse of above-mentioned circuits or holder in loose contact

ÐReplace fuse and repair contacting section of holder.

Open circuit or loose contact between battery and alternator terminal B

ÐReplace.

Burnt fuse of above-mentioned circuits or holder in loose contact

ÐReplace fuse and repair contacting section of holder.

Defective IC regulator

ÐReplace.

122

Adjusting And Troubleshooting

SPECIAL TOOLS Style

G420 LP/Gasoline Engine

Tool No.

Tool name

Use

MD998781

Flywheel stopper

Holding flywheel

MD998785

Sprocket stopper

Holding counterbalance shaft sprocket

MD998778

Crankshaft spocket puller

Removal of crankshaft sprocket

MB990767

End yoke holder

Holding camshaft sprocket (Use with MD998719)

MD998719

Pulley holding pins

Holding camshaft sprocket when loosening or torquing bolt (Use with MB990767)

MD998443

Lash adjuster holder

Retainer for holding lash adjuster in rocker arm at timer of removal and installation of rocker arm and rocker shaft assembly

MD998442

Air bleed wire

Air bleeding of lash adjuster

MD998713

Camshaft oil seal installer Installation of oil seal

MB991654

Cylinder head bolt wrench(12)

123

Removal and installation of cylinder head bolt

Special Tools

Style

G420 LP/Gasoline Engine

Tool No.

Tool name

MD998772

Valve spring compressor

Compression of valve spring

MD998729

Valve stem seal installer

Installation of valve stem seal

MD998727

Oil pan remover

Removal of the oil pan

MD998162

Plug wrench

Removal and installation of front case cap plug

MD998783

Plug wrench retainer

Removal and installation of front case cap plug (Use with MD998162)

MD998375

Crankshaft front oil seal installer

Installation of crankshaft front oil seal

MD998285

Crankshaft front oil seal guide

Guide for installation of crankshaft front oil seal

MD998705

Silent shaft bearing installer

Installation of counterblance shaft front and rear bearing

MD998371

Silent shaft bearing puller

Removal of counterblance shaft front bearing

124

Use

Special Tools

Style

G420 LP/Gasoline Engine

Tool No.

Tool name

MD998372

Silent shaft bearing puller

Removal of counterbalance shaft rear bearing

MD998780

Piston pin setting tool

Removal and installation of piston pin

MD998776

Crankshaft rear oil seal installer

Installation of crankshaft rear oil seal

MB990938

Handle

Installation of crankshaft rear oil sear (Use with MD998776)

125

Use

Special Tools

SB2012E02 Oct. 2000

Service Manual Diesel Engine DC24 (2.4 Liter)

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. Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and understood the operation, Iubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal

Adjustment

Installation

Cleaning

Disassembly

Pay close attention-Important

Reassembly

Tighten to specified torque

Align the marks

Use special tools

Directional Indication

Lubricate with oil

Inspection

Lubricate with grease

Measurement

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops.

Vehicle Systems

-1-

Specifications

Index 1. General Informations ...........................................................................................................................................5 1.1. General Repair Instructions 1.2. Engine Model and Serial Number 1.3. Engine Specifications 1.4. Engine Assembly

2. Preventive Maintemance ...................................................................................................................................11 2.1. Preventive Maintenance 2.2. Torque Specifications

3. Major Maintenance.............................................................................................................................................16 3.1. Major Parts Fixing Bolts 3.3. Repair

3.2. Engine Repair Kit

4. Engine Disassembly and Reassembly ............................................................................................................26 4.1. External Parts 4.3. Inspection and Repair

4.2. Internal Parts 4.4. Reassembly

5. Lubricating System............................................................................................................................................59 5.1. General description 5.3. Oil Filter

5.2. OIl Pump 5.4. Oil Cooler

6. Cooling System ..................................................................................................................................................64 6.1. General Description 6.3. Thermostat

6.2. Water Pump

7. Fuel System ........................................................................................................................................................68 7.1. General Description 7.3. Injection Pump Calibration

7.2. Injection Nozzle

8. Intake and Exhaust System ..............................................................................................................................74 8.1. Intake Manifold

8.2. Exhaust Manifold

9. Special Tool List.................................................................................................................................................75

Appendix - Engine Assembly (ELFFO)

DC24 (2.4 Liter)

-3-

General Informations

1. General Informations 1.1. General Repair Instructions 1. For safty, park the truck on even ground or work station and fix the wheels using wedges or hand brake during operation 2. Before performing service operation, disconnect the grounding cable form the battery for reduce the chance of cable damage and burning due to short-circuliting. 3. Before performing service operation release the air pressure in the machine air line machine air line system for safty. To not do so in extremely dangerous. 4. Use covers for prevention the components from damage or pollution. 5. Brake oil and anti-freeze solution must be handled with reasonable to efficient and reliable service operation. 6. The use of proper tools and special tools where specificed is important to efficient and reliable service operation. 7. Use genuine DAEWOO parts necessarily. 8. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused. 9. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separate is very improtant as they vary in hardness and design depending on position of installation. 10. Clean the parts before inspection or reassembly. Also clean oil ports, etc. usig compressed air to make certain they are free form restrictions. 11. Lubricate rotation and sliding faces of parts with oil or grease before installation. 12. When necessary, use a sealer on gaskets to prevent leakage. 13. Carefully observe all specifications for bolts and nuts torques. 14. When service operation is completed, make a final check to be sure service has been done propery.

1.2. Engine Model and Serial Number The engine model and serial number is located on the engine as illustrated. These numbers are required when requesting warranty and ordering parts. They are also referred to as engine model and serial number because of their location.

Serial number

Engine serial No. (example 1 : DC24) DC24 O 00001 FO Suffix (ELFFO) Serial No. Production Year(2000) Engine Model

DC24 (2.4 Liter)

-5-

General Informations

1.3. Engine Specifications 1.3.1. Specification Engine Model

DC24

Items

ELFFO / N / L / E

Engine type

ELFFA / D / I / J

4 cycle in-line, Water-cooled type Naturally aspirated

Combustion chamber type

Swirl chamber

Cylinder liner type

Replaceable dry liner

Timing gear system

Gear driven type

No. of piston ring

Compression ring 2, oil ring 1

No. of cylinder-bore x stroke

(mm)

4 - 86 x 102

Total piston displacement

(cc)

2,369

Compression ratio

20 : 1

Engine dimension (length x width x height)

(mm)

702 x 559 x 677

Engine weight

(kg)

245

Rotating direction (viewed from flywheel)

Counter clockwise

Fuel injection order

1-3-4-2

Fuel injection timing (B.T.D.C static)

13û

Injection pump type Governor type Injection nozzle type

VE type

Zexel in-line ÒAÓ type

Mechanical governor

Mechanical governor type(RSV)

Throttle type

Fuel injection pressure

(kg/cm2)

120

Compression pressure

(kg/cm2)

28 (at 200 rpm)

Intake and exhaust valve clearance (at cold) Intake valve Exhaust valve

(mm)

0.45

Open at

11û (B.T.D.C)

Close at

40û (A.B.D.C)

Open at

51û (B.B.D.C)

Close at

9û (A.T.D.C)

Lubrication method

Full forced pressure feed type

Oil pump type

Rotor type driven by camshaft

Oil filter type

Full-flow, cartridge type

Lubricating oil capacity (oil pan)

(lit)

6.5

Oil cooler type

Water cooled

Water pump

Centrifugal type driven by belt

Cooling Method

Fresh water forced circulation

Cooling water capacity (engine only)

(lit)

5.2

Thermostat type

Wax pallet type (76.5 ~ 90 Cû)

Alternator voltage - capacity

(V - A)

12 - 50

Starting Motor voltage - output

(V - kW)

12 - 2.2

DC24 (2.4 Liter)

-6-

General Informations

1.3.2. Engine Power Production tolerance : ±5% Engine Model

Performance

Model

Suffix

Power (PS/rpm)

Torque (kg.m/rpm)

Low idle (rpm)

High idle (rpm)

DC24

Base

56/3,000

15/2,000

ELFFA

44/2,300

14.5/2,000

850-900

2,600-2,650

ELFFD

49~53/2,900

12.7~14.2/2,200

600-750

3,170-3,250

ELFFE

44~48/2,400

14.5/2,000

775-825

2,600-2,700

ELFFI

44/2,300

14.5/2,000

850-950

2,600-2,650

ELFFJ

49/2,650

14.5/2,000

600-700

2,920 L 50

ELFFL

46.2/2,400

14.5/2,000

775-825

2,650-2,700

ELFFN

45/2,400

14.5/2,000

775-825

2,650-2,700

ELFFO

44/2,250

14.5/1,800

775-825

2,500-2,600

* Note : All data are based on operation without cooling fan at KS-R1004

DC24 (2.4 Liter)

-7-

General Informations

1.3.3. Engine Performance 1) Engine suffix : ELFFO

Performance

KS-R1004

Power (max.)

44 PS/2,250 rpm

Maximum torque

14.5 kg.m/1,800 rpm

Fuel consumption rating (min.)

DC24 (2.4 Liter)

200 g/PS.h

-8-

General Informations

2) Engine suffix : ELFFN

Performance

KS-R1004

Power (max.)

45 PS / 2,400 rpm

Maximum torque

14.5 kg.m / 2,000 rpm

Fuel consumption rating (min.)

DC24 (2.4 Liter)

200 g / PS.h

-9-

General Informations

1.4. Engine Assembly 4

2 1

12 13

1. Fly wheel. 2. Rear plate. 3. Oil filter. 4. Nozzle holder assÕy. 5. Fuel injection pipe. 6. Oil filler cap. 7. Water outlet 8. Cooling fan. 9. Crank shaft pulley. 10. Injection pump. 11. Oil pan. 12. Oil pressure switch. DC24 (2.4 Liter)

13. Alternator. 14. Exhaust manifold. 15. Oil level gauge. 16. Intake manifold. 17. Lifting hook. 18. Power take off. 19. Starter. 20. Water pump assÕy. 21. Intake stake. 22. Breather hose. 23. Cylinder head cover. 24. Pre heater plug. - 10 -

General Informations

2. Preventive Maintenance 2.1. Preventive Maintenance The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine.

2.1.1. Cooling Water =Regarding the cooling water that is to be used for engine, the soft water not the hard water must be used. =The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 ~ 5%. =The density of above solution and additive must be inspected every 500 hours to maintain it properly. NOTE : The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine.

=Since DC24 diesel engine cylinder liner is dry type, particularly the cooling water control should be applied thoroughly. =The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC260M or DAEWOO 60.99901-0038) =How to use the cooling water test kit (1) When the cooling water temp of engine is in the range of 10 ~ 55 ûC, loosen the plug for cooling water discharge and fill the plastic cup about a half. NOTE : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosening the cooling water discharge plug. (2) At the state of a test paper soaked in the sampled water, after taking the paper out through water agitation, shake off the water. (3) Wait for about 45 sec. till the color change of test paper. NOTE : However, it should not elapse longer than 75 sec, and if it did, the hue would change. (4) Make the numerical value by comparing the test paper which hue has changed with the color list of label on storage bottle. (5) By comparing thehue changed into yellowish green or so with the green color indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%). (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storqge bottle. (7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water.

DC24 (2.4 Liter)

- 11 -

General Informations

=Amount of Anti-freze in winter Ambient Temperature (¡C)

Cooling water (%)

Anti-freeze (%)

Over -10 -10 -15 -20 -25 -30 -40

85 80 73 67 60 56 50

15 20 27 33 40 44 50

2.1.2. Fan Belt = Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated. = Check the fan belt for belt tension. If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection : 10 ~ 15 mm when pressed down with thumb)

2.1.3. Engine Oil = Check oil leel with the oil level gauge and replenish if necessary. = Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge. = Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed simultaneously. = Engine oil change interval : at least 2 times/year First oil change

After the first

1,000km (50hr)

Every 3,000km (250hr)

= Suggested engine oil Engine model

DC24

DC24 (2.4 Liter)

Recommend engine oil SAE No.

API No.

Remark

SAE 15W40

API CD grade or CE grade above

SAE 15W40 SAE 10W40

ACEA-E2 or ACEA-E3 (APICH-4)

Bellow 0.05% sulfur

- 12 -

General Informations

2.1.4. Oil Filter = Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. = Change the oil filter cartridge simultaneously at every replacement of engine oil.

2.1.5. Fuel Filter = The fuel filter should be replaced at every 18,000km (1,200hr)

2.1.6. Air cleaner = In case that elements are deformed, damaged or if the air cleaner has a crack, replace it. = By the definite interval, the elements must be cleaned and replaced.

2.1.7. Valve Clearance Adjust Procedure = After the first 1,000km(50 hr) operation. = When doing engine overhaul or dismantling Cylinder Head off the block. = When Abnormal sound from the valve train is noticed. = When Poor operation condition continues inspite of faultless fuel system. = Valve clearance(with engine cooled) : 0.45 mm for both intake and exhaust.

2.1.8. Cylinder Compression Pressure = Stop the engine after warming up, and take out nozzle holder assembly. = Install the special tool (compression gauge adapter) at the nozzle holder hold, and connect the compression pressure gauge thers. Standard valure

28 kg/cm2 over

Limit value

24 kg/cm2

Difference between each cylinder

Within ± 10 %

¥ Testing conditions : coolant temperature 20¡C, Engine rpm 200rpm (10 turns)

2.1.9. Injection Nozzle = Install a nozzle on the nozzle tester = If the inspected injection pressure is less than the specified value, adjust using the adjusting shims. Engine Model

DC24

Opening pressure

120 kg/cm2

= Check the atomizing state and replace it if abnormal.

DC24 (2.4 Liter)

- 13 -

General Informations

2.1.10. Fuel Injection Pump = Check the housing crack, damage etc. and replace it if abnormal. = Check if the idle operation and speed regulating leverÕs sealing is removed. = The adjustment and testing of fuel injection pump should necessarily be done at the test bench.

2.1.11. Battery = Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition. = Inspect for amount of electrolytic solution, and replenish if insufficient. = Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.

2.1.12. Air removal of Fuel System The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.13. Fuel Supply Pump Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned.

2.1.14. Starting Motor In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them with grease. Also, In case of washing engine (room) and so forth, inspect the wiring state being careful for water not to get in.

DC24 (2.4 Liter)

- 14 -

General Informations

2.2. Torque Specifications Standards bolts The torque values given in the following table should be applied where a particular torque is not specified.

Bolt identification

4T Low carbon steel

7T High carbon steel

6 x 1.0

0.4 - 0.8

0.5 - 1.0

8 x 1.25

0.8 - 1.8

1.2 - 22

1.7 - 3.1

10 x 1.25

2.1 - 3.5

2.8 - 4.7

3.8 - 6.4

✽10 x 1.5

2.0 - 3.5

2.8 - 4.7

3.8 - 6.4

Bolt diameter x pitch

9T Alloy steel

12 x 1.25

5.0 - 7.5

6.2 - 9.3

7.7 - 11.6

✽12 x 1.75

4.6 - 7.0

5.8 - 8.6

7.3 - 10.9

14 x 1.5

7.8 - 11.7

9.5 - 14.2

11.6 - 17.4

✽14 x 2.0

7.3 - 10.9

9.0 - 13.4

10.9 - 16.3

16 x 1.5

10.6 - 16.0

13.8 - 20.8

16.3 - 24.5

✽16 x 20

10.2 - 15.2

13.2 - 19.8

15.6 - 23.4

18 x 1.5

15.4 - 23.0

19.9 - 29.9

23.4 - 35.2

20 x 1.5

21.0 - 31.6

27.5 - 41.3

43.3 - 64.9

22 x 1.5

25.6 - 42.2

37.0 - 55.5

43.3 - 64.9

24 x 2.0

36.6 - 55.0

43.9 - 72.5

56.5 - 84.7

The ✽ indicates that the bolts used for female-threaded parts that are made of soft materiails such casting, etc.

DC24 (2.4 Liter)

- 15 -

General Informations

3. Major Maintenance 3.1. Major Parts Fixing Bolts 3.1.1. Cylinder Head and Block (kg.m)

DC24 (2.4 Liter)

- 16 -

General Informations

3.1.2. Crankshaft and Camshaft (kg.m)

DC24 (2.4 Liter)

- 17 -

General Informations

3.1.3. Injection Pump and Other

(kg.m)

3.1.4. In-line Injection Pump Type

(kg.m)

3.1.5. VE Injection Pump Type

(kg.m)

DC24 (2.4 Liter)

- 18 -

General Informations

3.2. Engine Repair Kit

1. Gasket : Cylinder head. 2. Gasket : Cylinder head cover. 3. Gasket : Intake and exhaust manifold. 4. Gasket : Joint bolt 5. Seal : Crankshaft(Rear). 6. Gasket : Front plate. 7. Gasket : Drain plug. 8. Gasket : Oil pan. 9. Gasket : Oil pan to bearing cap 10. Gasket : Tappet chamber cover. 12. Gasket : Gear case. 13. Oil Seal.

DC24 (2.4 Liter)

14. Gasket : Gear case. 15. Gasket : Water pump to cylinder block. 16. Gasket : Outlet pipe. 17. Gasket : Housing cylinder head. 18. Seal Ring 19. Gasket : Oil filter to block. 20. Seal Ring. 22. Seal Ring. 23. Seal Ring. 25. Gasket : Bracket to front plate 27. Gasket : Head cover bolt. 28. Repair Kit : Top overhaul kit

- 19 -

General Informations

3.3. Repair 3.3.1. Cylinder Head Bolt Tighten the cylinder head bolts in sequence as shown in the figure. Torque(kg¥m)

8.0 L 0.5

3.3.2. Valve Clearance Adjust the valve clearance in the following manner using a feeler gauge. Standard (in cold) Intake and exhaust (mm)

0.45

Feeler gauge

EA0O4014

1. Bring the piston in either the No.1 cylinder or the No.4 cylinder to top dead center on the compression stroke by turning the crankshaft until the TDC notched line on the crankshaft pulley is aligned the timing pointer. 2. Check to see if there is play in the No.1 intake and exhaust valve rocker arms. If the No.1 cylinder intake and exhaust valve rocker arms are deprssed, the No.4 piston is at TDC on the compression stroke.

T 13° 18° D C EA0O4011

Adjust the clearances of valves marked with an arrow. Rocker arm screw lock nut torque (kg¥m)

2.5

<------ Front side

DC24 (2.4 Liter)

- 20 -

Rear side ----->

General Informations

After adjusting the valve clearances referring to the figure, turn the crankshaft one full turn in the rotative direction and align the TDC mark with the pointer, then adjust the remaining valve clearances.

<------ Front side

Rear side ----->

3.3.3. Injection Timing 1) In-Line Injection Pump Timing

13¡ ± 1¡ T 13° 18° D C EA0O4011

Check the notched line on the injection pump is in alignment with the notched line on the injection pump bracket.

2) VE Injection Pump =Turn the crank pulley until No. 1 piston is placed in the ÒTDCÓ position of notch marks on the crank pulley, and then turn again the crank pulley clockwise until showing the notch mark of the right figure corresponding to the injection timing is aligned with the pointer ( ) on the crank pulley. DC24 Fuel injection timing (B.T.D.C static)

T 13° 18° D C EA0O4011

13¡

=Check the alignment of the notched lines injection pump and timing flange =Loosen 2 fixing bolts of the injection pump. =Turn the injection pump until the notch mark of the injection pump attached to the fuel injection pump flange is aligned with the notch mark of the flange. =Tighten the fixing bolts to specified torque. Torque (kg¥m) DC24 (2.4 Liter)

3.5 ~ 4.5 - 21 -

General Informations

3.3.4. Compression Pressure Remove the glow plugs from all cylinders, then check the comprssion pressure in each cylinder with a compression gauge by engaging starter. (kg/cm2, 200rpm) Standard

Limit

22.0 - 23.0 EA0O4015

3.3.5. Fuel System Injection nozzle Check the spraying condition and injection starting pressure Injection starting pressure (kg/cm2)

120

EA0M3002

Adjustment Adjust the injection starting pressure with the adjusting screw using a nozzle tester

EA0M3003

Air Bleeding of the Fuel System

Bleeder screw

1) In-Line Injection Pump Bleed the system by manually operating the priming pump with the fuel filter outlet joint bolt and injection pump bleeder screw loosened.

Priming pump EA0O4010

2) VE Injection Pump After the cleaning of the fuel filter or after the engine stop by the lack of fuel, the bleeding of the fuel system must be executed by all means. Bleed the system by manually operating the priming pump with fuel injection pipe nut and filter bleeder screw loosened. ¥ Press the priming pump cap repetitively until the fuel without bubbles comes out from the bleeding screw ¥ After the whole air is pulled out, close the screw of the fuel filter and fuel injection pipe nut. DC24 (2.4 Liter)

- 22 -

General Informations

Feed pump strainer Remove the strainer using a screw driver. Wash the stainer in clean diesel fuel.

Strainer

EA0O4008

Fuel filter replacement Remover and installer(filter wench)

EA3M1031

Apply diesel fuel to o-ring. Turn in filter until sealing face is brought into contact with the o-ring. Further tighten 2/3 of a turn.

EA0M3005

Fuel sedimentor (if eguipped) Removal steps Disconnect water separator sensor wiring at the connector. Remove the filter using filter wrench.

EA3M1031

Installation steps Install the water separator sensor in the new filter. Apply diesel fuel to o-ring.

DC24 (2.4 Liter)

- 23 -

General Informations

Fill the filter sufficiently with diesel fuel before installing it in the housing. Apply diesel fuel to o-ring. Turn in filter until sealing face is brought into contact with the o-ring. Further tighten 2/3 of a turn.

3.3.6. Lubricating System Main oil filter replacement

Cartridge (Oil filter)

Remove the filter cartridge using filter wrench

Oil filter head

EA0M3006

3.3.7. Fan Belt

Depress here Fan pulley

Adjust belt tension by moving generator pulley. Specified belt deflection(mm)

about 10mm

10 Generator pulley

EA0M3009

Crank pulley

3.3.8. Pre-Heating System Q.O.S System Q.O.S System makes the pre-heating time short and easy start.

Acc "OFF"

"ON"

ST Stater S/W

Batt DC 12V

IND. Lamp

Relay

Glow plug

5 Thermo O/N 60°C

EA0M3010

Thermo Switch Operating temperature Operating temperature

15¡C

EA0M3011

DC24 (2.4 Liter)

- 24 -

General Informations

Glow Plug Check the continuity across the plug terminals and body.

EA0M3012

DC24 (2.4 Liter)

- 25 -

General Informations

4. Engine Disassembly and Reassembly 4.1. External Parts

DC24 (2.4 Liter)

Engine Assembly

4.2. Internal Parts (Timing gear train) 4.2.1. Major Components

4 5 EA0M4003

EA0M4003

<Disassembly steps> 1. Pulley. 2. Timing gear case cover.

3. Injection pump gear. 4. Idle gear.

Important Operations

Injection pump assembly Inspect the following items before timing gear removal. Backlash (Crankshaft gear, camshaft gear, injection pump gear) Standard

Limit

0.10-0.17 mm

0.3 mm

EA0M4004

Idle gear end play Standard

Limit

0.07 mm

0.2 mm

EA0M4004

DC24 (2.4 Liter)

Engine Assembly

4.2.2. Cylinder head

<Disassembly steps> ▲ 1. Spring seat and valve cotter 2. Valve spring 3. Valve

Important Operation =Spring seat and valve cotter (1) : Valve spring compressor

DC24 (2.4 Liter)

Engine Assembly

4.2.3. Piston and Connecting Rod Assembly

3 2

EA0M4008

<Disassembly steps> ▲ 1. Piston ring 2. Snap ring ▲ 3. Piston pin

DC24 (2.4 Liter)

4. Piston 5. Connecting-rod

Engine Assembly

Important Operation Piston ring : Remover

EA0M4009

Piston pin Remove the piston pin snap ring using a snap ring plier. Drive out the piston pin using a brass rod at normal temperature.

Piston Pin

4.2.4. Rocker Arm and Shaft Assembly

<Disassembly steps> 1. Rocker arm (A) 2. Rocker arm shaft bracket 3. Rocker arm (B)

DC24 (2.4 Liter)

4. Rocker arm shaft bracket 5. Rocker arm shaft

Engine Assembly

4.3. Inspection and Repair Make necessary corrction or parts replacement if wear, if wear, damage or any other abnormal conditions are found through inspection.

4.3.1 Cylinder Body and Liner Cylinder body warpage

Overall length Thickness (H)

Standard

Limit

0.05 mm

0.2 mm

247.97-248.03 mm 247.7 mm EA0M4012

Grade datermination Take an average of 3 values obtained by measuring the diameters shown in the right. 90

Measunng point : Approx. 90 mm from the upper face. The mark on the upper face should be neglected in case of Engine overhaul.

= Cylinder block (steel liner)

bore dia Liner outer dia

¯88

EA0M4013

Grade tolerance

Standard

Cylinder

(mm)

Projection

¯88.010 ¯88.020 ~ ~

¯88.030 ~

¯88.040 ~

¯88.001 ¯88.011

¯88.021

¯88.031

¯88.020 ¯88.030 ~ ~ ¯88.011 ¯88.021

¯88.040 ~ ¯88.031

¯88.050 ~ ¯88.041

Straight edge

Feeler gage

= Cylinder block (cast liner) Standard

EA0M4014

(mm) Grade tolerance 1

Cylinder bore dia

¯90

¯90.010 ~ ¯90.001

¯90.020 ~ ¯90.011

Liner outer dia

¯90

¯89.984 ~ ¯89.995

¯89.995 ~ ¯90.006

Amount of projection

(mm) Standard

Steel liner

-0.015~0.115 mm

Cast liner

0.008~0.070 mm

DC24 (2.4 Liter)

Engine Assembly

Cylinder liner replacement : Remover : Liner grip

Installer Wipe clean the cylinder liner and cylinder body to remove oil, then install the cylinder liner into cylinder bore using a bench press. The use of dry ice to cool the cylinder liner will invite contraction, facilitating smooth installation of the cylinder liner. Tightness

Bench press Installer

0 - 0.02 mm EA0M4016

4.3.2. Crankshaft and Bearing A

Crankshaft journal and pin diameter B

Standard Journal

¯ 69.92 - ¯ 69.932 mm

Pins

¯ 52.918 - ¯ 52.930 mm

Undersize bearings are available in 4 different sizes which include 0.25, 0.5, 0.75 and 1.0 mm undersizes.

EA0M4017

Crankshaft diameter when using undersize bearing Journal

U/S 0.25 ¯ 69.67-¯ 69.68 mm ¯ 52.67-¯ 52.68 mm U/S 0.50 ¯ 69.42-¯ 69.43 mm ¯ 52.42-¯ 52.43 mm U/S 0.75 ¯ 69.17-¯ 69.18 mm ¯ 52.17-¯ 52.18 mm U/S 1.00 ¯ 68.92-¯ 68.93 mm ¯ 51.92-¯ 51.93 mm

DC24 (2.4 Liter)

Engine Assembly

Uneven wear

Fillet section

Standard

Limit

Journal

0.001 mm

0.05 mm

0.001 mm

0.05 mm

Fillet section

Wear

Curvature of the fillet section on the crankshaft journals and pins should be finished as shown bellow.

Wear

EA0M4018

Standard Journal

R3.3 - R3.7 mm

When regrinding the crank shaft, the fillet section should be correctly finished. Avoid stepped portion or rough surface on it.

Clearance between crankshaft journal and bearing

Clearance

Standard

Limit

0.018-0.065 mm

0.12 mm

Crankshaft bearing cap bolt Torque(kg¥m)

18.5

Clearance between crank pin and connecting-rod bearing Standard

Limit

0.029-0.082 mm

0.12 mm

Crankshaft bearing cap bolt Torque(kg¥m)

8-9

EA0M4020

Bearing clearance Measurement Measure the clearance using plastic gauge.

EA0M4021

DC24 (2.4 Liter)

Engine Assembly

Bearing spread Limit Crankshaft bearing

74.5 mm

Connecting-rod bearing

56.5 mm

EA0M4022

Run-out Standard

Limit

0.03 mm

0.06

EA0M4023

Crankshaft gear replacement Removal : Remover

Remover

EA0M4024

Installation : Installer

Installer

EA0M4025

Pilot bearing replacement : Remover

EA0M4026

DC24 (2.4 Liter)

Engine Assembly

4.3.3. Flywheel Inspect the following parts for wear, damage or other abnormal conditions.

EA0M4027

Ring gear replacement Remove the ring gear from the flywheel by tapping around the side face of the gear with a brass bar.

EA0M4028

Heat the ring gear evenly with a gas burner(Max. temperature 200¡C) to invite volumetric expansion. Install the ring gear on the flywheel when it is sufficently heated.

EA0M4029

4.3.4. Maintenance of cylinder block, cylinder liner and piston To maintain the engine in optimum condition and retain maximum performance for a long time, the cylinder block, cylinder liner and piston which have the same grade marking number (the same size tolerance) should be assembled. The marking number (the partÕs grade) and marking position is as follows.

Marking

= Cylinder block a) Marking number ; 1 or 2 (Size grade for of cylinder bore diameter) b) Marking position ; Middle of the cylinder block side surface. Piston grade of cylinder No.4

DC24 (2.4 Liter)

Cylinder block grade

Engine Assembly

lCylinder liner a) Marking number ; 1A, 1B, 2A or 2B 1A Can used the piston A grade Can used the cylinder block 1 grade b) Marking position ; Cylinder liner lower surface

lPistion a) Marking number ; A or B (Size grade for piston outer diameter) b) Marking position ; Center of the piston upper surface

Marking

EA4M2021

Assembly process of cylinder block, cylinder liner and piston (1) Check the marking number (1 or 2) of cylinder block. (Middle of side surface) (2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just the same with it on the cylinder block. (3) Assemble the piston whose marking is just same with the second digit (A or B) of the assembled cylinder linerÕs marking.

4.3.5. Piston Piston clearance Piston outside diameter Take measurement in direction at a right angle to the piston pin hole. Grading position ; 14mm. The piston grade should be selected by referring to the following table, so that specified piston clearance can be obtained.

EA0M4030

=Piston grade for steel liner Piston grade

Standard

¯ 85.970 mm ~ ¯ 85.985 mm

¯ 85.980 mm ~ ¯ 85.996 mm

¯ 85.990 mm ~ ¯ 86.006 mm

¯ 86.000 mm ~ ¯ 86.016 mm

= Piston grade for cast liner Piston grade

Standard

¯ 85.970mm ~ ¯ 85.985mm

¯ 85.980mm ~ ¯ 85.996mm

DC24 (2.4 Liter)

Engine Assembly

Cylinder inside diameter (mm)

Cylinder inside diameter

Grade

Cast liner

¯86.020 ~ ¯86.031

¯86.031 ~ ¯86.042

Steel liner

¯86.020~¯86.060

Piston clearance

0.035~0.062

Piston pin outside diameter Standard

Limit

¯26.995-¯27.0 mm

¯26.96 mm

Fitting interference between piston pin and piston Standard

0.004 - 0.015mm EA0M4031

Clearance between piston ring and ring groove Standard

Limit

1st compression ring

0.085 - 0.115mm

0.2mm

2nd compression ring

0.05 - 0.085mm

0.15mm

Oil ring

0.03 - 0.065mm

0.15mm

EA0M4032

Piston ring gap Standard

Limit

1st compression ring

0.20 - 0.40mm

1.5mm

2nd compression ring

0.20 - 0.40mm

1.5mm

Oil ring

0.10 - 0.30mm

1.5mm

Feeler Gouge

EA0M4033

4.3.6. Connecting Rod Connecting-rod Distortion and parallelism Standard

Limit

Distortion

0.05 mm

0.20 mm

Parallelism

0.05 mm

0.15 mm EA0M4034

DC24 (2.4 Liter)

Engine Assembly

Bushing Clearance between bushing and piston pin Standard

Limit

0.008 - 0.02mm

0.05mm

EA0M4035

Bushing Replacement Removal : Remover Installation : Installer

The inner face of the bushing must be finished with a reamer after installation of the bushing. Inside diameter

27.008 - 27.015 mm

EA0M4036

4.3.7. Cylinder Head H

Cylinder head warpage Standard

Limit

Overall length

0.05 mm

0.2 mm

Thickness (H)

91.95-92.05mm

91.75 mm EA0M4038

Depression of hot plug Check the amount of depression of swirl chambers on No.1 through No.4 cylinder using a feeler gauge, with a straight edge held against the swirl chamber face. Limit

0.02 mm

EA0M4039

DC24 (2.4 Liter)

Engine Assembly

Swirl chamber Replacement Remove the hot plug in the following manner ; Insert a suitable round bar sizing 3 to 5mm in diameter into nozzle holer fitting hole to touch the swirl chamber, then drive out the swirl chamber using a hammer.

EA0M4040

Heat shield replacement Remove the heat shield using a brass bar and a hammer.

EA0M4041

Installation of new swirl chamber Install lock ball into groove in swirl chamber. Drive the swirl chamber into cylinder head by aligning lock ball in swirl chamber with groove in cylinder head.

EA0M4042

Press the swirl chamber into position by applying 4,500 to 5,000 kg pressure using a bench press with a piece of metal fitted against the swirl chamber face for protection. After installation, grind the face of swirl chamber flush with the face of the cylinder head.

EA0M4043

Installation of new heat shield Install the heat shield with the flanged side up on the cylinder head by tapping on the flange lightly with a brass bar.

EA0M4044

DC24 (2.4 Liter)

Engine Assembly

4.3.8. Valve and Valve Seat Insert Valve stem diameter Standard

Limit

Intake valves

¯7.946 - ¯7.961mm

¯7.88mm

Exhaust valve

¯7.921 - ¯7.936mm

¯7.85mm

III

EA0M4045

Depression Standard

Limit

Intake valves

0.65mm

2.5 mm

Exhaust valve

0.65mm

2.5 mm

Depression

EAOM4046

Contact width Standard

Limit

1.06mm

3.6 mm Contact width

EAOM4047

Valve seating angle Valve seating angle

45¡

EA0M4048 EA0M4048

Valve thickness Standard

Limit

Intake valve

1.3 mm

1.0 mm

Exhaust valve

1.3 mm

1.0 mm Thickness

EA0M4049

DC24 (2.4 Liter)

Engine Assembly

Valve seat replacement Arc-weld excess metal around inner face of the valve seat and allow to cool off a few minutes, then pull out the valve seat with vibration hammer

Valve seat

Cylinder head

Welding bead

Press a new valve seat insert into the bore using a bench press. After installation of the valve seat insert, grind finish the seating face with a seat grinder carefully noting the seating angle, contact width and depression. Lap the valve and seat as te final step.

EA0M4051

4.3.9. Valve Guide Clearance between valve stem and valve guide Standard

Limit

Intake valve

0.039 - 0.071 mm

0.20 mm

Eahaust valve

0.064 - 0.096 mm

0.25 mm EA0M4052

Valve guide replacement Removal : Remover

EA0M4053

Installation ; Valve guide installer. Apply engine oil to the outer circumference of the valve guide. Set the installer to the valve guide, then the guide into position from the upper face of the cylinder head a hammer.

EA0M4054

DC24 (2.4 Liter)

Engine Assembly

Height of valve guide upper end

Intake

12.5 ± 0.2mm

from cylinder head upper face

Exhaust 12.5 ± 0.2mm

Discard used oil seals and install new ones.

4.3.10. Valve Spring Inclination

Free lenght and inclination Standard

Limit

lnner

47.9mm

46.5mm

Outer

47.3mm

45.8mm

lnner

1.0mm

Outer

1.0mm

Set length

Standard

Limit

Ineer

37.0 mm

5.55 - 6.25 kg

5.02 kg

Outer

39 mm

19.65 - 22.15 kg

18.1 kg

Free length

Inclination

Free Length

Square

EA0M4055 EA0M40

Free lenght and inclination

EA0M4056

4.3.11. Rocker Arm and Rocker Arm Assembly Run-out Limit

0.4 mm

EA0M4057

Rocker arm shaft diameter Standard

Limit

¯18.98 - ¯19.00 mm

¯18.85 mm

EA0M4058

DC24 (2.4 Liter)

Engine Assembly

Rocker arm Clearance between rocker arm shaft and rocker arm Standard

Limit

0.020 - 0.070 mm

0.2 mm

If the amount of wear is beyond the limit, replace either the shaft or rocker arms depending on the condition of wear.

EA0M4059

It is necessary to drill an oil port in the new rocker arm bushing as it is not provided with the oil port.

EA0M4060

4.3.12. Camshaft Assembly

EA0M4061

Camshaft diameter and height of cam lobe Standard Journal diameter Height of cam lobe

Limit

¯47.945 - ¯47.975mm ¯47.6mm 40.568mm

40.2mm I II

A C

B D

I II

EA0M4062

Clearance between camshaft and bearing Camshaft bearing

Standard

Limit

0.05 mm

0.12 mm

EA0M4063

DC24 (2.4 Liter)

Engine Assembly

Cam bearing replacement Removal : remover and installer

Remover and installer EA0M4064

Installation : remover and installer The oil port in the cylinder body must be aligned with that in the camshaft bearing.

Align oil port

Run-out Standard

Limit

0.05 mm

0.1 mm

EA0M4066

End play Standard

Limit

0.05-0.11mm

0.2 mm

EA0M4067

Camshaft gear replacement Removal : remover

EA0M4068

DC24 (2.4 Liter)

Engine Assembly

Installation Drive the gear to the shaft, aligning the key groove on the gear with the key on the shaft.

EA0M4069

Tappet Inspect tappet for wear, damage or other abnormal condition. Pitting

Crack

Normal contact

Irregular contact

EA0M4070

Diameter Standard

Limit

¯12.977-¯12.990mm

¯12.95 mm

Clearance between tappet and cylinder body Standard

Limit

0.03 mm

0.1 mm

EA0M4072

4.3.13. Push Rod Run-out Limit

DC24 (2.4 Liter)

0.4 mm

Engine Assembly

4.3.14. Idle Gear and Shaft Idle gear shaft Standard

Limit

¯44.945 - ¯44.975mm

¯44.845 mm

EA0M4074

Clearance between shaft and idle gear Standard

Limit

0.025-0.085mm

0.2 mm

EA0M4075

Timing gear case cover oil seal replacement Removal : Remover

EA0M4076

Installation : Installer

EA0M4077

DC24 (2.4 Liter)

Engine Assembly

4.4. Reassembly 4.4.1. Minor Components = Cylinder Head

EA0M4078

<Reassembly steps> 1. Valve ▲2. Valve spring

3. Retainer and valve cotter

Important operations = Valve spring (2) Install the valve spring with the painted end down.

Painted portion EA0M4079

= Retainer and valve cotter (3) : Compressor

DC24 (2.4 Liter)

Engine Assembly

=Rocker arm and shaft assembly

3 21 4

13 14

16 EA0M4080

<Ressembly steps> 1. Rocker arm shaft 2. Waving washer 3. Snap ring ▲ 4. Rocker arm (A) 5. Rocker arm shaft bracket ▲ 6. Rocker arm (D) 7. Spring ▲ 8. Rocker arm (C) 9. Rocker arm shaft bracket ▲ 10. Rocker arm (D)

11. Spring ▲ 12. Rocker arm (C) 13. Rocker arm shaft bracket ▲ 14. Rocker arm (D) 15. Spring ▲ 16. Rokcer arm (C) 17. Rocker arm shaft bracket ▲ 18. Rocker arm (B) 19. Waving washer 20. Snap ring

Important operations = Rocker arm (A) (4) = Rocker arm (C) (8, 12, 16) Difference between rocker arm (A) and (C)

Rocker arm(B)

Rocker arm(D)

EA0M4081 EA M

=Rocker arm (B) (18) =Rocker arm (D) (6, 10, 14) Difference between rocker arm (B) and (D)

Rocker arm(C)

Rocker arm(A)

EA0M4081

DC24 (2.4 Liter)

Engine Assembly

= Piston and connecting-rod assembly

<Reassembly steps> 1. Piston and connecting-rod 2. Piston pin

3. Snap ring 4. Piston ring

Important operations = Piston and connecting-rod Install the piston on the connecting-rod, so that combustion chamber on piston head is on the same side with the cylinder number mark side (side with bearing stopper) of the connecting-rod big-end. Daewoo mark on the connecting-rod should be on the same side of the front mark on the piston head.

= Piston pin Install the piston pin after heating the piston to about 100¡C

DC24 (2.4 Liter)

Engine Assembly

= Snap ring Install the snap ring into the piston using snap ring pliers, then check to make certain the snap ring is fitted properly into the groove. Snap ring

Piston ring Use piston ring installer. Install the 1st and 2nd compression rings with manufacturerÕs mark turned up. Oil ring can be installed on the piston with either side up. Piston ring gaps should be positioned as shown in the figure.

2nd Ring

Use Cr-coating piston ring for cast liner and nominal piston ring for steel liner. 120

EA0M4090

Important operations =Crankshaft and bearing Journal diameter

Fit correctly

With oil hole and groove

¯70 mm

Install the crankshaft after applying engine oil to the face of the bearing in contact with the crankshaft. EA0M4083

Cap side

Block

The bearings should be installed correctly in their respecive position. Install the thrust bearing with the oil grooved side turned outward.

EA0M4106

= Installation of bearing cap arch gaskets. Install the arch gasket on the No.1 and No.5 bearing caps. No. 5

Amount of projection of gasket

0 - 0.05 mm

Arch gasket

0-0.05

No. 1 0-0.05

DC24 (2.4 Liter)

EA0M4084

Engine Assembly

Apply a coat of silicon gasket evenly to the joining faces of the No.5 bearing cap and cylinder block. The No.1 and No.5 bearing caps should be installed flush with the face of the cylinder Block.

No. 5 bearing cap

EA0M4085

Install front and rear side thrust bearings with the oil groove turned to the timing gear and flywheel, respectively.

EA0M4086

Tighten crankshaft bearing cap bolts in numerical order. Torque (kg-m)

18.5

Bolt lenght

89 mm

Apply engine oil

= Rear oil seal Apply engine oil to the lipped portion of the rear oil seal, then install it in position using installer.

EA0M4087

Cylincer block Oil seal Crankshaft Installer

Engine oil

Hammer

EA0M4088

Flywheel Tighten the bolts in the numerical order as the illustration Torque (kg-m)

12.0

EA0M4089

DC24 (2.4 Liter)

Engine Assembly

= Piston and connecting-rod Lightly oil the piston rings fitted to the piston, then position piston ring gaps as illustrated in the drawing.

2nd Ring

1st Ring

Oil Ring 120

EA0M4090

Piston ring compressor Install the piston and connecting-rod with mark turned to the front of engine. Use the piston sleeve.

EA0M4091

Install the connecting-rod bearing caps by matching numbers. Torque (kg-m)

8.0 - 9.0

Matching number EA0M4092

= Oil jet pipe Tighten the oil jet pipe fixing bolts in the order.

EA0M4093

Inspect the gap between oil Jet pipe and piston.

Oil jet pipe

EA0M4094

DC24 (2.4 Liter)

Engine Assembly

Liquid gasket applying portion

Rubber gasket Liquid gasket applying portion 45

= Crank case Apply liquid gasket to the arch gasket fitting face of the No.1 and No.5 bearing caps.

Crankshaft EA0M4095

4.4.2. Internal Parts (Timing gear train) = Major components : Gear drive type

EA0M4096

<Reassmbly steps> ▲1. Idle gear assembly ▲2. Injection pump gear

DC24 (2.4 Liter)

▲3. Timing gear case cover ▲4. Crank shaft pulley

Engine Assembly

Important operations = Idle gear (1) Install the idel gear, so that the oil port in the idle gear shaft is turned to the crankshaft gear side and bolt holes are aligned.

Oil port

Align the marks on the camshaft gear, idle gear and crankshaft gear.

EA0M4098

=Injection pump gear (2) Install the injection pump gear together with injection pump by aligining the mark with that on the camshaft.

EA0M4099

=Timing gear case cover (3) Check to make sure the o-ring is fitted properly into ring groove in the timing gear case cover.

EA0M4107

Crank shaft pulley (4) Bolt

Torque (kg-m)

19.0

EA0M4100

DC24 (2.4 Liter)

Engine Assembly

=Adjustment of injection timing 1) In-Line Injection pump Bring the piston in No.1 cylinder to the injection timing before T.D.C on compression stroke so that T.D.C line on the pulley is aligned with the point. Timing

T 13° 18° D C EA0M4011 EA0O4

13¡ ± 1¡

Bring the mark on the injection pump housing with the mark on the injection pump backet.

2) VE Injection pump =Turn the crank pulley until No. 1 piston is placed in the ÒTDCÓ position of notch marks on the crank pulley, and then turn again the crank pulley clockwise until showing the notch mark of the right figure corresponding to the injection timing is aligned with the pointer ( ) on the crank pulley. T 13° 18° D C

DC24 Fuel injection timing (B.T.D.C static)

EA0O4011

13¡

=Check the alignment of the notched lines injection pump and timing flange =Loosen 2 fixing bolts of the injection pump. =Turn the injection pump until the notch mark of the injection pump attached to the fuel injection pump flange is aligned with the notch mark of the flange. Tighten the fixing bolts to specified torque. Torque (kg.m)

DC24 (2.4 Liter)

3.5 ± 4.5

Engine Assembly

4.4.3. Internal Components

<Reassembly steps> ▲ 1. Cylinder head gasket ▲ 2. Cylinder head

DC24 (2.4 Liter)

▲ 3. Rocker arm shaft assembly 4. Water pump

Engine Assembly

Important operations = Cylinder head gasket (1) Install head gasket on the cylinder block with ÒTOPÓ mark side up.

"TOP" 0048

"TOP" mark

EA0M4102

=Cylinder head (2) Tighten cylinder head bolts in numerical sequence.

1st step

2nd step

New bolt

6.5 kg.m

8.0 kg.m

Reused bolt

6.5 kg.m

10.0 ± 0.5 kg.m

=Rocker arm shaft assembly (3) Tighten rocker arm shaft bolts in numerical sequence. Rocker arm bracket torque

DC24 (2.4 Liter)

1.3 - 2.3 kg.m

Engine Assembly

4.4.4. External Components

Important operations

Depress here Fan pulley

= Fan belt (6) Specified belt deflection Fan belt

about 10mm

Generator pulley

10 mm

Crank pulley

DC24 (2.4 Liter)

EA0M3009

Engine Assembly

5. Lubricating System 5.1. General Description Oil filter assembly Relief valve

War ning lamp

Batter y Oil filter

Cylinder block main oil galler y

Regulation valve

Crankshaft bear ing

Camshaft bear ing

Connectingrod bear ing

Cylinder head valve mechanism

Timing gear

Piston Oil jet

Oil pump

Piston

EA0M5001

5.2. Oil Pump Disassembly =Rotor type

2 4

EA0M5002

<Disassembly steps> 1. Oil pipe 2. Strainer DC24 (2.4 Liter)

3. Pump cover 4. Vane 59

Lubricating System

Inspection and repair Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Clearance between vane and body Standard

Limit

0.02 - 0.07 mm

0.15 mm

Clearance between rotor and vane Standard

Limit

0.02 - 0.13 mm

0.15 mm

Clearance between vane and pump body

Standard

0.2 - 0.27 mm

Clearance between rotor shaft and pump body Standard

Limit

0.04 mm

0.2 mm

Pinion replacement Removal File off caulked end of the pinion stopper, then drive out the pin toward opposite side.

Installation Install a new stopper pin and caulked end of the pin after installation.

EA0M5006

DC24 (2.4 Liter)

Lubricating System

Rotor replacement Removal Drive out the pin from one side.

EA0M5008

Installation When the pin is installed, check to make sure the end of the pin is not projected from the end of rotor.

EA0M5009

Reassembly To assemble, follow the disassemble procedure in reverse order.

DC24 (2.4 Liter)

Lubricating System

5.3. Oil Filter =Without oil cooler type

2 3 5 1 EA0M5010

<Disassembly steps> 1. Drain plug 2. Plug screw 3. Plug screw

4. Oil filter cartridge 5. Relief valve assÕy 6. Oil filter housing

Inspection and repair Make necessary correction or parts replacement if damage or any other abnormal conditions are found through inspection. Reassembly To assemble, follow the disassembly procedure in reverse order.

DC24 (2.4 Liter)

Lubricating System

5.4. Oil Cooler 5.4.1. Oil Jet Pipe and Oil Pressure Regulating Valve Make necessary correction or parts replacement if wear, damage or any other abmormal conditions are found through inspection.

= Oil jet pipe Inspect for wear or any other abmormal conditions.

EA0M5015

Inspect the regulating valve moving smoothly when it is pressed using a screw driver.

EA0M5016

DC24 (2.4 Liter)

Lubricating System

6. Cooling System 6.1. General Description

Thermostat

By-pass

Car heater

Radiator

Cylinder head

Cylinder block

Water pump

EA0M6001

6.2. Water Pump Disassembly

<Disassembly steps> 1. Cover 2. Set screw ▲ 3. Hub DC24 (2.4 Liter)

▲ 4. Impeller and mechanial seal 5. Unit bearing

Lubricating System

Important operation = Hub (3)

EA0M6003

= Impeller and Mechanical seal Heat the pump body in hot water (80-90¡C). (For aluminum body only.)

EA0M6004

Remove impeller using a bench press and a suitable bar.

EA0M6005

Inspection and repair Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Check the bearing for abmormal noise, binding and other abnormal conditions.

EA0M6006

2.4 Liter (DC24)

Cooling System

Reassembly

<Reassembly steps> ▲ 1. Unit bearing 2. Set screw ▲ 3. Impeller and Mechanical seal

4. Cover ▲ 5. Hub

Important operations = Unit bearing (1) Press the unit bearing into place by aligning set screw hole in bearing with that in the pump body, then secure the unit bearing in position with the screws. Set screw hole

EA0M6008

= Impeller and Mechanial seal (3) Apply thin coat of liquid gasket (Belco bond No.4) to the outer periphery of Mechanial seal before installing the Mechanial seal.

Apply liquid gasket here EA0M6009

2.4 Liter (DC24)

Cooling System

Install the impeller in position using bench press, so that the specified clearance is provided between the impeller and pump body. Clearance

0.3 - 0.6 mm

EA0M6010

After installation, check that rear face of the impeller is indented from the face of the pump body. Depth

1.0 mm

EA0M6011

= Fan center (5) Distance between fan fitting face and rear face of the rear cover Distance

110.7 - 111.3 mm

EA0M6012

6.3. Thermostat

Thermometer

Inspection and repair Make necessary correction or parts replacement if wear, damage or any other abmormal conditions are found through inspection. Valve opening Temperature

Valve lift at testing Temperature

82 ¡C

8 mm(at 95¡C)

Rule

Wood piece

EA0M6013

2.4 Liter (DC24)

Cooling System

7. Fuel System 7.1. General Description 1) In-Line Injection pump

Nozzle holder Fuel filter

Injection pump

Fuel tank

EA0M7001

2) VE Injection pump

DC24 (2.4 Liter)

Lubricating System

=With the VE type injection pump, the number of the plungers has no relationship to the number of engine cylinders, and there is only one plunger. =This single plunger reciprocates while rotating, and fuel oil is injected into each cylinder through the injection pipes in accordance with the engine`s firing order.

2.4 Liter (DC24)

Fuel System

7.2. Injection Nozzle Disassembly

2 6

1 5 4

<Disassembly steps> 1. Cap nut 2. Nut 3. Adjusting screw 4. Nozzle spring 5. Push rod

6. Nozzle nut ▲7. Nozzle 8. Nozzle holder screw 9. Connector

Important operations =Nozzle (7) After removal of nozzle assembly from the nozzle body, keep them separate to maintain proper needle valve to body combinations.

Reassembly To reassemble, follow the disassembly procedure in reverse order. Refer to ÒFUEL SYSTEMÓ in general information for injection of spraying condition and injection starting pressure adjustment.

DC24 (2.4 Liter)

Lubricating System

7.3. Injection Pump Calibration 7.3.1. VE Injection pump (ELFFO/FFN/FFL/FFE) (1) Injection pump

65.11101 - 7329 (104780 - 9340 ZEXEL) - ELFFO 65.11101 - 7665 (104780 - 7120 ZEXEL) - ELFFN / L / E (2) Nozzle & holder assÕy ALTERNATIVE =Nozzle & holder assÕy : 65.10101 - 7075A (DOOWON) Nozzle ass`y 65.10102 - 6012 (105000 - 1740) =Nozzle & holder assÕy 65.10101 - 7076A (LUCAS) Nozzle ass`y 65.10102 - 6030 (9135-173) (3) Injection pipe: 65.10301 - 6301 (4) Injection order: 1-3-4-2 (5) Injection timing: BTDC 13 ± 1¡ (A) Test condition for injection pump

Nozzle

105000-2010

Opening pressure: 150 kg/cm2

Holder AssÕy

105780-2080

Injection pipe(IDxOD-L) Test oil (B) Engine stan dard parts

Nozzle & holder AssÕy

Injection pipe(ID x L)

¯2.0 x ¯6.0-840 mm

ISO4113

Temperature: 40 ± 5 ¡C

65.10101-7075A (DOOWON)

Nozzle (¯1.0)

65.10101-7076A (LUCAS)

Opening pressure: 120 kg/cm2

65.10301-6301

¯2.0 x 500 mm

INJECTION SYSTEM Plunger diameter

¯10

Plunger spring

k=7.25 kg/mm

Delivery valve spring

k=0.48 kg/mm

Damping valve spring

k=0.182 kg/mm

4.4¡/600 ~ 1,125 rpm

Timer spring

TIMER SYSTEM Timer advance ELFFO characteristic

ELFFN/L/E 4.4¡/600 ~ 1,200 rpm

Advance angle/Piston stroke

ELFFO

k=2,05 kg/mm

ELFFN/L/E

k=1.9 kg/mm

ELFFO

k=0.03 kg/mm

1¡/0.82

GOVERNOR SYSTEM Governor

ELFFO

k=0.104 kg/mm

spring

ELFFN/L/E k=0.122 kg/mm

Idle spring constant I

Idle spring constant II ELFFN/L/E

k=0.23 kg/mm

FUEL CUT MAGNET VALVE Rated voltage

12 V

Power consumption

16 W

Starting voltage

bellow 6.5 V

Holding voltage

above 2.5V

Opening voltage

0.5 V

at Full load

bellow 3.0kg

CONTROL LEVER REACTION FORCE at Idle

2.4 Liter (DC24)

above 0.3kg

Fuel System

6) Injection pump calibration (DC24 : ELFFO) (1) Governor adjustment Pump speed (rpm)

Average quantity Max. various between cylinder (mm3/stroke) (mm3/stroke)

500

(41.0 ± 2.0)

900

41.0 ± 1.0

1125

(41.0 ± 1.0)

Governing

1285

9.0 ± 3.0

Idling

425

7.5 ± 2.0

Start (idling)

100

(60.0 ± 20)

Full load

3.0

2.0

Adjust Remark

✻

Full load

✻

Governing

✻

Idling

(2) Timer and pump adjustment Pump speed (rpm)

Pressure of pump camber (kg/cm2)

Timer stroke (mm)

700

(3.4 ± 0.3)

(0.6 ± 0.4)

900

4.0 ± 0.2

1.8 ± 0.4

1125

(4.7 ± 0.3)

3.4 ± 0.4

Adjust

Remark Check point

✻

Adjust of pump and timer Check point

7) Injection pump calibration (DC24 : ELFFN / L / E) (1) Governor adjustment

Pump speed (rpm)

Average quantity (mm3/stroke)

500

(34.5 ± 2.0)

900

35.5 ± 1.0

1200

(36.0 ± 1.0)

Governing

1320

8.5 ± 3.0

Idling

425

7.5 ± 2.0

Start (idling)

100

(60.0 ± 20)

Full load

Max. various between cylinder (mm3/stroke)

Adjust Adjust

Remark

3.0

✻

Full load

✻

Governing

✻

Idling

2.0

(2) Timer and pump adjustment Pump speed (rpm)

Pressure of pump camber (kg/cm2)

Timer stroke (mm)

700

(3.2 ± 0.3)

(0.4 ± 0.4)

900

3.8 ± 0.2

1.3 ± 0.4

1200

(4.6 ± 0.3)

3.4 ± 0.4

DC24 (2.4 Liter)

Adjust

Remark Check point

✻

Adjust of pump and timer Check point Lubricating System

7.3.2. In-line Injection pump (ELFFA / FFD / FFI / FFJ) 1) Injection pump assÕy - Fuel injection pump - Governor - Timer - Feed pump 2) Nozzle & holder assÕy : =Nozzle & holder assÕy : Nozzle ass`y =Nozzle & holder assÕy Nozzle assÕy 3) Injection pipe: 4) Injection order: 5) Injection timing: (A) Test condition for injection pump

65.11101 - 7289 (101441 - 9830 ZEXEL) 101044 - 9160 (NP - PES4A65C312LS2000) 105419 - 2610 (NP - EP/RSV200 - 1600A021A301) 105621 - 0370 (NP - EP/SCD500 - 1750A6LN106) 105200 - 6450 (NP - FP/KS - A) ALTERNATIVE 65.10101 - 7075A (DOOWON) 65.10102 - 6012 (105000 - 1740) 65.10101 - 7076A (LUCAS) 65.10102 - 6030 (9135 - 173) 65.10301 - 6172 1-3-4-2 BTDC 13 ± 1¡

Nozzle

105780-0000

Opening pressure: 175 kg/cm2

Nozzle & holder AssÕy

105780-8140

Injection pipe(IDxOD-L)

(B) Engine standard parts

¯6.0 x ¯2.0 - 600 mm

Test oil

ISO4113

Temperature: 40 ± 5 ¡C

Nozzle & holder AssÕy

65.10101-7075A (DOOWON)

Nozzle (¯1.0)

65.10101-7076A (LUCAS)

Opening pressure: 120 kg/cm2

65.10301-6172

¯2.0 x 334 mm

Injection pipe(ID x L) Rack diagram and setting valve at each point Check Rack Point position

Pump speed

(mm)

(rpm)

(A) Test condition for inj. pump

(B) Engine standard parts

(mmHg)

12.5

750

37 ± 1.6

12.0

1200

38.5 ± 1.0

8.2

350

8 ± 1.1

18+30 RACK CAP:APPROX15.0

Injection Q`ty on RIG (mm3 / 1,000st)

Press.

A 12.2 12.0 11.2

0.5 +0.1

8.2 6.9

1325 +10 350 (1000) 1:00 1200+90 -10 (1160)

DC24 (2.4 Liter)

Lubricating System

8. Intake and Exhaust System 8.1. Intake Manifold Intake manifold Check intake manifold head side for flatness. Limit

0.4 mm

EA0M8006

Reassemble To reassemble, follow the disassembly procedure in reverse.

8.2. Exhaust Manifold Inspection and repair Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Limit

0.4 mm

Check manifold head side for flatness

DC24 (2.4 Liter)

Lubricating System

9. Special Tool List No.

Part No.

EF.122-254

Oil seal insert assÕy (Front)

EF.122-256

Oil seal insert assÕy (Rear)

EF.122-252

Pilot bearing puller

EF.122-250

Pilot bearing punch

EF.122-249

Valve spring press

EF.122-264

Crank gear punch

EF.122-177

Valve stem seal punch

EU.2-0525

Cylinder pressure tester adapter

EF.122-266

Piston sleeve

DC24 (2.4 Liter)

Figure

Tool Name

Lubricating System

No.

Part No.

EF.122-260

Cylinder liner insert

EF.122-258

Cylinder liner puller

EU.2-0131

Valve clearance adjust assÕy

60.99901-0027

Feeler gauge

T7610001E

Snap ring plier

T7621010E

Piston ring plier

DC24 (2.4 Liter)

Figure

Tool Name

Lubricating System

Appendix - Engine Assembly(ELFFO)

SB2007E01 M a y. 1 9 9 8

Service Manual Delce Remy CS-121 Series Alternators

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 ÒSafetyÓ section of the Service or Technical Manual. Additional safety precautions are listed in the ÒSafetyÓ 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.

Index Specifications Alternator................................................................. 5

Systems Operation Alternator................................................................. 6 CS-121 Alternator Operation ........................... 6 Alternator Components ............................ 7 Alternator Operation Schematic ............... 9 Introduction ...................................................... 6

Testing And Adjusting Alternator ............................................................... 11 Alternator Output Test ............................ 11 Machine Test .......................................... 11 Troubleshooting..................................................... 10 Troubleshooting Problem List ................ 10 Troubleshooting Problems ..................... 10

Delco Remy Alternators

Index

Specifications Alternator DELCO REMY ALTERNATOR COVERAGE CHART DAEWOO Delco Remy Series Voltage Part No. Part No. 8C5510

1101291

CS-121

BAT

12V

IDAS012B

CS-121 Alternator End View

ALTERNATOR SPECIFICATIONS DAEWOO Part No. Delco Remy Series Voltage Rating Polarity Rotation Test Speed Rated Output (Cold) Output Voltage

2 IDAS011B

Rotor Field Winding Resistance [At 27C(80¡F)] Field Current [At 14.0V or 27.5V and 27C(80¡F)] Stator Winding Resistance Turn On Speed (Max.) Slip Rings (3) : Maximum Runout (TIR) Minimum Diameter Brush Length (Measured On Longest Side) : New Minimum Pulley Nut (2) Torque

CS-121 Alternator Cross-Sectional View

Thru Bolt (1) Torque Terminal Torques : Bat Gnd

Delco Remy Alernators

8C5510 CS-121 12V Neg. Gnd. CW 6500 rpm 61A 14.0L0.5V -

100 L 7 N I m (75 L lb I ft) 3.6 L 0.8 N I m (32 L 7 lb I in) -

Specifications

Systems Operation The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage. This process is done by rotating a direct current (DC) electromagnetic field (rotor) inside a three phase stator. The alternating current and voltage (generated by the stator) are changed to direct current by a three phase, full wave rectifier system using six silicone rectifier diodes. This alternator does not have a diode trio. A solid state regulator is installed in the back of the alternator. Two brushes conduct current through two slip rings to the field coil on the rotor.

Alternator Introduction The CS-121 Delco Remy Alternators have three phase, full-wave, rectified output.

CS-121 Alternator Operation

There is also a capacitor mounted in the back of the alternator. The capacitor protects the rectifier from high voltages. It also suppresses electrical noise through a radio, if equipped. The alternator is connected to the battery through terminal ÒLÓ and the ignition or key start switch for alternator turn-on. Therefore, alternator excitation occurs when the switch is turned on.

IDAS001C

Delco Remy CS-121 Alternator

The alternator is an electrical and mechanical component driven by belt rotation from the engine. It is used to charge the storage battery during engine operation. This alternator is cooled by two fans that are a part of the alternator. The external fan is mounted behind the pulley. The fan pulls air through holes in the back of the alternator. The air exits the front of the alternator, cooling it in the process. The internal fan is mounted on the rotor. This fan pulls air through the holes in the back of the alternator to cool the rectifier bridge and regulator. The air exits the front of the alternator.

Delco Remy Alternators

Systems Operation

Alternator Components 2

6 7 10

IDAS002C

Alternator Components-Inside View of Rear Frame (2) Rear frame. (7) Brush holder. (9) Regulator. (10) Rectifier.

7 The major components of the alternator are stator (4), rotor (3), rectifier (10), regulator (9), brush holder (7) and frames (2) and (5). The CS-121 alternators feature a high ampere output per pound of weight, with a totally new and different regulator. A diode trio is not used. A delta wound stator, rectifier bridge, rotor with slip rings and brushes are electrically similar to the SI series. alternators. The CS stands for Charging System. The 121 denotes the outside diameter in millimeters of the stator laminations. This series of alternators has two fans for cooling the alternator.

8 IDAS013B

Alternator Components-Cross-Sectional View (1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end frame. (6) External fan. (7) Brush holder. (8) Internal fan.

IDAS014B

Stator (4) Stator.

Stator (4) consists of a stator core and coils. As the rotor turns, its varying magnetic field causes the stator coil to produce three phase alternating current (AC).

Delco Remy Alternators

Systems Operation

IDAS003C

Rotor (1) Slip rings. (3) Rotor. (8) Internal fan.

Rotor (3) consists of a core, coils and slip rings (1). The rotor provides the magnetic field between the rotor field winding and the stator. Slip rings (1) provide the surfaces for brush contact. Internal fan (8) pulls air through the rear frame to cool the rectifier bridge and regulator.

IDAS016B

Rectifier (10) Rectifier.

Rectifier (10) contains three positive (+) and three negative (-) diodes to form the full wave rectifier bridge which is connected to the stator. Rectifier (10) changes or rectifies three phase AC to DC.

IDAS015B

Brush Holder (7) Brush holder. (11) Brushes.

Brush holder (7) contains two brushes (11). They contact the two rotating slip rings on the rotor. Current flows to the rotor coil through the brushes and slip rings. There is one positive (+) and one negative (-) brush. The brush material is copper graphite.

IDAS017B

Regulator (9) Regulator.

Regulator (9) controls alternator output. Most regulators limit the alternator voltage to a preset value by controlling the field current. It operates electronically to alternately "turn off" and "turn on" the voltage across the field winding. This regulator switches the field current on and off at fixed frequency of about 400 cycles per second. By varying the on-off time, the correct average field current for proper system voltage control is obtained. The regulator is mounted in the back of the alternator.

Delco Remy Alternators

Systems Operation

Alternator Operation Schematic

The field current is sufficient to cause the alternator to turn on when the engine is started. At engine idle speeds, voltage induced in the stator will cause the stator to supply field current and also output voltage and current at the Bat terminal for the vehicle electrical system.

The integral charging system schematic and explanation that follow indicate the terminals and basic circuitry for the CS-121 series alternator.

SWITCH

INDICATOR LAMP

BATTERY

RESISTOR

The regulator switches the field voltage on and off at a fixed frequency of about 400 cycles per second. Voltage control is obtained by varying the "on-off" time of the field current. Thus, at low speeds, the field may be turned on 90 percent of the time and off 10 percent of the time. This results in a relatively high average field current, which, when combined with the low alternator speed, produces the desired system voltage.

BAT P

As alternator speed increases, less field current is needed to generate the desired system voltage. The duty cycle changes to reduce the average field current. For example, at high engine speeds, the regulator may be on only 10 percent of the time and off 90 percent of the time. This duty cycle will change as operating factors change to provide just the right amount of voltage.

TR1 REGULATOR

FIELD RECTIFIER BRIDGE

Most regulators are temperature compensated to provide the maximum voltage needed for battery charging. As the temperature increases, the voltage setting will decrease. Under cold weather conditions, the regulator will operate at a higher voltage setting to provide the higher voltage required by the battery for charging under these conditions.

STATOR

IDAS018B

The regulator circuitry is designed to perform a special function in the charging system called Load Response Control. Without this function, a change in engine speed may occur at low engine speeds when an electrical load is added to the system. This can happen when the engine is low idle and a fan blower is turned on.

CS-121 Integral Charging System Schematic

When the switch is closed, the indicator lamp turns on and a voltage is applied to the regulator at the "L" terminal to cause transistor TR1 to rapidly "turn on" and "turn off". The transistor will be turned on about 30 percent of the time and turned off 70 percent of the time. The battery will supply field current which will flow into the alternator output or Bat terminal and then through TR1 and the field coil to ground. Field current does not flow through the indicator lamp.

Delco Remy Alternators

Load Response Control Causes the field current and the alternator output current to increase gradually. This avoids changes in engine speed. Instead of instantly supplying the added amperes needed to operate the blower motor, the alternator provides these added amperes over a period of a few seconds. At first, the battery supplies the added load, which is then gradually transferred to the alternator.

Systems Operation

Problem 2: Alternator Charge Rate Is Low Or Not Regular

Testing And Adjusting

Probable Cause:

Troubleshooting

1. Loose Drive Belt For Alternator: Adjust the alternator drive belt. 2. Loose Alternator Drive Pulley: Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct torque shown in Specifications.

Troubleshooting can be difficult. On the page that follows is a list of possible problems. To make a repair to a problem, make reference to the probable cause. This list of problems and probable causes will only give an indication of where a possible problem can be and what repairs are needed. Sometimes more or other repair work is needed beyond the recommendations in the list. Remember that a problem is not normally caused by one part, but by the relation of one part with other parts. This list cannot give all possible problems and probable causes. The serviceman must find the problem and its source, then make the necessary repairs.

5. Rectifier Is Defective: Replace the rectifier.

Troubleshooting Problem List

6. Brushes Are Worn Or Dirty: Install a new brush holder.

1. Alternator Does Not Charge.

Problem 3: Alternator Charges Too Much

2. Alternator Charge Rate Is Low Or Not Regular.

Probable Cause:

3. Alternator Charges Too Much.

1. Alternator Or Regulator Has Loose Connections: Tighten all connections to alternator or regulator.

3. Charging Or Ground Return Circuit Or Battery Connections Defective: Inspect all cables and connections. Clean and tighten all connections. Replace defective parts. 4. Regulator Is Defective: Replace the regulator.

4. Alternator Is Noisy.

2. Regulator Is Defective: Install a new regulator.

Troubleshooting Problems

Problem 4: Alternator Is Noisy

Problem 1: Alternator Does Not Charge

Probable Cause:

1. Drive Belt For Alternator Is Worn Or Defective: Install a new drive belt for the alternator.

1. Loose Drive Belt For Alternator : Adjust the alternator drive belt.

2. Loose Alternator Drive Pulley: Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct torque shown in Specifications.

2. Loose Alternator Drive Pulley : Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct torque shown in Specifications.

3. Drive Belt And Drive Pulley For Alternator Are Not In Alignment: Make an adjustment to put the drive belt and drive pulley in correct alignment.

3. Charging Or Ground Return Circuit Or Battery Connection Are Defective: Inspect all cables and connections. Clean and tighten all connections. Replace defective parts.

4. Alternator Bearings Are Worn: Install new bearings in the alternator.

4. Rotor Field Winding Or Regulator Is Defective: Install a new rotor or regulator.

Delco Remy Alternators

Testing and Adjusting

Alternator Alternator Output Test NOTE: If the CS-121 alternator fails this test, it must be replaced. It is only serviced as a complete unit.

Tools Needed Digital Multimeter or Equivalent AC/DC Clamp-On Ammeter

1 1

Machine Test 1. Put the multimeter positive (+) lead on the Bat terminal of the alternator. Put the negative (-) lead on the ground terminal or the frame of the alternator. Put the clamp-on ammeter around the positive output wire of the alternator. 2. Turn off all electrical accessories. With the fuel off, crank the engine for 30 seconds. Wait two minutes to let the starter cool. If the system appears to be up to specifications, crank the engine again for 30 seconds. NOTE: Cranking the engine for 30 seconds partially discharges the batteries in order to do a charging test. If the battery is already low in charge, skip this step. Jump-start engine or charge as required. 3. Start the engine and run at approximately 1/2 throttle. 4. Immediately check output current. This initial charging current should be equal to or greater than the full output current shown below: 5. Within approximately 10 minutes at 1/2 throttle (possible longer, depending upon battery size, condition and alternator rating), the alternator output voltage should be as follows to indicate the alternator is performing within spec. See the Fault Conditions And Possible Causes Chart. 12V System ................................. 14.0L0.5V 6. The charging current during this period should taper off the less than approximately 10 Amps, depending again upon battery and alternator capacities. See the Fault Conditions And Possible Causes Chart.

Delco Remy Alternators

Testing and Adjusting

FAULT CONDITIONS AND POSSIBLE CAUSES CHART Current At Start-Up

Voltage After About 10 Min. Is Below Spec.

Voltage After About 10 Min. Is In Spec.

Below Specification.

Repair alternator (defective regulator, open stator phase, and/or rectifier). Check ignition or key start switch circuit.*

Reached Specification and then tapered off.

Repair alternator (defective regulator).

Turn on all accessories. If voltage drops below spec., repair alternator (open rectifier and/or stator phase). Alternator and battery in spec. Turn on all accessories to verify. Voltage must stay in spec. Alternator in spec. Check battery.

Exceeds Specification Check battery. and stays high.

Voltage After About 10 Min. Is Above Spec. -

Repair alternator (shorted regulator). Repair alternator (shorted regulator). Also check battery for possible damage.

* Some models that have the CS-121 alternator do not have a resistor in the ignition of key start switch circuit, if the indicator lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the alternator may not have any output. This is because the battery may be too low to send current to the alternator. The alternator needs current to start the charging process.

Delco Remy Alternators

Testing and Adjusting

SB4050E00 Oct. 2000

Service Manual CS-105D Series Alternator

Index Specifications Alternator................................................................. 5

Systems Operation Alternator................................................................. 6 CS-105D Alternator Operation......................... 6 Alternator Components ............................ 7 Alternator Operation Schematic ............... 9 Introduction ...................................................... 6

CS-105D Alternator

Index

Specifications Alternator DELCO REMY ALTERNATOR COVERAGE CHART DAEWOO Supplier Series Voltage Part No. Part No. A274017

219299

CS-105D

12V

CS-105D Alternator End View

ALTERNATOR SPECIFICATIONS DAEWOO Part No. Series Voltage Rating Polarity Rotation Test Speed Rated Output (Cold) Output Voltage Rotor Field Winding Resistance [At 27¡C(80¡F)] Field Current [At 14.0V or 27.5V and 27¡C(80¡F)] Stator Winding Resistance Turn On Speed (Max.) Slip Rings (3) : Maximum Runout (TIR) Minimum Diameter Brush Length (Measured On Longest Side) : New Minimum Pulley Nut (2) Torque

CS-105D Alternator View

2.97 ~ 3.05 OHMS 0.08 17.0 L 0.3 mm

Thru Bolt (1) Torque

100 L 10 N I m (900 L 90 lb I in) -

Terminal Torques : Bat

10 L 1.0 N I m (90 L 10 lb I in)

Gnd

CS-105D Alternator

A274017 CS-105D 12V Neg. Gnd. CW 6500 rpm 50A 14.5 L 0.3V

Specifications

Alternator Introduction The CS-105D Alternators have three phase, full-wave, rectified output.

CS-105D Alternator Operation

CS-105D Alternator

Systems Operation

Alternator Components 10 7

2 9

P0004349

Alternator Components-Inside View of Rear Frame (2) Rear frame. (7) Brush holder. (9) Regulator. (10) Rectifier.

The major components of the alternator are stator (4), rotor (3), rectifier (10), regulator (9), brush holder (7) and frames (2) and (5). The CS-105D alternators feature a high ampere output per pound of weight, with a totally new and different regulator. A diode trio is not used. A delta wound stator, rectifier bridge, rotor with slip rings and brushes are electrically similar to the SI series. alternators. The CS stands for Charging System. The 105 denotes the outside diameter in millimeters of the stator laminations. This series of alternators has two fans for cooling the alternator.

Alternator Components-Cross-Sectional View (1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end frame. (6) External fan. (7) Brush holder. (8) Internal fan.

IDAS014B

Stator (4) Stator.

Stator (4) consists of a stator core and coils. As the rotor turns, its varying magnetic field causes the stator coil to produce three phase alternating current (AC).

CS-105D Alternator

Systems Operation

10 1 3

P0004350

P0004349

Rotor (1) Slip rings. (3) Rotor. (8) Internal fan.

Rectifier (10) Rectifier.

P0004349

Regulator (9) Regulator.

11 IDAS015B

Brush Holder (7) Brush holder. (11) Brushes.

CS-105D Alternator

Systems Operation

Alternator Operation Schematic The field current is sufficient to cause the alternator to turn on when the engine is started. At engine idle speeds, voltage induced in the stator will cause the stator to supply field current and also output voltage and current at the Bat terminal for the vehicle electrical system.

The integral charging system schematic and explanation that follow indicate the terminals and basic circuitry for the CS-105D series alternator.

On some models, a resistor is used in parallel with the indicator lamp. This feature insures alternator turn-on in the event the lamp burns out. The zener diodes in the rectifier bridge protect the system against high voltages in the stator. The regulator switches the field voltage on and off at a fixed frequency of about 400 cycles per second. Voltage control is obtained by varying the "on-off" time of the field current. Thus, at low speeds, the field may be turned on 90 percent of the time and off 10 percent of the time. This results in a relatively high average field current, which, when combined with the low alternator speed, produces the desired system voltage. As alternator speed increases, less field current is needed to generate the desired system voltage. The duty cycle changes to reduce the average field current. For example, at high engine speeds, the regulator may be on only 10 percent of the time and off 90 percent of the time. This duty cycle will change as operating factors change to provide just the right amount of voltage.

CS-105D Integral Charging System Schematic

When the switch is closed, the indicator lamp turns on and a voltage is applied to the regulator at the "L" terminal to cause transistor to rapidly "turn on" and "turn off". The transistor will be turned on about 30 percent of the time and turned off 70 percent of the time. The battery will supply field current which will flow into the alternator output or Bat terminal and then through transistor and the field coil to ground. Field current does not flow through the indicator lamp.