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G424 Service Manual

Engine System

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ENGINE SYSTEM

Engine Overview

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 V-type
valves and high efficient combustion is intended.

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.

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Summary of Contents for G424 Gasoline

Page 1: ...Service Manual G424 Gasoline LP Engine G424 LP Engine Low Emission Version G20E 3 G25E 3 G30E 3 GC20E 3 GC25E 3 GC30E 3 SB2215E01 O c t 2 0 0 1 ...

Page 2: ...llowing symbol 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...

Page 3: ...elay Test 35 Start Motor 36 Operation 36 Removal and Installation 39 Disassembly and Reassembly 42 CHARGING SYSTEM 47 General Description 47 Alternator 47 IGNITION SYSTEM 50 Breakerless Ignition System 50 Distributor 51 Removal and Installation 54 Distributor disassembly and reassembly 56 GASOLINE FUEL SYSTEM 58 General Description 58 Geasoline Carburetor Operation 59 Removal and Installation 64 G...

Page 4: ...rature Sender 119 BASE ENGINE SERVICE PROCEDURE 120 Timing Belt 120 Intake Manifold 129 Exhaust Manifold and Water Pump 130 Rocker Arms and Camshaft 133 Cylinder Head and Valves 139 Front Case and Oil Pan 145 Piston and Connecting Rod 154 Crankshaft and Cylinder Block 162 ADJUSTMENT AND TROUBLESHOOTING 169 Adjustment 169 Valve Clearnce Adjustment 169 Ignition Timing Adjustment 169 Idle Speed Adjus...

Page 5: ...r 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 4 Classification of Major Maintenance Service points When there are major points relative to maintenance and servicing procedures such as essential maintenance and servic...

Page 6: ...tter 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 Operating procedures cautions etc on removal installation disassembly and reassembly are described 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 ...

Page 7: ... marks to the parts where no function is adversely affected 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 Tightening Torque Tighten the part properly to specified torque Sealant Use specified brand of sealant Use of sealant other than specified sealant may cause water or oil leaks ...

Page 8: ...nd Grease Before reassembly apply specified oil to the rotating and sliding parts 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 1EN0022 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 damage...

Page 9: ...e models and numbers Indication of engine model and number The engine model and serial number are stamped on the right side of cylinder block surface Engine model Fuel type G424 Gasoline LPG LPG Low Emission Version Engine model Engine number 4G64 AA0001 to YY9999 ...

Page 10: ...er outlet bolt Intake manifold bolt nut Exhaust Oil level gauge guide bolt manifold Heat protector bolt Exhaust manifold nut Water inlet pipe bolt Water pump bolt Rocker arm Rocker cover bolt and camshaft Bearing cap bolt M8 B 25 M6 B 65 Cylinder head valve Cylinder head bolt Item Remarks Torque kg m lb ft N m 0 9 6 5 9 2 5 18 1 25 2 5 18 1 25 1 2 8 7 12 1 1 8 0 11 0 9 6 5 9 4 9 35 4 48 4 9 35 4 4...

Page 11: ...nut connecting rod Flywheel bolt Rear plate bolt Crankshaft cylinder block Rear plate cover Oil seal case bolt Bearing cap bolt Starter motor Starter motor bolt Item Remarks Torque kg m lb ft N m 4 0 28 9 39 0 7 5 1 7 1 9 13 7 19 1 0 7 2 10 2 4 17 4 24 3 7 26 8 36 45 32 5 44 1 9 13 7 19 1 7 12 3 17 1 0 7 2 10 2 4 17 4 24 13 5 97 6 132 0 9 6 5 9 6 0 43 4 59 1 1 8 0 11 1 1 8 0 11 2 7 19 5 26 2 0 kg ...

Page 12: ...2 30 4 41 7 3 52 8 72 Head mark 7 0 5 0 5 3 6 0 9 6 5 8 8 2 2 15 9 22 4 5 32 5 44 8 6 60 0 81 14 0 101 3 137 Head mark 10 1 2 8 7 12 3 0 21 7 29 6 0 43 4 59 10 7 77 4 105 14 5 104 9 142 Head mark 4 1 3 9 4 13 2 6 18 8 25 4 7 34 0 46 Head mark 7 0 6 4 3 5 9 1 0 7 2 9 8 2 4 17 4 24 5 0 36 2 49 9 5 68 7 93 New Tightening Method By Use of Bolts to be Tightened in Plastic Area A new type of bolts to be...

Page 13: ... 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 speci...

Page 14: ...f lubricating oil cm3 liter U S gal Quantity of coolant cm3 liter U S gal IDLE RPM LOW RPM 700 L 25 HIGH RPM 2700 L 50 Water cooled 4 cycle gasoline powered and L P G powered 4 in line Semi spherical OHC 2350 2350 143 86 5 B 100 3 41 B 3 94 146 322 8 6 1128 11 5 163 5 12 BTDC 40 ABDC 54 BBDC 6 ATDC 1 3 4 2 4 740 gasoline 9 740 L P G 4 740 dual fuel Mechanical diaphragm type Down draft type Air flo...

Page 15: ... 63 1 8740 to 1 8752 40 30 to 40 33 1 5866 to 1 5878 40 60 to 40 63 1 5984 to 1 5996 41 62 1 6386 41 62 1 6386 33 935 to 33 950 1 33602 to 1 33661 0 05 to 0 09 0 0020 to 0 0035 106 6 4 197 105 2 4 142 42 05 1 6555 7 960 to 7 975 0 31339 to 0 31398 7 930 to 7 950 0 31220 to 0 31299 45 to 45 5 1 2 0 047 2 0 0 079 0 025 to 0 058 0 00098 to 0 00228 0 050 to 0 088 0 00197 to 0 00346 48 0 1 89 176 5N 18...

Page 16: ...o 0 40 0 0098 to 0 0157 0 45 to 0 60 0 0177 to 0 0236 0 20 to 0 60 0 0079 to 0 0236 0 03 to 0 07 0 0012 to 0 0028 0 03 to 0 07 0 0012 to 0 0028 22 002 to 22 005 0 86622 to 0 86634 7350 to 17160 750 to 1750 1650 to 3860 149 9 to 150 0 5 902 to 5 906 0 05 0 0020 0 10 0 0039 0 10 to 0 25 0 0039 to 0 0098 0 05 to 0 18 0 0020 to 0 0071 56 982 to 57 000 2 24338 to 2 24409 44 985 to 45 000 1 77106 to 1 7...

Page 17: ...ure C F Valve lift Oil Pressure Low Idle 50 kPa 7psi High Idle 450 kPa 65psi 1 2 11 0 90 or less 3000 29 4 1 16 0 05 0 0020 0 5 0 020 0 5 to 2 0 0 020 to 0 079 0 1000 20 5000 0 80 23 280 1 08 to 1 32 22 1 to 29 9 0 7 to 0 8 0 028 to 0 031 82 180 95 203 8 0 31 or more Starter motor Distributor Ignitio n coil Spark plug Tahermostat Standard value Item Remarks Limit 28 8 1 13 0 1 0 0039 0 2 0 008 Wea...

Page 18: ...ick To ensure that you are not getting a false reading make sure the following steps are taken before checking the oil level 1 Stop engine if in use 2 Allow sufficient time approximately 2 minutes for the oil to drain back into the oil pan 3 Remove dipstick Wipe clean and reinstall Push dipstick all the way into the dipstick tube 4 Remove dipstick and note the oil level 5 Oil level must be between...

Page 19: ...vel should be equal to the COLD mark on the coolant recovery tank Periodically remove the cooling system pressure cap and check coolant level inside system The coolant level should be equal to the sealing surface of the pressure cap If level is low replace pressure cap and repair any all other leaks On closed systems visually inspect the coolant recovery tank and hoses for physical damage On open ...

Page 20: ...al 6 for damage Replace it if necessary 7 Install the filter element 2 spring 3 magnet 4 and cover 5 on bottom cover 1 Align the scribe line on the covers 8 Install the cover retaining screws Tighten the screws in a sequence opposite each other 9 Open the fuel valve by slowly turning the valve counterclockwise 10 Crank the engine only enough to produce a vacuum at the fuelock Turn the ignition key...

Page 21: ...Gasoline fuel system section Inspect Pressure Regulator Vaporizer See pressure regulator vaporizer in LP fuel system section Inspect LP Mixer Standard LP Truck See LP mixer in LP fuel system section Inspect Variable Venturi Air Fuel Mixer Low Emission LP Truck See Variable Venturi Air Fuel Mixer in LP fuel system Low emission version section Inspect Complete Exhaust System for Leaks Damage Perform...

Page 22: ... Fuel Lock Off Filter Section Replace LP fuel filter element O Replce gasoline fuel filter O Inspect lock off and filter for fuel leaks O Ensure lock off stops fuel flow when engine is off O Pressure Regulator Section Test regulator pressures O Inspect pressure regulator for oil build up O Inspect pressure regulator assembly for fuel coolant leaks O Carburetor Section Check for air leaks in filter...

Page 23: ... skirt system The cylinder heads have hemisphere combustion chambers are of cross flow type arranged with V type valves and high efficient combustion is intended 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 ...

Page 24: ...G424 Service Manual Engine System 23 Gasoline Engine ...

Page 25: ...G424 Service Manual Engine System 24 LPG Engine Low Emission Version ...

Page 26: ... 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 ...

Page 27: ...vibromotive moment in the rolling direction thus making possible quieter operation of the vehicle The two silent shafts are arranged as shown in the 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 t...

Page 28: ...o zero 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 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 3 At end of Valve Lif...

Page 29: ...System 28 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 Gasoline Engine ...

Page 30: ...G424 Service Manual Engine System 29 LPG Engine Low Emission Version ...

Page 31: ...e System 30 Electrical System 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 Wiring Diagram Gasoline Engine ...

Page 32: ...G424 Service Manual Engine System 31 Wiring Diagram LPG Engine Low Emission Version ...

Page 33: ...the solenoid close the circuit between the battery and the starting motor just before the pinion engages the ring gear This causes the starting motor to rotate This type of motor turn on is a positive shift starting motor When the engine begins to run the overrunning clutch portion of the pinion drive prevents damage to the armature caused by excessive speeds The clutch does this by breaking the m...

Page 34: ...5 to 20 amps the start relay can easily switch this load The starting motor solenoid has two functions 1 Engages the pinion with flywheel 2 Is a high current switch rated about 1000 amps that actually turns on the starting motor The starting motor solenoid has two coils Pull in coil W draws about 40 amps and hold in coil X requires about 5 amps The instant the start relay closes both coils W and X...

Page 35: ... starting motor 3 Measure current draw on the battery cable between the battery and the starting motor solenoid with the clamp on ammeter The maximum current draw allowed is 350 Amp At temperatures below 27 C 80 F the voltage will be less and the current draw will be higer If current draw is too much the starting motor has a problem and must be removed for repair or replacement NOTE If voltage at ...

Page 36: ...ent IIf it does not crank check for blocked engagement of the pinion and flywheel ring gear NOTE Blocked engagement and open solenoid contacts will give the same electrical symptoms Start Relay Tests D167422 Relay 1 Put the multimeter on the 200 ohm scale 2 Put the multimeter lead to the 85 and 86 terminals 3 The indication on the meter must be 82 L 5 ohms If the indication is not correct the star...

Page 37: ... is transmitted to the pinion gear Operation 1 When the ignition key IG SW is turned to the ST 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 starter s brush commutator and armature and then the armature begins to gently turn Planetary Gear Reduction Drive Type ...

Page 38: ...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 magn...

Page 39: ...n 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 charac...

Page 40: ...motor body positive terminal to terminal S Caution This test must be performed quickly in less than 10 seconds to prevent the coil from burning out 3 Set switch to ON 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 magn...

Page 41: ...med quickly in less than 10 seconds to prevent coil from burning 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 Cauti...

Page 42: ...l stained metal rotates at too low speeds Friction between armature core and pole piece Motor output torque is insufficient Armature coil and or field coil not properly grounded Armature coil short circuited Current is too large and motor does Electromagnetic switch not properly grounded not rotate at all Armature coil and or field coil not properly grounded Seizure of metal No current is availabl...

Page 43: ...ic switch 3 Screw 4 Screw 5 Rear bracket 6 Brush holder 7 Brush 8 Rear bearing 9 Armature 10 Yoke assembly 11 Ball 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 A A C C A B B 6EN1917 ...

Page 44: ...pliers and then remove stop ring and overrunning clutch 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 mo...

Page 45: ...ted 0 2 mm 0 008 in 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 ri...

Page 46: ... 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 6 Armature Coil Ground Test Check the insulation between ground commutator segment and the armature coil core If there should be no continuity 7 Armature Coil Open Circuit Check ...

Page 47: ...24 Service Manual Starting System 46 Reassembly Service Points A Stop ring snap ring Installation Using a suitable pulling tool pull overrunning clutch stop ring over snap ring Stop Stop ring Overrunning ...

Page 48: ...r are changed to direct current by a three phase full wave rectifier system using six silicone rectifier diodes Some alternators have three exciter diodes or a diode trio They rectify the current needed to start the charging process Direct current flows to the alternator output terminal A solid state regulator is installed in or on the back of the alternator Two brushes conduct current through two...

Page 49: ...tage 12 volts Polarity is negative ground Rotation is clockwise Output at 6500 rpm cold 61 amps Output voltage 14 0 L 0 5 volts 1 Torque for battery terminal nut 3 6 L 0 8 NIm 32 L 7 lbIin 2 Torque for pulley nut 100 L 7 NIm 75 L 5 lbIft D187478 IDES043S IDES044S IDES045S 1 2 1 ...

Page 50: ...ator NOTE Hood seat and dry air cleaner have been removed for photographic purposes 1 Disconnect wire 1 and wire 2 2 Remove bolt and washer 3 and remove belt 4 3 Remove alternator 5 NOTE For the installation of the alternator reverse the removal steps 1 2 4 3 5 ...

Page 51: ...to permit battery current flow through the ignition system These components must have closed current connections to complete the operation of the ignition circuit Coil 3 and spark plugs 5 are of the standard type The ignition coil changes the low voltage current into high voltage current to make a spark at the gap of the spark plug The coil has two windings around a soft iron core The primary has ...

Page 52: ...m 51 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 ...

Page 53: ...s 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 ...

Page 54: ...owing 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 ...

Page 55: ...anual Ignition System 54 Removal and Installation Removal steps 1 Drive belt 2 Water pump pulley 3 Crankshaft pulley 4 Spark plug cable 5 Spark plug 6 High tension cable 7 Vacuum 8 Ignition 9 Harness 10 Distributor A ...

Page 56: ...he caps and covering for cracks 2 Measure the resistance values Standard value 16 kΩ m High voltage terminal Installation Service Points Distributor installation 1 Turn the crankshaft so that No 1 cylinder is at top dead center 2 Aligh the distributor housing and gear mating marks 3 Shift 1 tooth of gear to meet the pin with the mating mark of distributor housing as shown in the illustration 4 Ins...

Page 57: ...sassembly and Reassembly Disassembly steps 1 Distributor cap 2 Rotor 3 Cover 4 Signal rotor 5 Pickup coil assembly 6 Ignitor 7 Heat sink 8 Breaker assembly 9 Snap ring 10 Vacuum control 11 Connector assembly 12 O ring 13 Distributor housing A ...

Page 58: ...ndard value 420 to 540Ω 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 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 Signal rotor ...

Page 59: ...his air and fuel mixture then goes to the inlet manifold The air and fuel mixture takes in heat and is completely changed to vapor as it goes through the inlet manifold to the combustion chamber of each cylinder The fuel pump keeps a supply of fuel to the carburetor at all conditions of operation and speeds of operation The output of the fuel pump is controlled by the needs of the engine GASOLINE ...

Page 60: ...amber 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 Gasol...

Page 61: ...at 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 ...

Page 62: ...e 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 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...

Page 63: ...rged 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 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 ...

Page 64: ... 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 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 ref...

Page 65: ...tem 64 Removal and Installation 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 A B A 6EN1893 ...

Page 66: ...emoval of the pump Installation Service Points A 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 p...

Page 67: ...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...

Page 68: ...id applying a strong force to the plastic grommet of the rod fit in hole B 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 Don t tilt the main body as the pump discharge weight and the re...

Page 69: ...edle 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 C...

Page 70: ... 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 with...

Page 71: ...k ball and weight C Float float pin installation After the float and float pin have been installed make sure that the float is in a level position Strangler spring setting positions If the strangler spring of the choke valve shaft is out of position set it correctly in the positions shown in the illustration Size symbol Weight Check ball Hole A Spring Setting Positions Hole B Hole C 3rd Stage 2nd ...

Page 72: ...crew direction Clearance Remarks of rotation Clockwise Increases Fast idle speed increases Counterclockwise Decreases Fast idle speed decreases 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...

Page 73: ...G424 Service Manual Gasoline Fuel System 72 6EN0861 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 ...

Page 74: ...el to a vapor The fuel receives heat in the converter from the LP Fuel System Components 1 Converter 2 Fuelock 3 Carburetor 4 Coolant ontlet line 5 Coolant inlet line 6 Balance hose 7 LP fuel line to carburetor engine coolant that flows in line 5 and out line 4 Carburetor vacuum activates the converters operation and the fuel flows to the carburetor through line 7 From carburetor 3 the vapor fuel ...

Page 75: ...ar the fuel tank It cleans the fuel before it gets to the fuelock and converter Converter Converter Components 1 LP fuel inlet opening 2 Primary regulator valve 3 Primary valve pin 4 Fulcrum 5 Primary diaphragm with lever 6 Cover 7 Secondary diaphragm 8 LP fuel outlet opening Converter Vaporized Chamber 1 LP fuel inlet opening 2 Primary regulator valve 9 Vaporizing chamber 10 Vapor fuel outlet ope...

Page 76: ...ith the assistance of primary regulator spring 13 When primary regulator valve 2 is off its seat fuel is permitted to flow into vaporizing chambers 9 The fuel flows around and through the passages of the vaporizing chambers while the heat through the converter body is being taken in by the fuel which causes fuel to vaporize The heat is a product of the engine coolant that goes in opening 12 and ou...

Page 77: ...ere pressure vacuum in the carburetor The vacuum is felt through passage 5 in air valve 2 and in the upper side of diaphragm 3 As a result the atmospheric pressure flows in the carburetor and pushes up on the diaphragm Diaphragm 3 is lifted against the down pressure of metering spring 4 The vacuum that is felt on diaphragm 3 is variable according to engine speed and the position of throttle valve ...

Page 78: ...ent Low Idle Speed Adjustment Low Idle Speed Adjustment 1 Idle speed screw 1 Make sure the setting for ignition timing is correct See Ignition Timing 2 Connect the Electrical System Analyzer as shown in Engine RPM Check in the Testing And Adjusting 3 Start and run the engine until the engine reaches normal operating temperature 4 Adjust screw 1 to get the correct low idle speed 5 Check low idle sp...

Page 79: ...djustment must be done with the engine in a load condition A CO meter or exhaust ana lyzer testing equipment must be used to measure the CO content in the exhaust fumes To adjust the power mixture turn knob either toward the L lean or R rich fuel flow mixture for a 1 0 to 1 5 percent CO indi cation on the test equipment Start the adjustment with knob in the middle position NOTE A lift truck that d...

Page 80: ...this method after repair completion on the fuel system or after the fuel system has been connected together again Fuel Filter Check An indication of a dirty fuel filter that needs replacement is when frost freezing vapor is seen on the filter housing or the housing is very cold to touch A dirty filter causes a fuel pressure drop across the filter the fuel becomes a vapor and freezes In this condit...

Page 81: ...edure that follows 1 Put a plug in the fuel outlet openings 2 Put compressed air in the fuel inlet openings up to a maximum of 725 kPa 120 psi 3 Wait ten minutes and then check the converter or fuelock for air leaks Listen for air to come out around gaskets or seals 4 If there are no air leaks then the converter is good 5 If air does come out then the converter will have to be disassembled to find...

Page 82: ...10 3kPa 1 5 psi 12 The secondary gauge should read approximately negative0 1kPa 0 5 in H2O to negative 2 5kPa 10 in H2O 13 If readings are out of specification as required LP Gas Converter Inspect Converter for Oil Accumulation 1 Start engine 2 Close the liquid outlet valve in the fuel storage container 3 Run engine out of fuel 4 Remove the regulator secondary cover 5 Remove secondary diaphragm 6 ...

Page 83: ...urn spring 2 Accel wire assembly 3 Return spring support 4 LPG carburetor 5 Throttle chamber gasket 6 Throttle body 7 Carburetor gasket 8 Air governor 9 Air governor gasket 10 Fuel pump cover Disassembly Assembly LPG Carburetor Remove Install LP Gas Carburetor 6EN1890 ...

Page 84: ...r valve ring from the inner carburetor body 4 Remove power mixture screw 8 idle mixture screw 9 and the spring Remove four screws 10 Remove throttle body assembly 11 and the gasket 5 Remove gasket 12 6 Remove nut 13 7 Loosen the bolt and remove stop 16 8 Remove two screws 14 Remove throttle plate 15 9 Remove shaft assembly 17 from the throttle body P0004821 2 1 P0004822 3 4 5 6 P0003001 5 6 7 P000...

Page 85: ...l the two screws 5 Assemble in reverse order of disassembly NOTE Air valve diaphragm must be oriented with position mark pointing toward LPG inlet 6 See Testing Adjusting for proper test and adjust procedures End By a Install LP Gas Carburetor LP Gas Fuelock Remove Install LP Gas Fuelock 1 Disconnect fuel lines 1 2 Disconnect wire 2 3 Remove fuelock 3 NOTE For the installation of the LP gas fueloc...

Page 86: ... elbow on LP converter the elbow must be installed on the converter keeping the minimum distance shown in the figure to prevent contact with the secondary diaphragm Disassembly of LP Gas Converter 1 Remove six screws 1 cover 2 and diaphragm 3 from the converter 2 Remove screw 4 secondary lever 5 the seat the pin and the spring 6 3 Turn the converter body around remove the seven screws 7 back cover...

Page 87: ...nt chamber gasket 4 Clean regulator castings with parts cleaning colvent and inspect It is very rare for the castings to require replacement 5 Reassemble regulator 6 Use an anti seize compound on screws 7 Use an approved pipe sealant on fittings NOTE For assembly of the LP gas converter reverse the disassembly steps 1 Screw 6 2 Cover Assembly Secondary 3 Diaphragm Assembly Secondary 4 Screw 5 Leve...

Page 88: ...nent to the controller The controller then calculates any correction that may need to be made to the air fuel ratio The controller makes these corrections to the air fuel ratio by manipulating the inlet fuel pressure to the carburetor through the fuel control valve FCV Reducing the fuel pressure leans the air fuel mixfure Increasing the fuel pressure richens the air fuel mixture The controller use...

Page 89: ...R MUFFLER GOVERNER ENGINE Open loop LP Carburetion System G424 LP engine Closed loop LP Carburetion System G424 LP engine low emission version FUELOCK VALVE LP CONVERTER LP CARBURETOR GOVERNER ENGINE CATALYTIC MUFFLER TACHO SENSOR INTAKE BOOST OXYGEN SENSOR ENGINE CONTROL UNIT ECU FUEL CONTROL VALVE ...

Page 90: ...air valve vacuum chamber 8 through four vacuum transfer ports 9 in the air valve 3 A pressure force imbalance begins to build across the air valve diaphragm 5 between the air valve vacuum chamber 8 and atmospheric pressure below the diaphragm 10 As the negative pressure in the air valve vacuum chamber 8 reaches setting value of water column the air valve 3 begins to lift against the pressure of th...

Page 91: ...um is applied to the port 2 unit respponds and closes the electriccal contacts 1 so that current may pass Vacuum Switch 1 Electrical 2 Vacuum port 3 Main body The vacuum switch is a simple diaphragm unit consisting of a main body 3 housing a diaphragm spring two electrical connectors 1 and a vacuum port connection 2 The unit is normally open i e the electrical connectors 1 are not common when no v...

Page 92: ... heat exchanger chamber of the regulator 4 This heat is replaced by engine coolant which is piped through passage 12 in the heat exchanger section of the regulator Fuel will not flow through the regulator to the carburetor until a negative pressure signal is received When the engine is cranking or running a negative pressure signal is generated by the carburetor This negative pressure signal is co...

Page 93: ...e valve opens and connects the vaporizer secondary atmospheric vent chamber port 2 with the carburetor will provide a vacuum signal AVV which is therefore pulsed into the vaporizer secondary chamber when port 1 and 2 are connected i e when the valve is energized Fuel Lock Off 1 Solenoid coil 2 Fuel inlet connection 3 Fuel outlet connection 4 Electrical connector The fuel lock off unit is a direct ...

Page 94: ...nts is as follows If the EGO voltage is below 5 V considered a lean condition the controller steps FCV duty cycle to a lower value then begins decreasing the FCV duty cycle at a constant rate This decreases the flow of air valve vacuum AVV through the FCV to the secondary reference chamber of the fuel pressure regulator sometimes referred to as a vaporizer This vacuum is depleted at a relatively c...

Page 95: ...centration cell is characterized by a sharp change of the output voltage in the vicinity of the stoichiometric air fuel ratio Using such characteristics the oxygen sensor senses the oxygen concentration in the exhaust gas and feeds it to the engine control unit The engine control unit then determines if the air fuel ratio is richer or leaner as compared to the stoichiometric ratio and provides fee...

Page 96: ...ide the catalytic muffler contains a three way catalyst section 3 as well as sound dampening and spark arresting features The three way catalyst section 3 consists of a honeycomb coated with a mixture of platinum palladium and rhodium The hot exhaust gases enter the catalytic muffler through the inlet 1 Next the hot exhaust gases flow through the catalyst section 3 where an oxidation and reduction...

Page 97: ... 4 5 Remove air valve 2 and spring 3 6 Clean air valve with warm soapy water 7 Clean mixer throat with approved carburetor cleaner 8 Inspect air valve and mixer throat for wear repair replace as required 9 When reassembling mixer locate the notch on air gas valve diaphragm to point to fuel inlet 10 Open the fule storage container liquid outlet valve solwly 11 Check for leaks 12 start engine and ve...

Page 98: ...d vacuum pump to the nipple of the vacuum switch 2 Using a vacuum pump vacuum 0 7 or more kPa is applied to a vacuum sensor and the existence of continuity between sensor terminals is checked 3 If there is an abnormality replace the vacuum switch Inspection of Vacuum Switch MAP 1 Connect a hand vacuum pump to the nipple of the vacuum switch 2 Using a vacuum pump vacuum 24 or more kPa is applied to...

Page 99: ...tate where engine is poerated disconnent the oxygen sensor connector and connect a voltmeter Caution The right measurement cannot be pertormed if oxygen sensor connector is separated before engine starting 3 Measure the oxygen sensor output voltage Standard value 0 6 1 0V 4 If there is a deviation from the standard value replace the oxygen sensor Blue code White code Oxygen sensor side ...

Page 100: ...Emission Version 99 Disassembly Assembly LPG Carburetor Removal and Installation of LP Gas Carburetor Removal steps 1 Bracket Accel Wire 2 LPG Carburetor 3 Carburetor Gasket 4 Air Governor 5 Governor Gasket 6 Fuel pump Cover 7 Bolt 6EN2143 7 ...

Page 101: ...w Emission Version 100 Disassembly Assembly of LP Gas Carburetor Removal steps 1 Bolt 2 LPG mixer 3 Gasket 4 Vacuum switch 5 Fitting 6 Vacuum switch MAP 7 Idle adjustment screw 8 Idle adjustment screw spring 9 Throttle body assembly 6EN2147 ...

Page 102: ...ose 3 Vacuum hose 4 Fuel control valve 5 LPG shut off valve assembly 6 Balance hose 7 Check valve elbow fitting 8 Balance hose 9 Vacuum terminal 10 Balance hose 11 Jet 12 Elbow fitting 13 Elbow fitting 14 Fuel outlet plug 15 Bolt washer assembly 16 Converter Disassemble Assemble of LP Gas Converter See Disassembly Assembly of LP Fuel System Section 6EN2148 ...

Page 103: ... to the inlet manifold and is changed to a vapor It then goes to the combustion chamber of each cylinder NOTE Refer to the topics Gasoline Fuel System and Liquid Petroleum Fuel System for the operation of the components not explained here To change from gasoline to LP fuel selector switch 9 should first be put in the OFF position This is done to allow the gasoline in the line and the carburetor to...

Page 104: ...hrottle 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 2 Auxiliary operation The throttle plate openin...

Page 105: ... 13 Stabilizer piston 14 Piston shaft 15 Governor body A A A B Disassembly Service Points Caution Since the air governor has been adjusted and sealed in the manufacturer s 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 i...

Page 106: ...e shaft hole of the governor body Avoid cleaning the body in gasoline or any other solvent 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 A Adjusting screw and nut setting When assembling the air governor separately from the engine te...

Page 107: ... 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 OIl Filter Cam shaft Oil pressure switch Oil filter Oil pump Oil pickup Oil pan Crankshaft ...

Page 108: ...50 F it is recommended to change engine oil to SAE 5W 30 for that application Synthetic Oils Synthetic engine oils are not recommended for use in G424 Engine Synthetics may offer advantages in cold temperature pumpability and high temperature oxidation resistance However synthetic oils have not proven to provide operational or economic benefits over conventional petroleum based oils in G424 Engine...

Page 109: ...he crankcase 2 Defect in the oil pressure indicator light or oil pressure sensor unit 3 Restriction to oil pump screen 4 Leakage at the oil line connections 5 Worn connecting rod or main bearings Worn gears in the oil pump 6 Oil pressure relief valve worn or stuck in the OPEN position 7 Oil filter bypass valve stuck open Oil filter is restricted Replace oil filter High Oil Pressure Oil pressure wi...

Page 110: ... released to prevent personal injury 2 Remove LP pressure switch 1 or oil pressure switch 2 Install the pressure gauge in adapter 3 Start the engine and allow it to warm up to normal operating temperature 4 Run the engine at 2000 rpm Read the pressure gauge 5 The oil pressure must be approximately 200 kPa 29 psi at 2000 rpm There is no adjustment to the oil pressure relief valve For the possible c...

Page 111: ...ant is cold cool the thermostat will be closed The coolant circulates makes a complete circuit from the water pump and through the cylinder block until the temperature of the coolant is warm enough to make the thermostat open When thermostat 2 is open the coolant will go through radiator top hose 5 and into the top tank of radiator 8 Coolant then goes through the cores of the radiator The air from...

Page 112: ... the cooling system before testing with testing equipment Cooling System Visual Inspection Do not loosen the filler cap or pressure cap on a hot engine Steam or hot coolant can cause severe burns 1 After the engine is cool loosen the filler cap on a radiator with a pressure cap turn it to the first stop to let pressure out of the cooling system Then remove filler or pressure cap 2 Check coolant le...

Page 113: ... to 110 kPa 12 to 16 psi 4 If the pressure cap is bad install a new pressure cap Cooling System Leak Check To test the cooling system for leaks use the following procedure If the engine has been in operation and the coolant is hot slowly loosen the pressure cap to the first stop and let the pressure out of the cooling system then remove the pressure cap 1 Remove pressure cap from the radiator 2 Ma...

Page 114: ...irculate 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 Thermostat Test To test the thermostat opening temperature use the following procedure The pan water and thermostat will be very hot and can cause bur...

Page 115: ...her condition that can cause heat problems is the ignition timing Retarded late timing causes the engine to send more heat to the cooling system Advanced early timing causes the engine to send less heat to the cooling system Cooling System Recommendation Coolant Information NOTICE DAEWOO recommends that the coolant mix contain 50 commercially available automotive antifreeze and 50 water The coolan...

Page 116: ...uate water pump cavitation temperature for efficient water pump performance Premix coolant solution to provide protection to the lowest expected outside ambient temperature Pure undiluted antifreeze will freeze at 23 C 10 F Only use a greater concentration above 50 of commercially available automotive antifreeze an needed for anticipated outside ambient temperatures Do not exceed the recommendatio...

Page 117: ...n the belt on the other hand can lead to engine overheating and insufficient charging due to slipping belt CATUTION Never attempt to adjust tension of the fan belt while leaving the engine in operation V Belt Diagnosis Belts and pulleys wear evenly with use Unusual signs of wear indicate some correction is needed The correction of any of the listed conditions will help extend belt life Causes of B...

Page 118: ...t spots are most noticeable with variable speed drives Flat spots may disappear during normal engine operation If the flat spots remain replace the belts Internal Cord Damage Cords may be broken by prying the belt onto the pulley or debris on the pulley Internal cord damage will cause the belt to roll out of the pulley groove Replace the belt and adjust properly Service Procedures Draining and Fil...

Page 119: ...sit inside the radiator is a result of using hard high mineral content water in the cooling system The effect of heat on the minerals in the water causes the formation of scale or hard coating on metal surfaces within the radiator thereby reducing the transfer of heat Some hard water will produce a silt like deposit which restricts the flow of water Replace a radiator that is plugged or has a heav...

Page 120: ...stall Water Temperature Sender 1 Disconnect one wire connection 1 2 Remove water temperature sender 2 NOTE For the installation of the water temperature sender reverse the removal steps 3 Use thread sealant on the water temperature sender threads 2 1 ...

Page 121: ...Oil pump sprocket 8 Crankshaft bolt 9 Crankshaft washer 10 Crankshaft sprocket 11 Flang 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 D C B A E F G H BASE ENGINE SERVICE PROCEDURE Timing Belt Removal and Installation H G G G F E ...

Page 122: ...elt 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 B 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 C Crankshaft bolt removal 1 Ho...

Page 123: ...ens 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 2 If there is oil or water on each part check front case oil seals camshaft oil seal and water pump for leaks F Counterbalance shaft sprocket removal 1 Set the special tool as shown to prevent the counterbalance shaft spr...

Page 124: ...lt 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 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on tooth bottom 5 Cracks on belt sides 6 Abnormal wear of belt sides NOTE The sides are normal if they are sharp as if cut by a knife MB990767 MD998719 Cracks Crack...

Page 125: ...s show in the illustration lock the camshaft sprocket in position 2 Tighten the camshaft sprocket bolt to the specified torque B Engine support bracket installation 1 Coat the bolts illustrated with sealant before tightening Specified sealant 3MTM AAD Part No 8762 or equivalent C Counterbalance shaft sprocket installation 1 Install the counterbalance shaft sprocket and screw the bolt 2 Install spe...

Page 126: ...he illustration 4 Move the tensioner B 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 B When the bolt is tightened use care to prevent shaft from turning together If shaft is turned together belt will be over tensioned 5 Check to ensure that timing marks on sprockets and front ...

Page 127: ...terbalance 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 G 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 H Timing belt installati...

Page 128: ...nsion side of the belt tight 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 direc...

Page 129: ...ed 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 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 ...

Page 130: ...G424 Service Manual Base Engine Service Procedure 129 Removal steps 1 Water outlet 2 Gasket 3 Thermostat 4 Engine hanger 5 Intake manifold 6 Gasket Intake Manifold Removal and Installation 6EN1894 ...

Page 131: ...ter Pump Gasoline LPG Engine Removal and Installation 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 7 Exhaust manifold 8 Gasket 9 Water inlet pipe 10 O ring 11 Water hose 12 Water pump 13 Gasket A A 6EN1895 ...

Page 132: ...e 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 ...

Page 133: ...ersion Removal and Installation Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Heat protector A 5 Heat protector B 6 Oxygen sensor 7 Engine hanger 8 Exhaust manifold 9 Gasket 10 Water inlet pipe 11 O ring 12 Water hose 13 Water pump 14 Gasket A A T 4 5 32 5 45 ...

Page 134: ... 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 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 D D D C B B E F A G A 6EN1896 ...

Page 135: ... exceeded replace Standard value 41 62 mm 1 6386 in Limit 41 12 mm 1 6189 in 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 1 Prepare three containers and approximately five liters of die...

Page 136: ... the air bleed wire is pushed in hard 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 5 Place the lash adjuster in container B Then gently push down the internal steel ball using special to...

Page 137: ...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 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 operati...

Page 138: ...shafts face up and insert the installation bolts without tightening them C Wave washer installation Install the wave washer in correct direction as shown D 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 2 Install the bearing caps with their front marks pointing to the camshaft sprocket side Notch Front bearing c...

Page 139: ...the lash adjuster coming free and falling to the floor F 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 G Semi circular packing installation 1 Apply sealant to the location shown in the illustration Specified sealant 3MTM AAD Part No 8672 or equivalent MD998443 MD998713 A...

Page 140: ...er 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 A A C C D C B C B A B B 6EN1897 ...

Page 141: ...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 ...

Page 142: ...ess than specified replace the valve Standard value Intake 106 6 mm 4 197 in Exhaust 105 2 mm 4 142 in Limit Intake 106 1 mm 4 177 in Exhaust 104 7 mm 4 122 in 3 Valve Spring 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...

Page 143: ... valve and valve seat should be lapped with a lapping compound 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 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 ...

Page 144: ... 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 A Valve stem seal installation 1 Install the valve spring seat 2 Using special tool install the new valve stem seat to the valve guide Caution 1 Do not reus...

Page 145: ...the bolt threads and washers 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 th...

Page 146: ...lief plunger 15 Oil filter bracket 16 Oil filter bracket gasket 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 b...

Page 147: ...edge of the special tool to separate the oil pan from the cylinder block B Plug removal 1 Fit special tool MD998162 on the plug then hold it in position with special tool MD998783 2 Loose the plug C 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 3 Loosen th...

Page 148: ...e special tool MB991603 in front of the cylinder block 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 ...

Page 149: ...e 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 ...

Page 150: ...lock 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 C Counterbalance shaft front bearing installation 1 Using the special tool install the rear bearing MB991603 MD998705 MB991603 Rear bearing MD998705 MD998705 MD998705 Bearing Cylinder block ...

Page 151: ...allation 1 Using a suitable socket wrench install the oil pump oil seal into the front case F Crank shaft front oil seal installation 1 Using the special tool install the crankshaft front oil seal into the front case G Oil pump driven gear oil pump drive gear installation 1 Apply engine oil amply to the gears and line up the alignment marks Socket wrench Front case Oil seal Socket MD998375 Front c...

Page 152: ...the front case 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 I Flange bolt installation 1 Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the counterbalance shaft 2 Secure the oil pump driven gear onto the left counterbalance shaft by tightening t...

Page 153: ...g 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 3 Note the difference in bolt lengths at the location shown L Drain plug gasket installation 1 Install the drain plug gasket in the direct...

Page 154: ...rt No 8672 or equivalent Caution 1 Keep the end of threaded portion clear of sealant 2 Avoid an over tightening N 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 Sealant Engine Oil Bracket side ...

Page 155: ... Removal and Installation 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 7 Piston ring No 2 8 Oil ring 9 Piston pin 10 Piston 11 Connecting rod 12 Bolt C B A B G F E D E C A 6EN1899 ...

Page 156: ...sh 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 nu...

Page 157: ...o 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 2 Crankshaft Pin Oil Clearance Plastic Gauge Method 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 co...

Page 158: ...me 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 8 Place the piston onto the piston setting...

Page 159: ...nto position by finger See illustration 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 C 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 nea...

Page 160: ... 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...

Page 161: ...isassembly 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 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 44 995 to 45 000 1 77145 to 1 77165 1 487 to 1 491 0 05854 to 0 05870...

Page 162: ... 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 ...

Page 163: ...Installation Removal steps 1 Flywheel bolt 2 Flywheel 3 F W Housing 4 Cover F W Housing 5 Oil seal case 6 Oil seal 7 Crankshaft bearing cap bolt 8 Crankshaft bearing cap 9 Crankshaft bearing lower 10 Crankshaft 11 Crankshaft bearing upper 12 Thrust bearing 13 Cylinder block C B B B F E D C 6EN1900 ...

Page 164: ...ng 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 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 gask...

Page 165: ...etween 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 ...

Page 166: ...tside diameter and select a bearing appropriate for the measured value Cylinder Crankshaft Identification Crankshaft journal block bearing bearing for mark or outside diameter bore No 3 color Identification Size Identification Identification Identification color mm in mark mark or color mark or color Yellow 0 1 or Green 0 or Black 1 2 or Yellow 1 or Green 2 3 or None 2 or Yellow None 0 2 or Yellow...

Page 167: ... 61 006 2 1 991 to 1 994 2 40157 to 2 40181 0 07839 to 0 07850 56 988 to 56 944 1 61 006 to 61 012 3 1 994 to 1 997 2 24362 to 2 24189 2 40181 to 2 40204 0 07850 to 0 07862 2 61 012 to 61 018 4 1 997 to 2 000 2 40204 to 2 40228 0 07862 to 0 07874 White 0 61 000 to 61 006 3 1 994 to 1 997 2 40157 to 2 40181 0 07850 to 0 07862 56 982 to 56 988 1 61 006 to 61 012 4 1 997 to 2 000 2 24338 to 2 24362 2...

Page 168: ...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 i...

Page 169: ...sealant or equivalent 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 F Rear plate installation 1 Be sure install the spring washers and special washers in correct position Seal ant Spring washer Special washer ...

Page 170: ...engine warm up until the engine coolant temperature rises to 80 to 95 C 176 to 203 F 2 Remove the vacuum hose at throttle body side and plug open end of the nipple with something like rubber cap 3 Connect the timing light to the No 1 spark plug and connect the power supply leads of the light to 12V battery 4 Aim the timing light at the timing indicator at the crankshaft pulley 5 Check that ignitio...

Page 171: ...2 Remove timing plate 6 from the converter housing The flywheel shoulder has a single timing mark on it Put a white chalk mark on it so it can be seen more easily 3 Rotate timing plate 6 180 and mount it on the converter housing again using the other mounting holes on plate 6 When plate 6 is mounted the timing marks should be close to the flywheel as shown 4 Rotate engine and align the timing mark...

Page 172: ...se rotation Decreases the engine speed decreases the engine installed load of spring 5 Anti Hunting Adjustment 1 Place all the hydraulic levers or powertrain 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 tensi...

Page 173: ...istributor cap or rotor E Vacuum leak on the intake manifold or carburetor base F Spark plugs fouled burned wrong heat range cracked porcelain G Dirty carburetor H Low compression Engine Starting Problems The following information will help to locate the starting problem 1 Determine which engine system is causing the problem To make an engine run basic components fuel spark ignition and compressio...

Page 174: ...d wiring or loose electrical connections B Circuit breaker tripped if equipped C Bad ignition switch D Bad starter solenoid E Defective starter motor Charging System Problems Symptom Cause 1 Gauges indicate no A Loose or broken drive belt battery charge B Loose or corroded electrical connections C Faulty ammeter or voltmeter D Battery will not accept charge E Faulty alternator or regulator 2 Noisy...

Page 175: ... with engine rpm are related to crankshaft rods pistons piston pins or flywheel Noises timed to one half engine rpm are valve train related 2 The use of a stethoscope can aid in locating a noise source However because noise will travel to other metal parts not involved in the problem caution must be exercised 3 If noise is believed to be confined to one particular cylinder ground the spark plug le...

Page 176: ...se in crankshaft area A Loose flywheel rear of engine B Drive plate C Main bearing D Rod bearing 11 Engine spark knock A Advanced timing B Low quality fuel C Engine running hot D Carbon deposits in engine 12 Popping through A Wrong ignition timing carburetor B Carburetor set too lean C Faulty accelerator pump gasoline D Vacuum leak E Valve adjustment F Valve timing G Burned or stuck valve 13 Hissi...

Page 177: ...ion Oil pressure may read high in the cooler times of the day and when engine is not up to operating temperature As the air temperature warms up and the engine is running at normal operating temperature it is normal for oil pressure to drop off slightly 6 Low engine oil pressure With modern engines and engine oils low oil pressure readings at idle or high rpm do not necessarily mean there is a pro...

Page 178: ...efective oil pressure gauge and or sender C Clogged or restricted oil passage D Oil pump relief valve stuck closed IMPORTANT Oil pressure slightly higher than normal does not always indicate a problem Tolerance stack up In the engine oil viscosity or weather conditions could cause high oil pres sure 3 Excessive oil consumption A Oil leaks B Oil diluted or of the wrong viscosity C Oil level too hig...

Page 179: ...exhaust system or head gasket 3 If the water is confined to crankcase it is usually caused by a cracked or porous block or condensation 4 If the water is located in both the cylinders and the crankcase it is usually caused by water in the cylinders getting past the rings and valves 5 Checking for rust in the intake manifold or exhaust manifolds is a good idea Rust in these areas will give clues if...

Page 180: ...erly installed timing chain and or gears H Blown head gasket s I Insufficient lubrication to moving parts of engine 2 Cooling system related A Loose or broken drive belt B Water shut off valve partially or fully closed if equipped C Clogged or improperly installed water strainer if equipped D Water inlet hose kinked or collapsed E Water pickup clogged F Defective thermostat G Obstruction in coolin...

Page 181: ...egulator No holes in hose and carburetor Clamps must be tight Watch for kinked and or pinched and or collapsed hose Fuel lock malfunction Check circuit wiring Check safety switch Check fuelock Repair replace fuelock as required Pressure regulator Test pressure regulator operation malfunction Use test kit Install primary pressure gauge Install secondary pressure gauge Crank engine and observe readi...

Page 182: ...l line Remove obstruction from fuel line Close liquid fuel valve Using caution disconnect fuel line Clear obstruction with compressed air Re connect fuel line Leak test Faulty vapor connection Check connection between pressure regulator No holes in hose and carburetor Clamps must be tight Watch for kinked and or pinched and or collapsed hose Pressure regulator Test pressure regulator operation mal...

Page 183: ...Check connection between pressure regulator No holes in hose and carburetor Clamps must be tight Watch for kinked and or pinched and or collapsed hose Pressure regulator freezes Check level in cooling system Must be full Check coolant strength 35F minimum Check coolant hoses Watch for kinks and or pinched hoses Verify one pressure hose and one return hose Incorrect idle speed Check idle speed Adju...

Page 184: ...uid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for click sound Open valve slowly Clogged fuel filter Repair replace as required Close liquid fuel valve Using caution disconnect fuel line Remove replace filter element Clean fuel filter housing Open liquid fuel valve Leak test Plugged fuel line Remove obstruction from fuel line Close liquid fuel valve Using cau...

Page 185: ...r kinked and or pinched and or collapsed hose Carburetor malfunction Check carburetor Remove air gas valve assembly Clean air gas valve and carb throat Check diaphragm for holes damage Check air gas valve for wear damage Repair replace as required Engine Mechanical See Troubleshooting section Rough Idle Weak Incorrect idle speed setting Check idle speed and adjust if necessaly Ignition Lean Condit...

Page 186: ... valve Using caution disconnect fuel line Clear obstruction with compressed air Re connect fuel line Leak test Faulty vapor connection Check connection between pressure regulator No holes in hose and carburetor Clamps must be tight Watch for kinked and or pinched and or collapsed hose Throttle butterfly not opening Verify wide open throttle Incorrect full load air fuel duty Verify full load air fu...

Page 187: ... idle Measure timing advance run Incorrect full load air fuel duty Verify full load air fuel duty cycle cycle Engine mechanical See Troubleshooting section Pressure regulator Test pressure regulator operation malfunction Use test kit Install primary pressure gauge Install secondary pressure gauge Crank engine and observe readings on pressure gauges Compare readings to specifications If readings ar...

Page 188: ...lug Replace spark plug Incorrect ignition timing Adjust ignition timing Defective carburetor Repair or replace carburetor Contaminated or clogged fuel filter element Clean fuel filter element and pipe and pipe Entry of air from carburetor or intake manifold Retighten set bolts or replace heat insulator and or intake manifold gasket Defective valves and related components Adjust or repair valves an...

Page 189: ...cover or anything proper on the front of radiator Engine out of order Refer to p 189 and make repairs Carburetor out of order Replace or replace distributor Defective distributor Repair or replace distributor Defective spark plug Replace spark plug Engine out of order Adjust of repair valves Defective carburetor Repair or replace carburetor Clogged air bleeder Clean or replace Damaged gaskets Repl...

Page 190: ...not properly Adjust or replace serviced Insufficient compression pressure Disassemble and repair engine Cylinder head gasket blow by Replace gasket Pressure leaks from cylinder head gasket Retighten cylinder head bolts and replace gasket Piston ring binding or worn Replace ring Piston ring or ring worn Disassemble and repair engine Oil leaks Loose oil drain plug Retighten plug Loose oil pan set bo...

Page 191: ...Replace bearing crankshaft bearing Fusion in crankshaft bearing Replace bearing and check lubrication system Worn connecting rod bearing Replace bearing Bent connecting rod Repair bent connecting rod or replace Fusion in connecting rod bearing Replace bearing and check lubrication system Excessive clearance due to worn cylinder Rebore and hone cylinder and install oversize piston Worn piston or pi...

Page 192: ...e accelerating pump plunger Disassemble or replace Clogged pump jet Clean or replace Defective accelerating linkage Replace linkage Malfunction power piston Replace power piston Malfunction power valve Replace Clogged power jet Clean or replace Float level too low Adjust float Throttle valve not opening completely Adjust valve Clogged main jet Clean Incorrect float level Adjust float Malfunction p...

Page 193: ...pencircuited Replace Magnet switch holding coil opencircuited Replace Brush in loose contact with commutator Reface as a result of wear Commutator burnt with consequent poor Exchange or replace commutators conduction of electricity High mica of commutator Perform under cutting Field coil not properly grounded or Replace short circuited Field coil not properly soldered Repair Armature not properly ...

Page 194: ...tator segments Repair or replace lifted causing brush to move Commutator in loose contact due Repair or replace to worn brush Chipped brush Repair or replace Worn starter clutch pinion end Replace Clutch rotates always freely Replace Deteriorated clutch drive spring Replace Does not rotate in overrunning direction Replace Poor sliding of splined section Rub surfaces smooth clean and repair Worn bu...

Page 195: ...rolyte and adjust specific gravity Defective plates internal short circuit Replace Terminals in loose contact Clean and then retighten Wiring Open circuit or loose contact between Repair key switch and alternator terminals L and R Burnt fuse of above mentioned circuits or Replace fuse and repair contacting holder in loose contact section of holder Open circuit or loose contact between Replace batt...

Page 196: ...h adjuster holder MD998442 Air bleed wire MD998713 Camshaft oil seal installer MB991654 Retainer for holding lash adjuster in rocker arm at timer of removal and installation of rocker arm and rocker shaft assembly Removal and installation of cylinder head bolt Installation of oil seal Air bleeding of lash adjuster Holding camshaft sprocket when loosening or torquing bolt Use with MB990767 Holding ...

Page 197: ...MD998705 MD998371 Silent shaft bearing puller Style Tool No Tool name Use Installation of crankshaft front oil seal Removal of counterblance shaft front bearing Installation of counterblance shaft front and rear bearing Guide for installation of crankshaft front oil seal Removal and installation of front case cap plug Use with MD998162 Removal and installation of front case cap plug Crankshaft fro...

Page 198: ...n pin setting tool MD998776 MB990938 Handle Removal of counterbalance shaft rear bearing Removal and installation of piston pin Installation of crankshaft rear oil seal Installation of crankshaft rear oil sear Use with MD998776 Style Tool No Tool name Use Crankshaft rear oil seal installer ...

Page 199: ... pressure or on dual fuel systems it may be used to measure gasoline fuel system pressure 0 5 psi gauge For measuring IMPCO pressure regulator primary pressure 0 10 H2O gauge For measuring IMPCO pressure regulator secondary pressure G2 2 lever gauge For correct adjustment of the IMPCO pressure regulator secondary lever Assorted fittings Hose Instructions FSA 1000 Fuel System Analyzer See instructi...

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