Description
Daewoo G15S-5, G18S-5, G20SC-5 GC15S-5, GC18S-5, GC20SC-5 G20E-5, G25E-5, G30E-5 GC20E-5, GC25E-5, GC30E-5, GC33E-5 Lift Truck Service Manual
Daewoo G15S-5, G18S-5, G20SC-5 GC15S-5, GC18S-5, GC20SC-5 G20E-5, G25E-5, G30E-5 GC20E-5, GC25E-5, GC30E-5, GC33E-5 Lift Truck Table of Contents:
Index
Chapter 1. GENERAL INFORMATION
Precautions before Service…………………………… 7
Tightening Torque ……………………………………… 10
Recommended Lubricants and Capacities……. 11
Engine Model and Engine Serial Number ……… 12
General Specification …………………………………. 13
Engine Power and Torque…………………………… 15
Chapter 2. RECOMMENDED
MAINTENANCE
General Maintenance………………………………….. 16
Test Fuel System for Leaks……………………… 16
Inspect Engine for Fluid Leaks …………………. 16
Inspect Vacuum Lines and Fittings……………. 16
Inspect Electrical System………………………… 16
Inspect Foot Pedal Operation…………………… 16
Engine Oil Classification………………………….. 17
Checking Engine Oil Level ………………………. 18
Replacing Engine Oil and Filter ………………… 18
Checking Compressed Pressure………………. 19
Adjusting Timing Belt Tension………………….. 20
Cooling System Maintenance………………………. 21
Coolant Recommendation……………………….. 21
Check Coolant Level ………………………………. 21
Inspect Coolant Hoses……………………………. 21
Checking coolant leaks …………………………… 22
Specific gravity test ………………………………… 22
Relation between Coolant concentration and
Specific Gravity……………………………………… 22
Checking and Adjusting Drive Belt ……………. 23
Adjusting………………………………………………. 24
Checking Belt for Damage ………………………. 24
Ignition System Maintenance………………………. 25
Inspect Battery System…………………………… 25
Inspect Ignition System…………………………… 25
Inspection of Ignition Timing ……………………. 25
Inspection of Spark Plug…………………………. 26
Fuel System Maintenance…………………………… 28
Replace LP Fuel Filter Element………………… 28
Testing Fuel Lock-off Operation……………….. 29
Pressure Regulator/Converter Inspection…… 29
Inspect Air/Fuel Valve Mixer Assembly ……… 30
Inspect for Intake Leaks………………………….. 30
Inspect Throttle Assembly……………………….. 30
Checking the TMAP Sensor…………………….. 30
Exhaust System Maintenance……………………… 30
Inspect Engine for Exhaust Leaks…………….. 30
Maintenance Schedule ……………………………….. 31
Chapter 3. ENGINE MECHANICAL
SYSTEM
General Information……………………………………. 33
Engine Outline………………………………………. 33
Specifications ……………………………………….. 34
Specifications ……………………………………….. 35
Torque Specification ………………………………. 38
Special Tools………………………………………… 39
Troubleshooting…………………………………….. 41
Timing Belt System……………………………………. 42
Components…………………………………………. 42
Removal ………………………………………………. 43
Inspection…………………………………………….. 44
Assembly……………………………………………… 46
PCV Valve …………………………………………………. 48
Outline and Operation Principle ……………….. 48
Service Procedure…………………………………. 49
Intake and Exhaust System…………………………. 50
Intake Manifold……………………………………… 50
Exhaust Manifold …………………………………… 52
Cooling System…………………………………………. 54
General Description ……………………………….. 54
Testing and Adjusting …………………………….. 55
Cooling System Recommendation ……………. 58
Coolant Pipe and Hose …………………………… 60
Water Pump………………………………………….. 61
Thermostat …………………………………………… 63
Cylinder Head Assembly …………………………….. 65
Lubrication System…………………………………….. 74
General Description ……………………………….. 74
Testing and Adjusting……………………………… 75
Oil Pressure Switch………………………………… 77
Front Case and Oil Pump………………………… 78
CAM Shaft, HLA, Timing Chain ……………………. 83
Components …………………………………………. 83
Removal ………………………………………………. 84
Inspection …………………………………………….. 85
Crankshaft…………………………………………………. 90
Flywheel and Housing ………………………………… 94
Piston and Connection Rod ………………………… 95
Cylinder Block………………………………………….. 110
Chapter 4. ENGINE ELECTRICAL
SYSTEM
Specifications ………………………………………….. 118
Ignition System………………………………………… 119
Coil-On-Plug Ignition System …………………. 119
COP Components………………………………… 119
Inspection of Ignition Timing…………………… 122
Inspection of Ignition Coil Drivers (Power TR)
…………………………………………………………. 122
Inspection of Ignition Coil ………………………. 123
Inspection of Spark Plug ……………………….. 124
Charging System……………………………………… 126
General Description ……………………………… 126
Troubleshooting …………………………………… 128
Disassembly and Installation ………………….. 134
STARTING SYSTEM………………………………….. 139
General Description ……………………………… 139
Diagnosis Procedure…………………………….. 140
Start Relay Tests …………………………………. 142
Troubleshooting…………………………………….143
Starter …………………………………………………144
Chapter 5. ENGINE MANAGEMENT
SYSTEM (EMS)
General Information……………………………………150
Specifications ……………………………………….150
Service Standard…………………………………..155
Component Location………………………………156
G420FE EMS (Engine Management System)
Overview…………………………………………………..160
General Description ……………………………….160
LPG Fuel System Operation ……………………163
MPI Gasoline System Operation………………170
Electronic Throttle System………………………171
Ignition System……………………………………..172
Exhaust System…………………………………….173
SECM………………………………………………….175
SECM Wiring Diagrams for G420FE…………178
G420F EMS (Engine Management System)
Overview…………………………………………………..180
General Description ……………………………….180
LPG Fuel System Operation ……………………183
MPI Gasoline System Operation………………187
Electronic Throttle System………………………187
Ignition System……………………………………..187
Exhaust System…………………………………….187
SECM………………………………………………….187
SECM Wiring Diagrams for G420F …………..188
EMS Inspection and Repair…………………………189
Engine Control Module (SECM) ……………….189
Camshaft Position Sensor ………………………191
Crank Shaft Position Sensor ……………………192
MAP (Manifold Absolute Pressure) Sensor ..193
IAT (Intake Air Temperature) …………………..194
G420F(FE) Service Manual 5 Index
Sensor ……………………………………………….. 194
Oxygen Sensor (Pre-Catalyst)………………… 195
Oxygen Sensor (Post-Catalyst) ………………. 196
ECT (Engine Coolant Temperature) Sensor 197
LP Fuel Temperature Sensor …………………. 199
Angle Sensor-Accelerator ……………………… 200
Transmission Oil Temperature Switch……… 201
Ground Speed Limit Switch (optional) ……… 202
Electronic Throttle Body ………………………… 203
Chapter 6. LPG FUEL DELIVERY
SYSTEM
G420FE LP System Inspection and Repair….. 204
Removal and Installation ……………………….. 204
Hose Connections……………………. 205
Removal and Installation of ……….. 206
N-2007 LP Regulator ……………….. 206
Removal and Installation of CA100
Mixer for G420FE…………………….. 207
Tests and Adjustments………………………….. 209
N-2007 Regulator Service Testing. 210
AVV (Air Valve Vacuum) Testing… 211
AVV (Air Valve Vacuum) Testing… 212
Connection of the MI-07 Service Tool
…………………………………………….. 212
Idle Mixture Adjustment…………….. 213
Parts Description………………………………….. 216
CA100 Mixer for G420FE Engine .. 216
N-2007 Regulator for G420FE Engine
…………………………………………….. 218
G420F LPG System Inspection and Repair….. 220
Removal and Installation ……………………….. 220
G420F Fuel System Connections.. 221
Removal and Installation of N-2001 LP
Regulator/Converter…………………. 222
Removal and Installation of CA100
Mixer for G420F………………………. 223
Tests and Adjustments………………………….. 225
N-2001 Regulator Service Testing .225
AVV (Air Valve Vacuum) Testing….227
Connection of the MI-07 Service Tool
………………………………………………227
Idle Mixture Adjustment ……………..228
Parts Description …………………………………..230
CA100 Mixer for G420F Engine …..230
N-2001 Regulator for G420F Engine
………………………………………………234
Chapter 7. MPI GASOLINE FUEL
DELIVERY SYSTEM
Specification……………………………………………..239
Special Tools …………………………………………….239
Components Location………………………………..240
Fuel Pressure Test …………………………………….241
Injector……………………………………………………..243
Injector Inspection……………………………………..245
Fuel Pump…………………………………………………247
Chapter 8. BASIC TROUBLESHOOTING
Preliminary Checks ……………………………………248
Before Starting ……………………………………..248
Visual/Physical check …………………………….248
Basic Troubleshooting Guide ……………………..249
Customer Problem Analysis Sheet……………249
Basic Inspection Procedure …………………….250
Connector Inspection Procedure………………251
Symptom Troubleshooting Guide Chart …….255
Basic Troubleshooting……………………………….261
Intermittents………………………………………….261
Surges and/or Stumbles …………………………262
Engine Cranking but Will Not Start / Difficult to
Start ……………………………………………………263
Lack of Power, Slow to Respond / Poor High
Speed Performance / Hesitation During
Acceleration………………………………………….265
Detonation / Spark Knock………………………. 267
Backfire ……………………………………………… 268
Dieseling, Run-on ………………………………… 268
Rough, Unstable, Incorrect Idle, or Stalling.. 269
Cuts Out, Misses………………………………….. 271
Poor Fuel Economy / Excessive Fuel
Consumption LPG Exhaust Smell …………… 272
High Idle Speed …………………………………… 273
Excessive Exhaust Emissions or Odors……. 274
Diagnostic Aids for Rich / Lean Operation … 275
Chart T-1 Restricted Exhaust System Check276
Chapter 9. ADVANCED DIAGNOSTICS
Reading Diagnostic Fault Codes………………… 277
Displaying Fault Codes (DFC) from SECM
Memory……………………………………………………. 277
Clearing Fault (DFC) Codes……………………….. 277
Fault Action Descriptions………………………….. 278
Fault List Definitions…………………………………. 278
Table 1. Fault List Definitions …………………. 279
Table 2. Diagnostic Fault Codes (Flash Codes)
…………………………………………………………. 289
Appendix
Service Tool Software (MotoView) ……………… 307
Service Tool Connection to SECM ………….. 308
Service Tool Display …………………………….. 309
SECM field update with Service Tool……….. 313
SECM field update with Service Tool……….. 314
Ground Speed Limits (Option) …………………… 318
LPG And LPG Fuel Tanks………………………….. 320
Regulatory Compliance…………………………….. 324
Special Conditions for Safe Use ………………… 324
Abbreviations…………………………………………… 325
