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SB4251E00
May. 2007

Service Manual
G424FE LP/Dual Fuel Engine
G424F LP Engine

G20P-5, G25P-5, G30P-5, G33P-5, G35C-5

GC20P-5, GC25P-5, GC30P-5, GC33P-5
 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 “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” 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.

DOOSAN 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 DOOSAN 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. DOOSAN dealers have the most current information available.

1
Index Inspect Battery System................................. 23
Inspect Ignition System................................. 23
Inspection of Ignition Timing ......................... 23

Chapter 1. GENERAL INFORMATION Inspection of Spark Plug ............................... 24

Fuel System Maintenance ................................. 26

Precautions before Service ................................. 7
Replace LP Fuel Filter Element..................... 26
Tightening Torque ............................................. 10
Testing Fuel Lock-off Operation .................... 26
Recommended Lubricants and Capacities....... 11
Pressure Regulator/Converter Inspection...... 27
Engine Model and Engine Serial Number ......... 12
Inspect Air/Fuel Valve Mixer Assembly ......... 27
General Specification ........................................ 13
Inspect for Intake Leaks................................ 27
G424F/G424FE Engine Power and Torque........ 15
Inspect Throttle Assembly............................. 27
Checking the TMAP Sensor.......................... 27
Chapter 2. RECOMMENDED
MAINTENANCE Exhaust System Maintenance........................... 27
Inspect Engine for Exhaust Leaks................. 27
General Maintenance......................................... 16
Test Fuel System for Leaks........................... 16 Maintenance Schedule ...................................... 28
Inspect Engine for Fluid Leaks ...................... 16
Inspect Vacuum Lines and Fittings................ 16 Chapter 3. ENGINE MECHANICAL
Inspect Electrical System .............................. 16
SYSTEM
Inspect Foot Pedal Operation........................ 16
Engine Oil Classification................................ 17
General Information........................................... 30
Checking Engine Oil Level ............................ 18
Engine Outline.............................................. 30
Replacing Engine Oil and Filter ..................... 18
Technical Specifications ............................... 31
Checking Compressed Pressure ................... 19
Shells Selection Table .................................. 33
Recommended Torque Values...................... 36
Cooling System Maintenance............................ 20
Troubleshooting............................................ 38
Coolant Recommendation............................. 20
Check Coolant Level ..................................... 20
Engine Exploded View....................................... 39
Inspect Coolant Hoses .................................. 20
Intake manifold and gasket ............................... 41
Checking coolant leaks ................................. 21
Exhaust Manifold and Gasket ........................... 45
Specific gravity test ....................................... 21
Timing Belt......................................................... 47
Relation between Coolant concentration and
Timing Belt Tensioner ....................................... 51
Specific Gravity............................................. 21
Checking and Adjusting Drive Belt ................ 22 PCV Valve .......................................................... 52

Adjusting....................................................... 22 Camshaft Timing Pulley and/or Seal................. 55

Checking Belt for Damage ............................ 22 Crankshaft Timing Pulley.................................. 55

Crankshaft Front Seal ....................................... 56

Ignition System Maintenance ............................ 23 Camshaft Case Cover and Gasket .................... 56

G424F(FE) Service Manual 3 Index

Crankshaft Accessory Pulley ............................ 57 Diagnosis Procedure ...................................116
Timing Belt Rear Cover ..................................... 57 Start Relay Tests .........................................118
Rocker Arms, Linkage, Valve Lifters With Troubleshooting...........................................119
Cylinder Head and Eegine............................... 59
Cooling System.................................................. 60 Chapter 5. ENGINE MANAGEMENT
Thermostat Housing .......................................... 66
SYSTEM (EMS)
Water Pump........................................................ 67
Lubrication System............................................ 68
General Information..........................................121
Oil Pan................................................................ 71
Specifications ..............................................121
Oil Pump............................................................. 72
Service Standard .........................................126
Oil Pump Assembly ........................................... 73
Component Location....................................127
Camshaft Case Assembly ................................. 74
Cylinder Head..................................................... 78 G424FE EMS (Engine Management System)
Valve, Spring or Seal ......................................... 79 Overview ...........................................................131
Engine Disassembly .......................................... 81 General Description .....................................131
Engine Assembly............................................... 85 LPG Fuel System Operation ........................134
Cylinder Block.................................................... 90 MPI Gasoline System Operation ..................141
Crankshaft.......................................................... 91 Electronic Throttle System ...........................142
Pistons and/or Connecting Rods ...................... 97 Ignition System............................................143
Rings .............................................................. 9999 Exhaust System...........................................144
SECM..........................................................146
Chapter 4. ENGINE ELECTRICAL SECM Wiring Diagrams for G424FE ............149

SYSTEM G424F EMS (Engine Management System)

Overview ...........................................................152
Specifications .................................................. 101 General Description .....................................152
Ignition System ................................................ 102 LPG Fuel System Operation ........................155
Wasted Spark DIS Ignition System.............. 102 Electronic Throttle System ...........................159
Inspection of Ignition Coil ............................ 103 Ignition System............................................159
Spark Plug Wire Inspection ......................... 104 SECM..........................................................159
Spark Plug Wire Replacement .................... 104 SECM Wiring Diagrams for G424F LP Engine
Spark Plug Replacement............................. 105 ....................................................................160
Spark Plug Inspection ................................. 105

Charging System ............................................. 107

General Description .................................... 107
Troubleshooting Procedure ......................... 110

STARTING SYSTEM......................................... 115

General Description .................................... 115

G424F(FE) Service Manual 4 Index

EMS Inspection and Repair ............................. 161 N-2001 Regulator Service Testing ........198
Engine Control Module (SECM) .................. 161 AVV (Air Valve Vacuum) Testing ..........200
Camshaft Position Sensor........................... 163 Connection of the MI-07 Service Tool ...200
IAT (Intake Air Temperature) Sensor........... 167 Idle Mixture Adjustment ........................201
Oxygen Sensor (Pre-Catalyst)..................... 168 Parts Description .........................................203
Oxygen Sensor (Post-Catalyst) ................... 169 CA100 Mixer for G424F Engine ............203
ECT (Engine Coolant Temperature) Sensor 170 CA100 Disassembly and Service ..........205
LP Fuel Temperature Sensor ...................... 172 CA100 Disassembled Service...............206
Angle Sensor-Accelerator ........................... 173 N-2001 Regulator for G424F Engine.....207
Transmission Oil Temperature Switch ......... 174 N2001 Regulator Disassembly Steps: ...209
Ground Speed Limit Switch (optional) ......... 175 N2001 Disassembled Service ...............211
Electronic Throttle Body .............................. 176
Chapter 7. MPI GASOLINE FUEL
Chapter 6. LPG FUEL DELIVERY
DELIVERY SYSTEM
SYSTEM
Specification .....................................................212
G424FE LP System Inspection and Repair ..... 177
Components Location......................................213
Removal and Installation ............................. 177
Fuel Pressure Test ...........................................214
Hose Connections................................ 178
Injector ..............................................................216
Removal and Installation of N-2007 LP
Fuel Pump.........................................................219
Regulator ............................................. 180
Removal and Installation of CA100 Mixer
Chapter 8. BASIC TROUBLESHOOTING
for G424FE .......................................... 181
Tests and Adjustments................................ 183
Preliminary Checks ..........................................220
N-2007 Regulator Service Testing........ 183
Before Starting ............................................220
AVV (Air Valve Vacuum) Testing.......... 185
Visual/Physical check ..................................220
Connection of the MI-07 Service Tool... 185
Idle Mixture Adjustment........................ 186
Basic Troubleshooting Guide ..........................221
Parts Description......................................... 189
Customer Problem Analysis Sheet...............221
CA100 Mixer for G424FE Engine ......... 189
Basic Inspection Procedure .........................222
N-2007 Regulator for G424FE Engine.. 191
Connector Inspection Procedure..................223
Symptom Troubleshooting Guide Chart .......227
G424F LPG System Inspection and Repair..... 193
Removal and Installation ............................. 193
Basic Troubleshooting .....................................233
G424F Fuel System Connections......... 194
Intermittents.................................................233
Removal and Installation of N-2001 LP
Surges and/or Stumbles ..............................234
Regulator/Converter............................. 195
Engine Cranking but Will Not Start / Difficult to
Removal and Installation of CA100 Mixer
Start ............................................................235
for G424F ............................................ 196
Lack of Power, Slow to Respond / Poor High
Tests and Adjustments................................ 198
Speed Performance / Hesitation During

G424F(FE) Service Manual 5 Index

 Acceleration................................................ 237 Appendix
Detonation / Spark Knock............................ 239
Backfire ...................................................... 240 Service Tool Software (MotoView)...................279
Dieseling, Run-on ....................................... 240 Introduction .................................................279
Rough, Unstable, Incorrect Idle, or Stalling.. 241 Connection of the Service Tool ....................280
Cuts Out, Misses......................................... 243 MotoView Display Screens ..........................281
Poor Fuel Economy / Excessive Fuel SECM field update with Service Tool ...........293
Consumption LPG Exhaust Smell ............... 244
High Idle Speed .......................................... 245 Ground Speed Limits (Option).........................297
Excessive Exhaust Emissions or Odors....... 246 LPG And LPG Fuel Tanks ................................299
Diagnostic Aids for Rich / Lean Operation ... 247 Regulatory Compliance....................................303
Chart T-1 Restricted Exhaust System Check248 Special Conditions for Safe Use ......................303
Abbreviations ...................................................304

Chapter 9. ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes..................... 249

Displaying Fault Codes (DFC) from SECM
Memory............................................................. 249
Clearing Fault (DFC) Codes............................. 249
Fault Action Descriptions................................ 250
Fault List Definitions........................................ 250
Table 1. Fault List Definitions ...................... 251
Table 2. Diagnostic Fault Codes (Flash Codes)
................................................................... 261

G424F(FE) Service Manual 6 Index