Caterpillar K21, K25 Gasoline Engine Service Manual - PDF DOWNLOAD

Service Manual K21, K25 Gasoline Engine

For use with GC15N-GC33N Chassis Service Manual.

99789-65120

FOREWORD

This service manual covers K21 and K25 Gasoline Engines installed in Cat ® Lift Trucks and gives detailed maintenance and repair information. For your convenience the instructions are grouped by systems as a ready reference.

The long productive life of your lift truck(s) depends on regular and proper servicing—servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair or rebuild job.

All descriptions, illustration, specifications, and serial numbers in this manual are effective as of the printing date of this manual. Cat Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation.

99789-65120

GROUP INDEX GROUP INDEX

GI

GENERAL INFORMATION

Items HOW TO USE THIS MANUAL, PRECAUTIONS FOR SAFETY AND QUALITY, PRECAUTIONS, TIGHTENING TORQUE, SPECIAL SERVICE TOOLS, ENGINE OUTSIDE DRAWINGS, MAIN SPECIFICATIONS, STANDARD AND REPAIR LIMIT, STAMPED LOCATION OF ENGINE NO., TROUBLE DIAGNOSIS

GI

MA

MAINTENANCE

ENGINE MAINTENANCE

MA

ET

ENGINE TUNE-UP

SPECIFICATIONS, TIGHTENING TORQUE, TROUBLE DIAGNOSIS, ENGINE INSPECTION AND ADJUSTMENT

ET

EM

ENGINE MECHANICAL

PRECAUTIONS, ENGINE OUTSIDE DRAWINGS, MAIN SPECIFICATIONS, ADJUSTMENT VALUE, TIGHTENING TORQUE, TROUBLE DIAGNOSIS, SPECIAL SERVICE TOOLS, REMOVAL AND INSTALLATION OF ENGINE, ENGINE SERVICE

EM

EC

ENGINE CONTROL

PRECAUTIONS, PREPARATION, DESCRIPTION, TROUBLE DIAGNOSIS, BASIC INSPECTION, COMPONENT PARTS INSPECTION, PCV GAS RECIRCULATION DEVICE, ECM COMPONENTS

EC

LC

ENGINE LUBRICATION & LUBRICATION SYSTEM, ENGINE COOLANT SYSTEM COOLING SYSTEM

EF

ENGINE FUEL

EE

ENGINE ELECTRICAL

LC

EMISSION CONTROL SYSTEM, ENGINE OUTSIDE DRAWINGS, SYSTEM DIAGRAM, UNIT LAYOUT, SERVICE DATA AND SPECIFICATIONS (SDS), LPG FUEL SYSTEM TROUBLE DIAGNOSIS, DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM, DISASSEMBLY AND ASSEMBLY OF INJECTOR HOLDER, DISASSEMBLY AND ASSEMBLY OF VAPORIZER

EF

ADJUSTMENT VALUE, TROUBLE DIAGNOSIS, STARTER MOTOR, ALTERNATOR

EE

5

GENERAL INFORMATION SECTION

GI

GI

CONTENTS HOW TO USE THIS MANUAL ..............................GI-2 Description ........................................................GI-2 Definition of Terms............................................GI-2 Definition of Units..............................................GI-2 Description ........................................................GI-2 PRECAUTIONS FOR SAFETY AND QUALITY ...GI-3 Reduction of Risk Operation .............................GI-3 Correct Operation .............................................GI-4 Precautions for Radio Equipment Installation ...GI-4 PRECAUTIONS .....................................................GI-5 Precautions in Draining Engine Coolant ...........GI-5 Precautions for Disconnecting Fuel Piping .......GI-5 Precautions for Removing and Disassembling...................................................GI-5 Precautions for Inspection, Correction, and Replacement.....................................................GI-5

Precautions for Assembly and Installation........GI-5 Parts Requiring Angle Tightening .....................GI-6 Caution for Use of Power Tools........................GI-6 Precautions for Liquid Gasket Application ........GI-6 TIGHTENING TORQUE ........................................GI-7 Standard Bolt Tightening Torque......................GI-7 Engine Part Tightening Torque.........................GI-8 SPECIAL SERVICE TOOLS ...............................GI-10 ENGINE OUTSIDE DRAWINGS .........................GI-11 MAIN SPECIFICATIONS.....................................GI-12 STANDARD AND REPAIR LIMIT .......................GI-15 STAMPED LOCATION OF ENGINE NO. ..........GI-19 TROUBLE DIAGNOSIS ......................................GI-20 Engine Adjustment..........................................GI-21 Engine LPG Fuel System ...............................GI-26

7

HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL

Description This manual explains how to use “removal, installation, disassembly, assembly, inspection and adjustment” and “diagnosis.”

Definition of Terms WARNING: Instructions and precautions that could lead to fatal hazards and/or serious injuries if not observed properly.

CAUTION: Instructions and precautions that require special attention and may lead to problems and/or accidents as well as damages to the vehicle and/or components.

NOTE: Provides additional information that facilitates operation.

Standard: Indicates tolerances for inspection and adjustment.

Repair limit: Indicates maximum or minimum values allowed for inspection and adjustment.

Definition of Units The units and numerical values in this Standard are SI units, and those given in ( ) in this Standard are based on the conventional unit system and are appended for informative reference.

Example: Tightening torque 59 - 78 N·m (6.0 - 8.0 kgf-m) SI (Metric system) Main unit changes Measure

SI

Conventional unit

Conversion factor to SI

Acceleration

m/s2

G

9.80665

Torque, moment Force Pressure

N·m N MPa

kgf-m kgf

9.80665 9.80665

kgf/cm2

0.0980665

Power efficiency

kPa kW W

mmHg PS kcal/h cc

0.133322 0.735499 1.16279 1

kgf/mm g/PS·h

9.80665 1.3596

Volume Spring constant Fuel consumption

cm3 N/mm *g/kW·h

* The conventional unit can be used for SI.

Description Precautions: Preparation:

Description:

At the beginning of each section, the precautions exclusive to the section are described.

At the beginning of each section and during the trouble diagnosis items, the Service Tools (STs), gauges, and other tools to be prepared before operation are described. Some commercial service tools, assumed to be available in any workshop, are omitted.

To perform correct operations, operational procedures, notes, STs, and other service information are described.

CAUTION: Descriptions of visual inspections and cleaning of removed parts are generally omitted. Please remember that actual operations require these processes.

8

GI-2

PRECAUTIONS FOR SAFETY AND QUALITY PRECAUTIONS FOR SAFETY AND QUALITY

•

•

The serviceman or mechanic may be unfamiliar with many of the systems on this engine. This makes it important to use caution when performing service work. Knowledge of the system and/or components is important before the removal or disassembly of any component. The following precautions must be carefully observed for safe and appropriate service work.

Only the qualified and designated personnel must perform inspections, repairs and adjustments.

Reduction of Risk Operation • •

• • • GIM0057

•

• •

• • GIM0058

•

• •

• GIM0059

•

Do not run engines inside the workshop without proper ventilation (ex. no ventilation ducts).

Keep the workshop well ventilated and free of any flammable materials. Special care should be taken when flammable or poisonous materials such as gasoline are handled.

Discard waste oil after oil changes or parts treatment in accordance with local laws and regulations.

Be careful of burns and injury when working on hightemperature parts, rotating parts, or sliding portions.

When working in a pit or enclosed area, ensure that adequate ventilation is provided for discharging any hazardous emissions.

Do not work underneath a vehicle supported only by a jack.

Always use rectangular lumbers at the prescribed points to support the vehicle.

Support it at the prescribed points and lock it in position with safety devices before lifting the vehicle.

When removing a heavy component such as the engine and vehicle side, be careful the vehicle body does not become offbalance and fall.

Do not smoke during service work.

Do not wear any rings and necklaces when working on machinery.

Before starting repair work that requires no battery power, always turn OFF the ignition switch, and disconnect the negative battery cable.

To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more.

Do not touch any metal portions immediately after the engine is stopped. Otherwise the heated metals may cause burns. Do not attempt to remove any cooling system parts such as the radiator cap while the engine is hot.

To perform repair work safely and efficiently, always use appropriate commercial service tools and specified STs and be sure you understand how to use them before performing any service work.

When two or more persons work together, each worker should pay attention to the safety of the other(s).

GIM0060

GI-3

9

PRECAUTIONS FOR SAFETY AND QUALITY Correct Operation • •

•

• • • • • • •

Make sure that you understand the symptoms before starting trouble diagnosis.

Check correct installation status prior to removal or disassembly. Make sure that they do not interfere with the function of the parts they are applied to if matching marks are required.

Once they are removed, always replace parts indicated as “do not reuse” with new ones. This includes: oil seals, gaskets, packings, O-rings, lock washers, cotter pins, and self-locking nuts.

Replace inner and outer races of tapered or needle roller bearings as a set.

Arrange disassembled parts in order and prevent them from being mixed-up.

Clean or flush disassembled parts prior to inspection or assembly.

Use Genuine Cat parts for replacement.

Use authorized grease and sealer.

Release the pressure before disconnecting pressurized piping or hoses.

Be sure to check for leakage after repairing fuel, oil, coolant, exhaust, or vacuum systems.

Precautions for Radio Equipment Installation Check the following when installing a commercial/ham radio or mobile phone. If mounting position is not chosen carefully, the unit may interfere with the electronic control system.

• Separate the antenna as far from the Engine Control System as possible.

• Route an antenna feeder line at least 20 cm apart from the control unit harness.

• Adjust antenna and feeder line to eliminate radio wave interference.

10

GI-4

PRECAUTIONS PRECAUTIONS

Precautions in Draining Engine Coolant •

Drain coolant only after the engine has cooled down.

Precautions for Disconnecting Fuel Piping • •

•

Operation should be done in a place free from fire.

Release fuel pressure before operation. (Electronic controlled specifications): Refer to “Release of Fuel Pressure” in EC section.

After disconnecting, plug the pipe to prevent fuel from draining.

Precautions for Removing and Disassembling • • • •

•

Use correct STs in the specified position. Always pay attention to safety.

Be careful not to lose surface accuracy of mating or sliding surfaces.

To prevent foreign material from entering the engine, close openings with appropriate tape as necessary.

Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or excessive wear and to ensure correct reassembly.

As a rule, nuts and bolts must be loosened in a diagonal manner starting from an outer one. If a particular tightening sequence is provided separately, follow the sequence.

Precautions for Inspection, Correction, and Replacement •

Following the inspection procedure, inspect the parts adequately and repair or replace as necessary. Perform the same inspections even for new parts and replace them if necessary.

Precautions for Assembly and Installation • •

• •

• • •

Always use a torque wrench when tightening bolts and nuts.

Unless otherwise specified, tighten nuts and bolts from inside to outside in a crisscross pattern. Tighten them gradually and evenly in 2 to 3 steps.

Always replace gasket, packing, oil seals, and O-rings with new ones.

For each part, perform adequate cleaning/washing and drying with a dryer. In particular, ensure that the oil and coolant passages are free from plugging and clogging.

Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine oil to sliding surfaces.

If coolant was drained, bleed air from the system.

After assembly, start engine and increase the engine speed, then check coolant, fuel, oil, grease, and exhaust gas for leakage.

GI-5

11

PRECAUTIONS Parts Requiring Angle Tightening • •

When tightening the following parts, use an angle wrench (ST).

Cylinder head bolt Before assembly, verify that no grease/oil and dust are present on the cylinder head, cylinder block mounting face, and head gasket. Then apply antirust oil or engine oil to the threads and head bottoms of the head bolts.

Caution for Use of Power Tools •

The use of power tools such as an air runner is only allowed for disassembly. Do not use them for assembly.

Precautions for Liquid Gasket Application REMOVING PARTS ATTACHED WITH LIQUID GASKET • Remove mounting nuts and bolts. Remove liquid gasket using a seal cutter (ST).

CAUTION: Be careful not to damage the mating surfaces.

•

GIM0061

In positions where a seal cutter is difficult to use, lightly tap with a plastic hammer, and remove.

CAUTION: Be careful not to scratch the mating surfaces when using a screwdriver.

LIQUID GASKET APPLICATION INSTRUCTION 1. Remove any old liquid gasket remaining on the gasket application surface and its mating surface using a scraper.

• Remove any old liquid gasket remaining in the gasket application groove and on the threads of bolts and bolt holes.

2. Wipe the gasket application surface and its mating surface using thinner or equivalent to remove any moisture, oil, and foreign material.

3. Set genuine liquid gasket to tube presser (commercial service tool).

GIM0062

4.

• • • • • • GIM0063

Apply a continuous bead of liquid gasket to the specified position at the specified diameter.

Apply liquid gasket in the application groove.

Apply liquid gasket inside bolt holes as a rule. Make sure to carefully read the relevant instructions.

Attaching should be done within 5 minutes after gasket application.

Immediately wipe off any protruding liquid gasket.

Do not retighten nuts and bolts after installation.

After finishing work, wait at least 30 minutes before refilling engine oil and coolant.

CAUTION: Follow any directions specified in the text on the following pages.

12

GI-6

TIGHTENING TORQUE Standard Bolt Tightening Torque Upper:

Lubricated (Antirust oil is applied to abrasive faces of threads and seating faces) No lubrication (Threads and seating faces are completely degreased)

Lower:

Thread size Diameter

Hexagon head bolt and nut

M6

M8

1

1.25

M10

1.5

M6

M8

1

1.25

1.25

M10

1.5

• •

Unit

4T (Bolt)

7T (Bolt)

9T (Bolt)

N·m

3.82 - 4.41

6.37 - 7.45

9.22 - 10.8

(kgf-m)

(0.39 - 0.45)

(0.65 - 0.76)

(0.94 - 1.1)

N·m

5.00 - 6.47

8.43 - 10.8

11.8 - 15.7

(kgf-m)

(0.51 - 0.66)

(0.86 - 1.1)

(1.2 - 1.6)

N·m

9.32 - 10.8

15.7 - 17.7

22.6 - 25.5

(kgf-m)

(0.95 - 1.1)

(1.6 - 1.8)

(2.3 - 2.6)

N·m

12.7 - 15.7

20.6 - 26.5

29.4 - 37.3

Pitch

1.25

Flanged bolt

TIGHTENING TORQUE

(kgf-m)

(1.3 - 1.6)

(2.1 - 2.7)

(3.0 - 3.8)

N·m

19.6 - 22.6

32.4 - 38.2

47.1 - 53.9

(kgf-m)

(2.0 - 2.3)

(3.3 - 3.9)

(4.8 - 5.5)

N·m

25.5 - 33.3

43.1 - 54.9

61.8 - 78.5

(kgf-m)

(2.6 - 3.4)

(4.4 - 5.6)

(6.3 - 8.0)

N·m

18.6 - 21.6

30.4 - 36.3

44.1 - 52

(kgf-m)

(1.9 - 2.2)

(3.1 - 3.7)

(4.5 - 5.3)

N·m

24.5 - 31.4

41.2 - 52

58.8 - 74.5

(kgf-m)

(2.5 - 3.2)

(4.2 - 5.3)

(6.0 - 7.6)

N·m

4.9 - 5.69

8.14 - 9.51

11.8 - 13.7

(kgf-m)

(0.5 - 0.58)

(0.83 - 0.97)

(1.2 - 1.4)

N·m

5.98 - 7.65

9.81 - 12.7

14.7 - 18.6

(kgf-m)

(0.61 - 0.78)

(1.0 - 1.3)

(1.5 - 1.9)

N·m

11.8 - 13.7

19.6 - 23.5

28.4 - 33.3

(kgf-m)

(1.2 - 1.4)

(2.0 - 2.4)

(2.9 - 3.4)

N·m

14.7 - 18.6

24.5 - 31.4

35.3 - 45.1

(kgf-m)

(1.5 - 1.9)

(2.5 - 3.2)

(3.6 - 4.6)

N·m

24.5 - 29.4

41.2 - 48.1

59.8 - 69.6

(kgf-m)

(2.5 - 3.0)

(4.2 - 4.9)

(6.1 - 7.1)

N·m

30.4 - 39.2

51.0 - 64.7

73.6 - 93.2

(kgf-m)

(3.1 - 4.0)

(5.2 - 6.6)

(7.5 - 9.5)

N·m

23.5 - 27.5

39.2 - 46.1

56.9 - 65.7

(kgf-m)

(2.4 - 2.8)

(4.0 - 4.7)

(5.8 - 6.7)

N·m

29.4 - 37.3

49.0 - 61.8

69.6 - 89.2

(kgf-m)

(3.0 - 3.8)

(5.0 - 6.3)

(7.1 - 9.1)

CAUTION: Except special nuts and bolts.

The bolts applicable to this table have one of the following marks embossed on their heads.

4T......4 7T......7 9T......9

GI-7

13

TIGHTENING TORQUE Standard Bolt Tightening Torque (Cont’d) TAPER SCREW TIGHTENING TORQUE Allowable materials for tightening

Aluminum Unit

Standard

Max. value

Standard

Max. value

7.8 0.796 69* 19.6 2.0 14 39.2 4.0 29

11.8 1.2 9 29.4 3.0 22 54.9 5.6 41

15.7 1.6 12 34.3 3.5 25 53.9 5.5 40

21.6 2.2 16 44.1 4.5 33 73.5 7.5 33

Normal size R1/8

R1/4

R3/8

Cast iron

N·m (kg-m) [ft-lb, in-lb*] N·m kg-m ft-lb N·m kg-m ft-lb

Engine Part Tightening Torque TIGHTENING TORQUE AT VARIOUS POINTS OF ENGINE Tightening point

Unit

Cylinder head (lubricated)

Separately given

Main bearing cap (lubricated)

Separately given N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb

Crankshaft pulley bolt Flywheel bolt (lubricated) Connecting rod nut (lubricated) Rear plate bolt Camshaft sprocket bolt Oil filter stud Oil filter element Spark plug Engine slinger bolt Rocker cover nut Water temperature gauge Oil pressure switch Exhaust manifold nut Straight screw plug (For head top face) Oil pan drain plug

14

GI-8

Standard

Max. value

220.5 22.5 163 132 13.47 94.4 31.4 3.2 23 44.1 4.5 33 39.2 4.0 29 29.4 3.0 22 14.7 1.5 11 19.6 2.0 14 22.6 2.31 16.7 14.7 1.5 11 15.7 1.6 12 15.7 1.6 12 41.2 4.2 30 44.1 4.5 33 29.4 3.0 22

240.1 24.5 177 142 14.49 104.8 37.3 3.81 27.6 58.8 6.0 43 49 5.0 36 39.2 4.0 29 20.6 2.1 15 29.4 3.0 22 25.5 2.6 19 16.7 1.7 13 19.6 2.0 14 21.6 2.2 16 48.1 4.91 35.5 58.9 5.5 40 39.2 4.0 29

TIGHTENING TORQUE Engine Part Tightening Torque (Cont’d) Tightening point Mass air flow sensor mounting screw

Fuel tube flare nut

Crankshaft position sensor plug bolt

Thermo-housing relief plug

Unit

Standard

Max. value

N·m

1.27

1.67

(kgf-m)

0.13

0.17

N·m

16.0

23.0

(kgf-m)

1.63

2.35

N·m

6.37

7.45

(kgf-m)

0.65

0.76

N·m

6.37

7.45

(kgf-m)

0.65

0.76

CYLINDER HEAD Tightening torque for general service is 68.6 N·m (7.0 kgf-m) in the place of the tightening torque (5) as shown in the figure.

MAM0142

MAIN BEARING CAP : 83.4 - 93.2 N·m (8.51 - 9.51 kgf-m) • Apply antirust oil or engine oil to the bolt threads and head bottom.

• Do not use any power tools such as an air runner for assembly.

GIM0064

GI-9

15

SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS Tool number

Tool name

91H20-09080

Engine attachment

91H20-09090 (1) 91H20-09091 (2) 91H20-09092

Engine stand assembly Engine stand Stand

GIM0066

GIM0067

91H20-09100 (1) 91H20-09110 (2) 91H20-09111 (3) 91H20-09112

Crankshaft main bearing cap puller Crankshaft main bearing puller Adapter Adapter

GIM0068

91H20-09120

Valve lifter

GIM0069

91H20-09150 91H20-09160 91H20-09170

Front oil seal drift Rear oil seal drift Drift rod

GIM0071

91H20-09020

Heated oxygen sensor wrench

Removing and installing heated oxygen sensor

GIM0072

16

GI-10

ENGINE OUTSIDE DRAWINGS ENGINE OUTSIDE DRAWINGS

ELECTRONIC CONTROLLED SPECIFICATIONS

GI-11

17

MAIN SPECIFICATIONS MAIN SPECIFICATIONS Engine type

K21

Engine control system

Electronic controlled specifications

Fuel specification

Gasoline

Total displacement (cc) Shape of combustion chamber

Combined

Bathtub

Valve mechanism

OHV

Bore x stroke mm (in)

89 x 83 (3.50 x 3.27)

Compression ratio Compression pressure [MPa

LPG 2,065

(kg/cm2)

[psi]/rpm]

Engine speed control system

8.7

9.3

8.7

1.45 (14.8) [210]/250

1.57 (16.0) [228]/250

1.45 (14.8) [210]/250

Engine Control System, electronically controlled throttle

Fuel in use (Note 1)

Unleaded regular gasoline

LPG

See the left column

37.4 (50.8)/2,400

37.4 (50.8)/2,400

Maximum output [kW (PS)/rpm]

2,400 rpm SPEC.

35.9 (48.8)/2,400

2,700 rpm SPEC.

39.6 (53.8)/2,700

41 (55.7)/2,700

40.7 (55.3)/2,700

Maximum torque [N·m (kg-m)/rpm]

2,400 rpm SPEC.

149 (15.2)/2,000

151 (15.4)/2,000

150 (15.3)/2,000

2,700 rpm SPEC.

149 (15.2)/2,000

151 (15.4)/2,000

150 (15.3)/2,000

Valve opening/closing timing (degree)

Intake open (ATDC)

4

Intake close (ABDC)

40

Exhaust open (BBDC)

36

Exhaust close (ATDC) Valve clearance mm (in)

0

Intake (when engine is hot)

0.38 (0.0150)

Exhaust (when engine is hot)

0.38 (0.0150)

Firing order

1-3-4-2

Ignition timing (idling)

degree (BTDC)

On board idle speed (rpm)

ATM

0 700

MTM

700

On board high-idle speed (rpm)

ATM

2,400/2,700

MTM

2,400/2,700

Allowable maximum engine speed (rpm)

Instantaneous, no load

3,600

Continuous load

3,000

PTO system Engine oil (originally fitted)

Silent chain-driven/side PTO Specification

10W-30 (Class SJ)

Amount (L) (US qt)

3.8 (4) (including oil filter)

Engine dimensions (length x width x height) (Note 2) mm (in)

732.7 x 568 x 743 (28.846 x 22.362 x 29.252)

Engine weight (w/o coolant, w/ oil) (Note 2) N (kg) [lb]

1,470 (150) [331]

Note 1: Fuel Gasoline: Use unleaded regular gasoline with an octane rating of 91 or more.

LPG: Use a fuel of 30P or more in cold seasons. In ambient temperature of -5˚C (23˚F) or less, use a 100P fuel.

Note 2: The engine dimensions and weight differs with the customer specifications. The above data should be deemed as reference.

18

GI-12

MAIN SPECIFICATIONS

Engine type

K25

Engine control system

Electronic controlled specifications

Fuel specification

Gasoline

Total displacement (cc) Shape of combustion chamber

Combined

Bathtub

Valve mechanism

OHV

Bore x stroke mm (in)

89 x 100 (3.50 x 3.94)

Compression ratio Compression pressure [MPa

LPG 2,488

(kg/cm2)

[psi]/rpm]

Engine speed control system

8.7

9.2

8.7

1.51 (15.4) [219]/250

1.57 (16.0) [228]/250

1.51 (15.4) [219]/250

Engine Control System, electronically controlled throttle

Fuel in use (Note 1)

Unleaded regular gasoline

LPG

See the left column

Maximum output [kW (PS)/rpm]

45.8 (62.2)/2,700

46.9 (63.7)/2,700

46.6 (63.5)/2,700

175 (17.8)/1,600

188 (19.2)/1,600

187 (19.1)/1,600

Maximum torque [N·m (kg-m)/rpm] Valve opening/closing timing (degree)

Intake open (ATDC)

4

Intake close (ABDC)

40

Exhaust open (BBDC)

36

Exhaust close (ATDC) Valve clearance mm (in)

0

Intake (when engine is hot)

0.38 (0.0150)

Exhaust (when engine is hot)

0.38 (0.0150)

Firing order

1-3-4-2

Ignition timing (idling)

degree (BTDC)

On board idle speed (rpm)

ATM

0 700

MTM

700

On board high-idle speed (rpm)

ATM

2,700

MTM

2,700

Allowable maximum engine speed (rpm)

Instantaneous, no load

3,600

Continuous load

3,000

PTO system Engine oil (originally fitted)

Silent chain-driven/side PTO Specification

10W-30 (Class SJ)

Amount (L) (US qt)

3.8 (4) (including oil filter)

Engine dimensions (length x width x height) (Note 2) mm (in)

732.7 x 568 x 743 (28.846 x 22.362 x 29.252)

Engine weight (w/o coolant, w/ oil) (Note 2) N (kg) [lb]

1,470 (150) [331]

Note 1: Fuel Gasoline: Use unleaded regular gasoline with an octane rating of 91 or more.

LPG: Use a fuel of 30P or more in cold seasons. In ambient temperature of -5˚C (23˚F) or less, use a 100P fuel.

Note 2: The engine dimensions and weight differs with the customer specifications. The above data should be deemed as reference.

GI-13

19

MAIN SPECIFICATIONS MAIN SPECIFICATIONS OF IGNITION SYSTEM Engine type

K21

Engine control system

Electronic controls

Fuel specification

Gasoline

Ignition device

LPG

Combined

Non-contact type (Engine Control System)

Ignition coil (with power transistor) Crankshaft position sensor

K25

Hanshin Electric type

AIC-4002G

Crankshaft position sensor (POS)

Hitachi Unisia Automotive

A29-640

Camshaft position sensor (PHASE)

Hitachi Unisia Automotive

A29-660

NGK type

FR2A-D

Gap (mm)

0.9

Spark plug

FUEL SYSTEM AND ENGINE SPEED CONTROL SYSTEM Engine type

K21

Engine control system

K25 Electronic controls

Fuel specification

Gasoline

Fuel device standard type

LPG

Combined

Electronically controlled fuel injection device (Engine Control System)

Fuel device

Gasoline injector

Air-fuel ratio control device

LPG injector

Gasoline & LPG

Air-fuel ratio feedback control

Starting auxiliary device

Electric throttle control actuator

Idle load control type

Electric throttle control actuator

Engine speed control type

Electric throttle control actuator

EXHAUST GAS CLEANUP DEVICE LIST Engine type

K21

Engine control system

Electronically controls

Fuel specification Catalytic device (Reducing HC, CO, NOX)

Gasoline Type

LPG

Combined

Three-way catalyst (Monolith)

Location

In counter weight with muffler separated

Capacity

0.45L

PCV gas recirculation device

20

K25

Closed type

GI-14

STANDARD AND REPAIR LIMIT STANDARD AND REPAIR LIMIT

INSPECTION AND ADJUSTMENT • Oil capacity H line (L) 3.5 • Oil capacity L line (L) 2.5 • (Oil filter capacity) (L) 0.3 • Fan belt deflection (When pressed by a force of approximately 10 kgf) (mm) Standard 11 - 13 • Compression [MPa (kgf/cm2)/rpm] Standard 1.45 (14.8)/250 (K21: Gasoline/Combined) 1.51 (15.4)/250 (K25: Gasoline/Combined) 1.57 (16.0)/250 (K21/K25: LPG) • Difference between each cylinder (kgf/cm2/rpm) Repair limit 1.0/300 • Spark plug gap (mm) Standard 0.8 - 0.9 • Distributor (Full transistor type) air gap (mm) Standard 0.35 - 0.45 • Valve clearance (Hot) (mm) Standard Intake: 0.38±0.03 Exhaust: 0.38±0.03 • Thermostat valve opening temperature (STD) (˚C) Standard 76.5 • Idle speed and ignition timing (BTDC˚/rpm) Standard 0/700±50 (K21) 0/700±50 (K25) CYLINDER HEAD • Cylinder head (mm) Material Aluminum alloy Distortion limit 0.1 CYLINDER BLOCK • Block upper surface (mm) Distortion limit 0.1 • Bore diameter dimension (mm) Standard 89.00 - 89.05 • Bore diameter wear (mm) Repair limit 0.2 • Bore diameter out-of-round (mm) Standard 0.02 or less • Bore diameter taper (mm) Standard 0.02 or less • Bore diameter out-of-round and taper (mm) Repair limit 0.1

GI-15

21

STANDARD AND REPAIR LIMIT PISTON • Piston (mm) Type Thermal flow type Material Aluminum alloy Outer diameter Standard 88.965 - 89.015 • Clearance between piston and cylinder (mm) Standard 0.025 - 0.045 (Selective fit service parts) • Piston pin outer diameter (mm) Standard 19.993 - 19.998 • Piston pin fitting quality Standard To a degree allowing movement by hand • Piston ring end clearance (mm) Standard Top 0.28 - 0.43 Second 0.45 - 0.60 Oil 0.20 - 0.60 Various limit values 1.00 • Clearance between piston ring and ring groove (mm) Standard Top 0.045 - 0.080 Second 0.030 - 0.070 Oil — Repair limit Top 0.10 Second 0.10 Oil — CONNECTING ROD • Distance between both end hole centers (mm) Standard 143.970 - 144.030 (K25) 152.470 - 152.530 (K21) • Large end hole diameter (mm) Standard 48.0 - 48.013 • Small end hole diameter (mm) Standard 19.965 - 19.978 • Bend (per 100 mm) (mm) Repair limit 0.05 • Torsion (per 100 mm) (mm) Repair limit 0.05 • Large end thrust clearance Standard 0.2 - 0.3 Repair limit 0.40 • Large end oil clearance (mm) Standard 0.030 - 0.066 Repair limit 0.10 • Difference of weight (Piston combination) (g) Standard 4 or less CRANKSHAFT • Bend (mm) Repair limit 0.05 • End play (mm) Standard 0.05 - 0.18 Repair limit 0.20 • Journal dimension (mm) Standard 62.942 - 62.955 • Pin standard dimension (mm) Standard 44.961 - 44.974 • Journal oil clearance (mm) Standard 0.020 - 0.073 Repair limit 0.10 22

GI-16

STANDARD AND REPAIR LIMIT •

Pin oil clearance (mm) Standard 0.032 - 0.066

FLYWHEEL • Flywheel surface swing (mm) Repair limit 0.10 • Ring gear surface swing (mm) Repair limit 0.50 • Flatness (mm) Repair limit 0.30 CAMSHAFT • Bend (mm) Repair limit 0.05 • Camshaft height (mm) Standard 36.750 - 36.800 (For both intake and exhaust) Size reduction limit 36.5 • Journal dimension (mm) Standard Front 45.434 - 45.447 Center 43.897 - 43.910 Rear 41.218 - 41.231 • End play (mm) Standard 0.025 - 0.255 Repair limit 0.40 • Journal oil clearance (mm) Standard Front 0.025 - 0.051 Center 0.038 - 0.064 Rear 0.025 - 0.051 Repair limit Front 0.10 Center 0.15 • Journal oil clearance (mm) Repair limit Rear 0.10 VALVE • Valve total length : mm (in) Standard Intake Exhaust •

•

•

•

98.85 - 99.45 (3.8917 - 3.9153) 98.95 - 99.55 (3.8957 - 3.9193)

Valve face angle Standard Intake 45˚30' Exhaust 45˚30' Head outer diameter : mm (in) Standard Intake 38.0 - 38.3 (1.496 - 1.508) Exhaust 32.0 - 32.3 (1.260 - 1.272) Valve stem outer diameter : mm (in) Standard Intake 6.965 - 6.980 (0.2742 - 0.2748) Exhaust 6.945 - 6.960 (0.273 - 0.274) Valve guide inner diameter : mm (in) Standard Intake 7.0 - 7.018 (0.2756 - 0.2763) Exhaust 7.0 - 7.018 (0.2756 - 0.2763)

GI-17

23

STANDARD AND REPAIR LIMIT •

•

•

•

• • • • • •

24

Clearance between valve stem and valve guide : mm (in) Standard Intake 0.020 - 0.053 (0.0080 - 0.0021) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) Repair limit Intake 0.10 (0.0039) Exhaust 0.10 (0.0039) Valve spring : mm (in) Free length Standard Intake and exhaust 44.92 (1.769) When opening valve is compressed : mm/N (mm/kg, in/lb) Standard Intake and exhaust 25.0/347.0 - 391.2 (25.0/35.4 - 39.9, 0.984/ 78.1 - 88.0) When closing valve is installed : mm/N (mm/kg, in/lb) Standard Intake and exhaust 33.8/177.9 - 200.7 (33.8/18.1 - 20.5, 1.331/ 39.9 - 45.2) Tilt : mm (in) Repair limit Intake and exhaust 1.5 (0.0059) Clearance between valve lifter and lifter guide : mm (in) Standard 0.016 - 0.052 (0.0006 - 0.0020) Clearance between crankshaft and flywheel : mm (in) Standard 0 - 0.038 (0 - 0.0015) Clearance between rocker shaft and rocker arm : mm (in) Standard 0.020 - 0.054 (0.0008 - 0.0021) Intake manifold : mm (in) Distortion limit 0.1 (0.004) Exhaust manifold : mm (in) Distortion limit 0.3 (0.012)

GI-18

STAMPED LOCATION OF ENGINE NO. STAMPED LOCATION OF ENGINE NO.

GIM0076

GI-19

25

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS

Refer to each section for details.

Application

Condition

Incident in ignition system

Incident in fuel system Refer to EF section for the LPG model.

Lowered compression pressure

26

Possible causes

Action

Common

Electronic controlled specifications

Carburetor specifications

√

•

Malfunction of low-voltage electronic distribution ignition coil

Replace.

•

Condenser malfunction

Replace.

•

Electric leakage from rotor cap and rotor

Clean or replace.

•

Spark plug malfunction

Clean, adjust gap or replace.

•

Inappropriate ignition timing

Adjust.

•

Ignition coil malfunction

Replace.

•

Open circuit in high-tension cable

Replace.

•

Loose or open primary wire connection

Repair or replace.

√

•

Insufficient fuel

Fill.

√

•

Contaminated fuel filter

Replace.

√

•

Plugged or contaminated fuel piping

Wash.

√

•

Plugged or contaminated fuel injector

Clean or replace.

•

Fuel pump malfunction

Repair or replace.

•

Carburetor choke malfunction

Check and adjust.

√

•

Inappropriate carburetor float level

Correct.

√

•

Inappropriate idling

Adjust.

•

Poor tightening of spark plug or inappropriate gasket

Tighten to correct torque or replace.

√

•

Inappropriate engine oil grade or deteriorated viscosity

Replace with appropriate grade of oil.

√

•

Inappropriate valve clearance

Adjust.

√

•

Compression pressure leak from valve Remove head and perform fine seat grinding to valve.

√

•

Stuck valve stem

Repair or replace cylinder head and valve.

√

•

Broken or chip valve spring

Replace valve spring.

√

•

Compression pressure leakage from head gasket

Replace head gasket.

√

•

Worn or stuck piston ring

Replace piston ring.

√

•

Worn piston ring or cylinder

Engine overhaul (Diagnosis procedure) a. Put a small amount of engine oil in the spark plug hole and measure the compression pressure. b. If the pressure builds up, a possible cause is in the cylinder or piston ring. c. If the pressure remains unchanged, the leakage can be attributed to the valve, cylinder head or head gasket.

√

GI-20

√ √ √ √ √ √

√ √

√

TROUBLE DIAGNOSIS Engine Adjustment Condition

Cause

Action

1. Engine noise Slapping noise of bearing and crankshaft

Slapping noise of piston, connecting rod

Slapping noise of camshaft

Timing chain noise

Bearing looseness

Replace.

Bearing seizure

Replace.

Crankshaft bend

Repair or replace.

Uneven wear of journal

Correct.

Excessive end play

Replace center bearing.

Bearing looseness

Replace.

Bearing seizure

Replace.

Piston looseness

Replace piston pin(s) or bushing(s).

Piston looseness relative to cylinder

Reselect.

Piston ring damage

Replace.

Poor rod alignment

Realign.

Bearing looseness

Replace.

Excessive axial looseness

Replace bearing thrust plate(s).

Rough gear tooth face(s)

Correct.

Gear damage

Replace.

Inappropriate tension

Adjust.

Damaged or sagged chain

Replace.

Worn sprocket

Replace.

Damaged or loose tensioner

Replace.

Excessive camshaft-to-bearing clearance Replace.

Slapping noise of valve gear

Slapping noise of water pump

Inappropriate valve clearance

Adjust.

Loose Adjust. screw(s)

Replace.

Worn rocker face(s)

Replace.

Worn valve guide(s)

Replace guide(s).

Loose valve spring(s)

Replace.

Valve seizure

Repair or replace.

Inappropriate end play

Replace.

Damaged impeller

Replace.

Inappropriate clearance

Adjust.

Valve stem - insufficient guide-to-guide clearance

Clean stem(s), ream guide(s).

2. Other mechanical damage Stuck valve

Burnt valve seat(s)

Loose or damaged spring

Replace.

Seized or damaged valve stem(s)

Replace or clean.

Poor fuel quality

Use good fuel.

Inappropriate valve clearance

Adjust.

Deteriorated valve spring(s)

Replace.

Edged valve end(s)

Replace bulb.

Too narrow valve seat width

Correct valve seat(s).

Engine over temperature (Overheat)

Repair or replace.

Overrun

Operate in optimum speed range.

Stuck valve guide(s)

Correct.

GI-21

27

TROUBLE DIAGNOSIS Engine Adjustment (Cont’d) Condition Excessive wear of cylinder piston(s)

Poor functioning of connecting rod(s)

Poor functioning of crankshaft bearing(s)

28

Cause

Action

Insufficient engine oil

Refill or replace oil.

Contaminated engine oil

Clean crankcase, replace oil filter.

Poor quality oil

Use specified oil.

Engine over temperature (Overheat)

Repair or replace.

Wrong combination of piston and connecting rod

Repair or replace.

Inappropriate clearance of piston ring

Reselect and adjust.

Piston ring damage

Replace.

Damaged air cleaner

Wash.

Too rich air-fuel mixture

Adjust.

Overrun

Operate in optimum speed range.

Stuck choke valve

Clean and adjust.

Excessive use of choke valve

Start engine properly.

Insufficient engine oil

Fill oil.

Low oil pressure

Repair.

Use of poor quality oil

Use specified oil.

Rough crank surface(s)

Grind surface(s), replace bearing(s).

Plugged oil passage

Clean.

Wear or damage of bearing

Replace.

Inappropriate bearing

Correct.

Bearing looseness

Replace.

Poor connecting rod alignment

Repair or replace.

Insufficient engine oil

Fill or replace oil.

Low oil pressure

Correct.

Use of poor quality oil

Use specified oil.

Uneven wear of crank journal(s)

Repair

Plugged oil passage of crankshaft

Wash.

Wear or damage of bearing

Replace.

Inappropriate bearing

Correct.

Damaged bearing(s)

Replace.

GI-22

TROUBLE DIAGNOSIS Engine Adjustment (Cont’d) Condition No or slow cranking

Engine is cranked but not started.

Refer to EF section for the LPG model.

Possible causes

Action

•

Inappropriate engine oil grade

Replace oil with a proper one.

•

Battery is discharged

Charge battery.

•

Battery damage

Replace battery.

•

Loose fan belt

Adjust belt tension.

•

Incident in charge system

Check.

•

Incident in starter system wiring

Repair.

•

Starter switch malfunction

Repair or replace.

•

Starter motor malfunction

Repair or replace.

(Starter circuit diagnosis procedure) If the light turns off or dims when the starter switch is turned to “ON” with the headlights on: a: Check the battery. b: Check the electric connections and wirings. c: Check the starter motor.

If the light remains bright when the starter switch is turned to “ON” with the headlights on: a: Check the wiring between battery and starter motor. b: Check the starter switch. c: Check the starter motor.

Such incidents are attributed to the following factors, but most likely, the ignition system or the fuel system is the main cause.

•

Incident in ignition system

(Diagnosis procedure)

•

Incident in fuel system

Check the spark plug following the steps below.

•

Dynamic valve system does not operate normally.

•

Poor compression

Disconnect the IGN/coil from the No. 1 plug and keep it 10 mm (0.394 in) away from the engine metal portions. Then crank the engine.

If a good spark is available: a. Check the ignition plugs. b. Check the ignition timing. c. Check the fuel system. d. Check the compression pressure.

If no spark is available: a. Check the primary coil current. b. If the current level is high, check the primary coil for short circuit.

•

Damaged or plugged fuel injector

•

Plugged air cleaner

Replace element.

•

Damaged manifold gasket or insulator

Replace gasket or insulator.

Inappropriate idling Incident in fuel system Refer to EF section for the LPG model.

Clean or replace.

Lowered compression pressure

Already described.

Engine power does not increase to an appropriate level

Adjust.

Lowered compression pressure Incident in ignition system

Already described.

•

Inappropriate ignition timing

Adjust.

•

Spark plug malfunction

Clean, adjust or replace.

GI-23

29

TROUBLE DIAGNOSIS Engine Adjustment (Cont’d) Condition Incident in fuel system

Possible causes

Action

•

Malfunction of carburetor choke system

•

Plugged fuel piping

Clean

•

Plugged or contaminated fuel filter

Replace.

•

Fuel pump malfunction

Repair or replace

•

Plugged carburetor jet or needle valve

Disassemble and clean.

•

Poor throttle valve opening

Adjust.

•

Fuel pump malfunction

Adjust.

•

Plugged air cleaner

Replace element

•

Air leakage from electronic throttle insulator

Replace insulator.

•

Air leakage from manifold gasket or carburetor insulator

Replace gasket or insulator.

•

Insufficient amount of coolant

Fill coolant.

•

Loose fan belt.

Adjust belt tension.

•

Worn or loose fan belt

Replace.

•

Malfunctioning thermostat

Replace.

•

Water pump malfunction

Replace.

•

Plugged or leaking radiator

Wash, repair, or replace.

•

Radiator cap damage

Replace.

•

Air in cooling system piping

Retighten cooling system piping, bleed system.

•

Improper engine oil grade

Replace with appropriate grade of engine oil.

•

Inappropriate ignition timing

Adjust.

•

Carburetor malfunction (too lean air-fuel mixture)

Overhaul carburetor.

Overcool

•

Malfunctioning thermostat

Replace.

Other

•

Inappropriate octane rating of fuel

Replace with specified octane rating of fuel.

•

Insufficient tire air pressure

Charge to specified air pressure.

•

Brake dragging

Adjust.

•

Clutch slippage

Adjust.

•

Engine overload

Operate with light load

•

Knocking due to carbon deposits

Remove cylinder head and eliminate carbon deposits.

•

Knocking due to inappropriate ignition timing Adjust ignition timing.

•

Knocking due to inappropriate octane rating of fuel

Use specified octane rating of fuel.

•

Too advance ignition (Inappropriate spark plug selection)

Use specified type of spark plug.

•

Strong and heavy noise from engine during acceleration

A possible cause is in damage/wear of bearing or uneven wear of crankshaft.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

Need to replace bearing and adjust or replace crankshaft.

•

If misfires at a particular cylinder stop the noise, that cylinder is the noise source.

•

This noise is also generated during engine acceleration but at a little more rapid pitch than crank slapping.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

•

If misfires at a particular cylinder almost stop the noises, that cylinder is the noise source.

Refer to EF section for the LPG model.

Incident in intake system

Engine over temperature (Overheat)

Adjust.

Engine noise Knocking

Mechanical slapping Crankshaft bearing slapping

Connecting rod bearing slapping

30

GI-24

Take the same action as that for crankshaft bearing.

TROUBLE DIAGNOSIS Engine Adjustment (Cont’d) Condition Piston and cylinder slapping

Piston pin slapping

Water pump noise

Possible causes

Action

•

Mechanical rapping noise that increases according the engine speed but decreases as the engine is warmed up is attributed to the pistons and cylinders.

This noise is caused by excessive wear of cylinders and accompanied by engine power deterioration and excessive oil consumption.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

For a corrective action, engine overhaul is needed.

•

This noise is generated at piston TDC and BDC positions.

A possible cause is wear of the piston pin hole or piston pin.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

Need to replace piston and piston pin assembly.

•

This noise is generated from worn or damaged bearing(s) due to the uneven sliding faces.

Replace water pump.

•

Worn piston ring groove(s) and ring(s)

Replace piston(s) and piston ring(s).

•

Deteriorated valve oil seal lip(s)

Replace valve oil seal(s).

•

Worn valve stem(s)

Replace valve(s).

•

Use of inappropriate quality of oil

Use specified oil.

•

Engine overheat

Already described

•

Excessive idling speed

Adjust to specified level.

•

Insufficient throttle return

Adjust.

•

Fuel leakage

Repair fuel piping and additionally tighten connections.

•

Use of inappropriate quality of oil

Replace specified oil.

•

Engine over temperature (Overheat)

Already described.

•

Oil pump regulator valve malfunction

Overhaul or replace oil pump.

•

Oil pump malfunction

Overhaul or replace oil pump.

•

Oil filter malfunction

Replace with a new one.

•

Enlarged clearance of each sliding component

Disassemble and replace relevant sliding component(s).

•

Clogged oil strainer

Wash.

•

Malfunction of oil pressure gauge pressure switch

Replace with a new one.

•

Low oil pressure

Already described.

•

Poor quality of oil or foreign objects in oil

Replace oil element and oil with appropriate ones.

•

Poor performance of air cleaner

Check element.

•

Overheat or excessive cooling

Already described.

•

Inappropriate air-fuel ratio

Check fuel system.

•

Low oil pressure

Already described.

•

Insufficient clearance

Adjust clearance to specified value.

•

Engine over temperature (Overheat)

Already described.

•

Inappropriate air-fuel ratio

Check fuel system.

Excessive oil consumption Oil leakage

Other

Inappropriate fuel consumption Refer to description of engine power deterioration.

Other Refer to EF section for the LPG model.

Incident due to other factors Low oil pressure

Excessive wear of sliding part(s)

Bite of sliding parts

GI-25

31

TROUBLE DIAGNOSIS Engine LPG Fuel System Condition

Possible causes

Action

Fuel leakage Nasty smell

Excessive fuel consumption

•

Looseness of piping connection

Tighten.

•

Operating malfunction of vaporizer

Repair and adjust.

•

Poor connection or some foreign object is caught in between plunger rubber seat and valve seat of solenoid valve

Clean and rub.

•

Looseness of piping connection

Retighten and adjust.

•

Primary side room pressure at idle is excessively high.

Clean and adjust.

•

Clogged air cleaner

Wash.

•

Operating malfunction of vaporizer

Repair and adjust.

•

Looseness of piping connection or clogged filter

Clean and retighten.

•

Adjusting malfunction of vaporizer primary room pressures

Adjust.

•

Use improper fuel.

Use proper fuel.

•

Clogged fuel passage

Clean.

•

Operating malfunction of electric throttle control actuator

Replace.

•

Operating malfunction of vaporizer

Repair and adjust.

•

Operating malfunction of vaporizer valve (It is Clean, adjust or replace. closed improperly.)

Engine hesitation or hunting

•

Operating malfunction of vaporizer

Adjust.

Poor starting engine

•

Insufficient fuel

Refill fuel.

•

Operating malfunction

Make sure that manual valve is opened.

•

Operating malfunction of solenoid valve

Check and repair wiring, switch, and solenoid valve.

•

Operating malfunction of vaporizer

Replace.

•

Water pump malfunction

Repair and adjust

•

Adjusting malfunction of vaporizer primary room pressures

Adjust.

•

Leakage from primary valve seats of vaporizer

Clean, adjust, or replace.

•

Damage of diaphragm

Replace.

•

Foreign materials enter vaporizer inside

Clean and adjust.

•

Leakage by looseness of setscrew

Tighten.

•

Overcool of vaporizer (Fur deposit, damage of hose, poor coolant circulation)

Check, clean, and adjust.

•

Tar deposit in valve

Remove tar and clean.

Low output

Inconsistent or rough idle

Operating malfunction of vaporizer

32

GI-26

MAINTENANCE SECTION

MA MA

CONTENTS ENGINE MAINTENANCE.................................... MA-2 Specifications.................................................. MA-2 Tightening Torque........................................... MA-6

Maintenance Schedule ................................... MA-8 Oil and Grease, and Capacity......................... MA-9 On Board Inspection and Service ................. MA-10

33

ENGINE MAINTENANCE ENGINE MAINTENANCE

Specifications INSPECTION AND ADJUSTMENT • Oil capacity H line (L) 3.5 • Oil capacity L line (L) 2.5 • (Oil filter capacity) (L) 0.3 • Fan belt deflection (When pressed by a force of approximately 10 kgf) (mm) Standard 11 - 13 • Compression [MPa (kgf/cm2)/rpm] Standard 1.45 (14.8)/250 (K21: Gasoline/Combined) 1.51 (15.4)/250 (K25: Gasoline/Combined) 1.57 (16.0)/250 (K21/K25: LPG) • Difference between each cylinder (kgf/cm2/rpm) Repair limit 1.0/300 • Spark plug gap (mm) Standard 0.8 - 0.9 • Distributor (Full transistor type) air gap (mm) Standard 0.35 - 0.45 • Valve clearance (Hot) (mm) Standard Intake: 0.38 Exhaust: 0.38 • Thermostat valve opening temperature (STD) (˚C) Standard 76.5 • Idle speed and ignition timing (BTDC˚/rpm) Standard 0/700±50 (K21) 0/700±50 (K25) CYLINDER HEAD • Cylinder head (mm) Material Aluminum alloy Distortion limit 0.1 CYLINDER BLOCK • Block upper surface (mm) Distortion limit 0.1 • Bore diameter dimension (mm) Standard 89.00 - 89.05 • Bore diameter wear (mm) Repair limit 0.2 • Bore diameter out-of-round (mm) Standard 0.02 or less • Bore diameter taper (mm) Standard 0.02 or less • Bore diameter out-of-round and taper (mm) Repair limit 0.1

34

MA-2

ENGINE MAINTENANCE Specifications (Cont’d) PISTON • Piston (mm) Type Thermal flow type Material Aluminum alloy Outer diameter Standard 88.965 - 89.015 • Gap between piston and cylinder (mm) Standard 0.025 - 0.045 (Selective fit service parts) • Piston pin outer diameter (mm) Standard 19.993 - 19.998 • Piston pin fitting quality Standard To a degree allowing movement by hand • Piston ring end gap (mm) Standard Top 0.28 - 0.43 Second 0.45 - 0.60 Oil 0.20 - 0.60 Various limit values 1.00 • Gap between piston ring and ring groove (mm) Standard Top 0.045 - 0.080 Second 0.030 - 0.070 Oil Repair limit Top 0.10 Second 0.10 Oil CONNECTING ROD • Distance between both end hole centers (mm) Standard 143.970 - 144.030 (K25) 152.470 - 152.530 (K21) • Large end hole diameter (mm) Standard 48.0 - 48.013 • Small end hole diameter (mm) Standard 19.965 - 19.978 • Bend (per 100 mm) (mm) Repair limit 0.05 • Torsion (per 100 mm) (mm) Repair limit 0.05 • Large end thrust gap Standard 0.2 - 0.3 Repair limit 0.40 • Large end oil clearance (mm) Standard 0.030 - 0.066 Repair limit 0.10 • Difference of weight (Piston combination) (g) Standard 4 or less

MA-3

35

ENGINE MAINTENANCE Specifications (Cont’d) CRANKSHAFT • Bend (mm) Repair limit 0.05 • End play (mm) Standard 0.05 - 0.18 Repair limit 0.20 • Journal dimension (mm) Standard 62.942 - 62.955 • Pin standard dimension (mm) Standard 44.961 - 44.974 • Journal oil clearance (mm) Standard 0.020 - 0.073 Repair limit 0.10 • Pin oil clearance (mm) Standard 0.032 - 0.066 FLYWHEEL • Flywheel surface swing (mm) Repair limit 0.10 • Ring gear surface swing (mm) Repair limit 0.50 • Flatness (mm) Repair limit 0.30 CAMSHAFT • Bend (mm) Repair limit 0.05 • Camshaft height (mm) Standard 36.750 - 36.800 (For both intake and exhaust) Size reduction limit 36.5 • Journal dimension (mm) Standard Front 45.434 - 45.447 Center 43.897 - 43.910 Rear 41.218 - 41.231 • End play (mm) Standard 0.025 - 0.255 Repair limit 0.40 • Journal oil clearance (mm) Standard Front 0.025 - 0.051 Center 0.038 - 0.064 Rear 0.025 - 0.051 Repair limit Front 0.10 Center 0.15 • Journal oil clearance (mm) Repair limit Rear 0.10

36

MA-4

ENGINE MAINTENANCE Specifications (Cont’d) VALVE • Head outer diameter : mm (in) Standard Intake 38.0 - 38.3 (1.496 - 1.508) Exhaust 32.0 - 32.3 (1.260 - 1.272) • Valve stem outer diameter : mm (in) Standard Intake 6.965 - 6.980 (0.2742 - 0.2748) Exhaust 6.945 - 6.960 (0.2734 - 0.2740) • Valve guide inner diameter : mm (in) Standard Intake 7.0 - 7.018 (0.2756 - 0.2763) Exhaust 7.0 - 7.018 (0.2756 - 0.2763) • Clearance between valve stem and valve guide : mm (in) Standard Intake 0.020 - 0.053 (0.0008 - 0.0021) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) Repair limit Intake 0.10 (0.0039) Exhaust 0.10 (0.0039) • Clearance between valve lifter and lifter guide : mm (in) Standard 0.016 - 0.052 (0.0006 - 0.0020) • Clearance between crankshaft and flywheel : mm (in) Standard 0 - 0.038 (0 - 0.0015) • Clearance between rocker shaft and rocker arm : mm (in) Standard 0.020 - 0.054 (0.0008 - 0.0021) • Valve clearance (Hot) : mm (in) Intake 0.38±0.03 (0.0150±0.0012) Exhaust 0.38±0.03 (0.0150±0.0012)

MA-5

37

ENGINE MAINTENANCE Tightening Torque Upper:

Lubricated (Antirust oil is applied to abrasive faces of threads and seating faces) No lubrication (Threads and seating faces are completely degreased)

Lower:

Thread size Diameter

Hexagon head bolt and nut

M6

M8

1

1.25

1.25

M10

1.5

M6

Flanged bolt

M8

Unit

4T (Bolt)

7T (Bolt)

9T (Bolt)

N·m

3.82 - 4.41

6.37 - 7.45

9.22 - 10.8

(kgf-m)

(0.39 - 0.45)

(0.65 - 0.76)

(0.94 - 1.1)

N·m

5.00 - 6.47

8.43 - 10.8

11.8 - 15.7

(kgf-m)

(0.51 - 0.66)

(0.86 - 1.1)

(1.2 - 1.6)

N·m

9.32 - 10.8

15.7 - 17.7

22.6 - 25.5

(kgf-m)

(0.95 - 1.1)

(1.6 - 1.8)

(2.3 - 2.6)

N·m

12.7 - 15.7

20.6 - 26.5

29.4 - 37.3

Pitch

1

1.25

1.25

M10

1.5

(kgf-m)

(1.3 - 1.6)

(2.1 - 2.7)

(3.0 - 3.8)

N·m

19.6 - 22.6

32.4 - 38.2

47.1 - 53.9

(kgf-m)

(2.0 - 2.3)

(3.3 - 3.9)

(4.8 - 5.5)

N·m

25.5 - 33.3

43.1 - 54.9

61.8 - 78.5

(kgf-m)

(2.6 - 3.4)

(4.4 - 5.6)

(6.3 - 8.0)

N·m

18.6 - 21.6

30.4 - 36.3

44.1 - 52

(kgf-m)

(1.9 - 2.2)

(3.1 - 3.7)

(4.5 - 5.3)

N·m

24.5 - 31.4

41.2 - 52

58.8 - 74.5

(kgf-m)

(2.5 - 3.2)

(4.2 - 5.3)

(6.0 - 7.6)

N·m

4.9 - 5.69

8.14 - 9.51

11.8 - 13.7

(kgf-m)

(0.5 - 0.58)

(0.83 - 0.97)

(1.2 - 1.4)

N·m

5.98 - 7.65

9.81 - 12.7

14.7 - 18.6

(kgf-m)

(0.61 - 0.78)

(1.0 - 1.3)

(1.5 - 1.9)

N·m

11.8 - 13.7

19.6 - 23.5

28.4 - 33.3

(kgf-m)

(1.2 - 1.4)

(2.0 - 2.4)

(2.9 - 3.4)

N·m

14.7 - 18.6

24.5 - 31.4

35.3 - 45.1

(kgf-m)

(1.5 - 1.9)

(2.5 - 3.2)

(3.6 - 4.6)

N·m

24.5 - 29.4

41.2 - 48.1

59.8 - 69.6

(kgf-m)

(2.5 - 3.0)

(4.2 - 4.9)

(6.1 - 7.1)

N·m

30.4 - 39.2

51.0 - 64.7

73.6 - 93.2

(kgf-m)

(3.1 - 4.0)

(5.2 - 6.6)

(7.5 - 9.5)

N·m

23.5 - 27.5

39.2 - 46.1

56.9 - 65.7

(kgf-m)

(2.4 - 2.8)

(4.0 - 4.7)

(5.8 - 6.7)

N·m

29.4 - 37.3

49.0 - 61.8

69.6 - 89.2

(kgf-m)

(3.0 - 3.8)

(5.0 - 6.3)

(7.1 - 9.1)

CAUTION: Except special nuts and bolts.

The bolts applicable to this table have one of the following marks embossed on their heads.

4T......4 7T......7 9T......9

38

MA-6

ENGINE MAINTENANCE Tightening Torque (Cont’d) Tightening point

Unit

Cylinder head (lubricated) Crankshaft pulley bolt

Oil filter element

Spark plug

Engine slinger bolt

Rocker cover nut

Water temperature gauge

Oil pressure switch

Crankshaft position sensor plug bolt

Thermo-housing air relief plug

MA-7

Max. value

Refer to MA-10.

N·m

220.5

240.1

kg-m

22.5

24.5

ft-lb

163

177

N·m

14.7

20.6

kg-m

1.5

2.1

ft-lb

11

15

N·m

19.6

29.4

kg-m

2.0

3.0

ft-lb

14

22

N·m

22.6

25.5

kg-m

2.31

2.6

ft-lb

16.7

19

N·m

14.7

16.7

kg-m

1.5

1.7

ft-lb

11

13

N·m

15.7

19.6

kg-m

1.6

2.0

ft-lb

12

14

N·m

15.7

21.6

kg-m

1.6

2.2

ft-lb

12

16

Exhaust manifold nut Oil pan drain plug

Standard

Refer to MA-10.

N·m

29.4

39.2

kg-m

3.0

4.0

ft-lb

22

29

N·m

6.37

7.45

kg-m

0.65

0.76

in-lb

56

66

N·m

6.37

7.45

kg-m

0.65

0.76

in-lb

56

66

39

ENGINE MAINTENANCE Maintenance Schedule Make sure to perform appropriate maintenance and service work to maintain the initial performances of the MITSUBISHI Forklift Trucks.

PERFORM INSPECTION Make sure to perform the periodical inspections at appropriate times, according to the month basis or the operating hour basis, whichever comes first. ...... Inspection period DAILY / WEEKLY INSPECTION Operator’s inspection No. Inspection items

Days of use

Daily

Weekly

Operation hours

10

50

1

Cooling fan (rotation & damage)

I

2

Engine coolant level

I

3

V-belt (fan & alternator) tension

4

Battery electrolyte level

I

5

Engine (exhaust, noise, & vibration)

I

6

Engine oil level

7

Fuel hose, pipes & joints

8

Fuel level (leakage)

9

Air cleaner element

I

I

I (2) for LPG

I I

(1)

I

FIRST MONTH / PLANNED INSPECTION See “CAUTION” for figures in ( ) and symbols on the next page.

Engine system inspection (except LPG fuel system)

No. Inspection items

Months of use

1

Operation hours (x 100 hours)

2

5

10

15

20

25

30

A

A

A

A

A

A

I

I

I

I

I

I

R

R

1

Intake/exhaust valve clearance

A

2

Cylinder head bolt and manifold nut

T

3

Radiator

4

Engine oil

Fin

5

Oil filter

(1)

Filler cap

I

3

4

5

6

7

8

9

I (1) (1)

R R

10 11 12 13 14 15 16 17 18

I R

R

R

(every 500 hours or 3 months, whichever comes first) R R R R

R

R

R

(every 500 hours or 3 months, whichever comes first) R

6

Engine coolant

7

Spark plug

8

PCV valve

9

PCV hose

10

Air cleaner element

11

Rubber hose condition

I

12

Battery electrolyte specific gravity

I

40

2

I (1)

I

I

I

I

I

R

I

I

I

I

I

I

I

I

I

I

I

I

R

R

R

I I

MA-8

I

I

I

I

I

ENGINE MAINTENANCE Maintenance Schedule (Cont’d) Engine system inspection (LPG models)

No.

Inspection items

Months of use

1

Operation hours (x 100 hours)

2

5

10

15

20

25

30

D

D

D

D

D

D

D

C

C

C

R

C

C

1

Tar in vaporizer

(3)

2

LPG filter

(3)

3

Vaporizer rubber parts

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

R

•

• •

CAUTION: (1) The maintenance work should be performed more frequently if the vehicle is being used in dusty and dirty environments.

(2) Apply soap suds to the piping joints to check for any gas leakage after replacing the LPG tank.

(3) When fuel with poor quality is used, check, drain, clean and change more frequently.

Meanings of symbols: I = Inspection. Repair or replace if necessary.

R = Replacement A = Adjustment C = Cleaning D = Draining T = Tightening (Retightening)

Oil and Grease, and Capacity OIL, LLC Items

Specification

Remarks

Engine oil

10W-30 (Class SJ)

Antifreeze

Recommended long life coolant

(Class SL; Factory shipping) Consult your local dealer.

Filling capacity (guideline) Unit: L (US qt) Items Engine oil

MA-9

Capacity (Liter) K21

3.8 (4) (including filter)

K25

3.8 (4) (including filter)

41

ENGINE MAINTENANCE On Board Inspection and Service Tightening torque

Tightening procedure

Tightening torque N m (kg-m, ft-lb) (Reference) 19.6 - 23.5 (2.0 - 2.3, 14 - 17) Tightening for brake-in 68.6 (7.0, 51) 0 (0, 0)

Return

19.6 - 23.5 (2.0 - 2.3, 14 - 17)

Step

Retightening

90 - 92

TIGHTENING OF HEAD BOLT Tighten head bolts from inside to outside as shown in the figure.

Tighten bolts gradually as shown in the figure.

Tightening torque: 68.6 N·m (7.0 kg-m) [51 ft-lb] (This tightening torque can be used in step (5) as shown in the figure for service.)

CAUTION: Check tightening angle with an angle wrench (SST) or a protractor. Do not simply estimate tightening angle.

Assembly sequence 9

3

1

6

8

5

2

4

10

Crankshaft pulley side 7

Precautions before assembling Do not allow oil or dust to get on cylinder head, mounting surface of cylinder block,and head gasket.

Apply anticorrosive oil onto head bolt thread and surface under the head.

MAM0147

RETIGHTENING OF MANIFOLD NUT AND BOLT CAUTION: Do not retighten nut and bolt until manifold components get cold. It may cause to get burned.

Tightening torque for manifold and nut Models

N·m

kg-m

ft-lb

K21

41.2 - 48.1

4.2 - 4.91

30.4 - 35.6

K25

41.2 - 48.1

4.2 - 4.91

30.4 - 35.6

(Do not use power tools such as air runner to tighten.)

INTAKE/EXHAUST VALVE CLEARANCE ADJUSTMENT • Adjustment must be made with the vehicle in hot condition.

1. Warm up engine until engine coolant temperature gauge shows nearly center, and then stop it.

2. Remove rocker cover.

3. Turn the crankshaft.

CAUTION: Disconnect IGN/coil from ignition coil when rotating crankshaft with starter motor.

42

MA-10

ENGINE MAINTENANCE On Board Inspection and Service (Cont’d) 4.

5.

Set the piston for the No. 1 cylinder to the compression TDC and adjust the valves of (1), (2), (3), and (5) in the figure.

Set the piston for the No. 4 cylinder to the compression TDC by rotating crank again and adjust the valves of (4), (6), (7), and (8) in the figure.

Intake/exhaust valve clearance (Hot) Unit: mm (in)

MAM0143

Models

Intake

Exhaust

K21

0.38 (0.015)

0.38 (0.015)

K25

0.38 (0.015)

0.38 (0.015)

INSPECTION AND ADJUSTMENT OF ENGINE DRIVE BELT CAUTION: Make sure that engine stops. Wash hands.

1.

2.

Visually check fan belt for wear, damage, and cracks. Do not contact the belt with pulley groove bottom.

Push the belt between pulleys. Check tension.

Belt deflection: 11 - 13 mm (0.43 - 0.51 in) Force: 98 N (10 kgf) [22 lb]

ETM0046

REPLACEMENT OF OIL AND OIL FILTER 1. Warm engine.

2. Remove oil pan drain plug and oil filler cap, and discharge all oil.

CAUTION: Be careful not to get burned when engine or engine oil is heated.

• If the oil looks milky, it is contaminated with coolant. Repair if necessary.

• If the viscosity is lower than specified, the oil is mixed with gasoline. Repair if necessary.

3. Wipe around drain hole. Install drain plug.

Tightening torque for oil pan drain plug: 29.4 - 39.2 N·m (3.0 - 4.0 kgf-m) [22 - 29 ft-lb] •

MA-11

43

ENGINE MAINTENANCE On Board Inspection and Service (Cont’d) 4.

• •

Replace oil filter.

Remove oil filter using an oil filter wrench (ST).

Wipe oil filter mounting surface with a clean shop cloth.

•

Apply a small amount of engine oil to the lip of the new oil filter.

•

Screw in the oil filter by hand until it contacts cylinder block boss, and then screw in another 2/3 of a turn.

5.

Fill the oil according to the specified lubricant amount.

MAM0144

MAM0145

MAM0146

Standard oil amount Including filter

3.8L

Not including filter

3.5L

6.

7.

44

Start engine, and make sure that there is no leakage around drain plug and oil filter. Replace drain plug and oil filter if there is some leakage.

Run engine, and stop it after engine coolant temperature gauge is in nearly center position. Check oil level after waiting for a few minutes. Refill oil if necessary.

MA-12

ENGINE TUNE-UP SECTION

ET

CONTENTS SPECIFICATIONS ................................................ ET-2 TIGHTENING TORQUE ....................................... ET-3 TROUBLE DIAGNOSIS ....................................... ET-4

ET

ENGINE INSPECTION AND ADJUSTMENT....... ET-9 Engine Body Related ....................................... ET-9 Ignition and Fuel Systems ............................. ET-13

45

SPECIFICATIONS SPECIFICATIONS Items Valve clearance (Hot) mm (in) Fan belt deflection

Engine type

K21

K25

Intake

0.38 (0.015)

Exhaust mm (in)

Belt push force

N (kg) [lb]

Engine oil amount

L (US qt)

11 - 13 (0.43 - 0.51) 98 (10) [22]

(including oil filter)

3.8 (4)

(not including oil filter) Compression pressure

3.5 (3-3/4) [MPa (kg/cm2) [psi]/rpm

Gasoline/Combined

1.45 (14.8) [210]/250

1.51 (15.4) [219]/250

LPG

1.57 (16.0) [228]/250

1.57 (16.0) [228]/250

Minimum value Spark plug type

FR2A-D

Plug gap

mm (in)

Ignition timing/idle speed

BTDC deg./rpm

Maximum engine speed without load

rpm (instantaneous)

2,700

Maximum engine speed with load

rpm

2,700

46

0.9 (0.035) 700±50

ET-2

TIGHTENING TORQUE TIGHTENING TORQUE

Unit : N·m (kgf-m) Cylinder head bolt

See the figure on the left

Manifold nut

41.2 - 48.1 (4.2 - 4.91)

Oil pan drain plug

29.4 - 39.2 (3.0 - 4.0)

Spark plug

19.6 - 29.9 (2.0 - 3.0)

CYLINDER HEAD Tightening torque for general service is 68.6 N·m (7.0 kgf-m) in the location of the tightening torque (5) as shown in the figure.

Apply antirust oil or engine oil to the threads and head bottom of each head bolt.

MAM0142

ET-3

47

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS Condition No or slow cranking

Engine is cranked but not started.

Refer to EF section for the LPG model.

48

Possible causes

Action

•

Inappropriate engine oil grade

Replace oil with a proper one.

•

Battery is discharged

Charge battery.

•

Battery damage

Replace battery.

•

Loose fan belt

Belt tension adjustment

•

Incident in charge system

Inspection

•

Incident in starter system wiring

Repair

•

Starter switch malfunction

Repair or replace

•

Starter motor malfunction

Repair or replace (Starter circuit diagnosis procedure) If the light turns off or dims when the starter switch is turned to “ON” with the headlights on: a: Inspect the battery b: Inspect the electric connections and wirings c: Inspect the starter motor If the light remains bright when the starter switch is turned to “ON” with the headlights on: a: Inspect the wiring between battery and starter motor b: Inspect the starter switch c: Inspect the starter motor

Such incidents are attributed to the following factors, but most likely, the ignition system or the fuel system is the main cause.

•

Incident in ignition system

(Diagnosis procedure)

•

Incident in fuel system

Inspect the spark plug following the steps below

•

Dynamic valve system does not operate normally.

•

Poor compression

Disconnect the IGN/coil from the No. 1 plug and keep it 10 mm (0.394 in) away from the engine metal portions. Then crank the engine.

If a good spark is available: a. Inspect the ignition plugs. b. Inspect the ignition timing c. Inspect the fuel system d. Inspect the compression pressure.

If no spark is available: a. Inspect the primary coil current b. If the current level is high, check the primary coil for short circuit

ET-4

TROUBLE DIAGNOSIS

Application Condition Incident in ignition system

Incident in fuel system Refer to EF section for the LPG model.

Lowered compression pressure

Possible causes

Action

Electronic controlled specifications

•

Malfunction of low-voltage electronic distribution ignition coil

Replace

√

•

Condenser malfunction

Replace

√

•

Spark plug malfunction

Clean, adjust gap or replace

√

•

Ignition coil malfunction

Replace

√

•

Loose or open primary wire connection

Repair or replace

√

•

Insufficient fuel

Fill

√

•

Contaminated fuel filter

Replacement

√

•

Plugged or contaminated fuel piping

Washing

√

•

Plugged or contaminated fuel injector

Clean or replace

√

•

Fuel pump malfunction

Repair or replace

√

•

Poor tightening of spark plug or inappropriate gasket

Tighten to correct torque or replace

√

•

Inappropriate engine oil grade or deteriorated viscosity

Replace with appropriate grade of oil

√

•

Inappropriate valve clearance

Adjustment

√

•

Compression pressure leakage from valve seat

Remove head and perform fine grinding to valve

√

•

Stuck valve stem

Repair or replace cylinder head and valve.

√

•

Broken or chip valve spring

Replace valve spring.

√

•

Compression pressure leakage from head gasket

Replace head gasket.

√

•

Worn or stuck piston ring

Replace piston ring.

√

•

Worn piston ring or cylinder

Engine overhaul (Diagnosis procedure) a. Put a small amount of engine oil from the ignition plug hole and measure the compression pressure. b. If the pressure builds up, a possible cause is in the cylinder or piston ring. c. If the pressure remains unchanged, the leakage can be attributed to the valve, cylinder head or head gasket.

√

ET-5

49

TROUBLE DIAGNOSIS

Condition

Possible causes

Action

Inappropriate idling Incident in fuel system Refer to EF section for the LPG model.

•

Plugged or damaged carburetor jet

Clean or replace

•

Damaged or plugged fuel injector

Clean or replace

•

Inappropriate idle adjustment

Adjustment

•

Plugged air cleaner

Replace element

•

Damaged manifold gasket or carburetor insulator

Replace gasket or insulator.

•

Inappropriate carburetor float level adjustment

Adjustment

Lowered compression pressure

Already described

Engine power does not increase to an appropriate level

Adjustment

Lowered compression pressure Incident in ignition system

Incident in fuel system Refer to chapter EF section for the LPG model.

Incident in intake system

Engine over temperature (Overheat)

Already described •

Inappropriate ignition timing

Adjustment

•

Spark plug malfunction

Clean, adjust or replace.

•

Malfunction of carburetor choke system

Adjustment

•

Plugged fuel piping

Clean

•

Plugged or contaminated fuel filter

Replacement

•

Fuel pump malfunction

Repair or replace

•

Plugged carburetor jet or needle valve

Disassemble and clean.

•

Poor throttle valve opening

Adjustment

•

Fuel pump malfunction

Adjustment

•

Plugged air cleaner

Replace element

•

Air leakage from electronic throttle insulator

Replace insulator.

•

Air leakage from manifold gasket or carburetor insulator

Replace gasket or insulator.

•

Insufficient amount of coolant

Fill coolant.

•

Loose fan belt.

Belt tension adjustment

•

Worn or loose fan belt

Replacement

•

Malfunctioning thermostat

Replacement

•

Water pump malfunction

Replacement

•

Plugged or leaking radiator

Wash, repair, or replace

•

Radiator cap damage

Replacement

•

Air in cooling system piping

Retighten cooling system piping, bleed system.

•

Improper engine oil grade

Replace with appropriate grade of engine oil.

•

Inappropriate ignition timing

Adjust.

•

Carburetor malfunction (too lean air-fuel mixture)

Overhaul carburetor

Overcool

Malfunctioning thermostat

Replacement

Other

•

Inappropriate octane rating of fuel

Replace with specified octane rating of fuel.

•

Insufficient tire air pressure

Charge to specified air pressure.

•

Brake dragging

Adjustment

•

Clutch slippage

Adjustment

50

ET-6

TROUBLE DIAGNOSIS Condition

Possible causes

Action

Engine noise Knocking

•

Engine overload

Operation with light load

•

Knocking due to carbon deposits

Remove cylinder head and eliminate carbon deposits

•

Knocking due to inappropriate ignition timing

Adjust ignition timing

•

Knocking due to inappropriate octane rating of fuel

Use specified octane rating of fuel.

•

Too advance ignition (Inappropriate spark Use specified type of spark plug. plug selection)

•

Strong and heavy noise from engine during acceleration

A possible cause is in damage/wear of bearing or uneven wear of crankshaft.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

Need to replace bearing and adjust or replace crankshaft.

•

If misfires at a particular cylinder stop the noise, that cylinder is the noise source.

•

This noise is also generated during engine acceleration but at a little more rapid pitch than crank slapping.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

•

If misfires at a particular cylinder almost stop the noises, that cylinder is the noise source.

•

Mechanical rapping noise, which increases according the engine speed but decreases as the engine is warmed up, is attributed to the pistons and cylinders.

This noise is caused by excessive wear of cylinders and accompanied by engine power deterioration and excessive oil consumption.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

For a corrective action, engine overhaul is needed

•

This noise is generated at piston TDC and BDC positions.

A possible cause is wear of the piston pin hole or piston pin.

•

To identify the noise generation point, attempt to cause misfires at each cylinder.

Need to replace piston and piston pin assembly.

•

This noise is generated from worn or damaged bearing(s) due to the uneven sliding faces.

Replace water pump.

•

Worn piston ring groove(s) and ring(s)

Replace piston(s) and piston ring(s).

•

Deteriorated valve oil seal lip(s)

Replace valve oil seal(s).

•

Worn valve stem(s)

Replace valve(s).

•

Use of inappropriate quality of oil

Use specified oil.

•

Engine overheat

Already described

•

Excessive idling speed

Adjust to specified level

•

Insufficient throttle return

Adjustment

•

Fuel leakage

Repair fuel piping and additionally tighten connections.

Mechanical slapping Crankshaft bearing slapping

Connecting rod bearing slapping

Piston and cylinder slapping

Piston pin slapping

Water pump noise

Take the same action as that for crankshaft bearing.

Excessive oil consumption Oil leakage

Other

Inappropriate fuel consumption Refer to description of engine power deterioration.

Other Refer to EF section for the LPG model.

ET-7

51

TROUBLE DIAGNOSIS Condition

Possible causes

Action

Incident due to other factors Low oil pressure

Excessive wear of sliding part(s)

Bite of sliding parts

52

•

Use of inappropriate quality of oil

Replace specified oil.

•

Engine over temperature (Overheat)

Already described

•

Oil pump regulator valve malfunction

Overhaul or replace oil pump

•

Oil pump malfunction

Overhaul or replace oil pump

•

Oil filter malfunction

Replace with a new one.

•

Enlarged clearance of each sliding component

Disassemble and replace relevant sliding component(s).

•

Clogged oil strainer

Washing

•

Malfunction of oil pressure gauge pressure switch

Replace with a new one.

•

Low oil pressure

Already described

•

Poor quality of oil or foreign objects in oil

Replace oil element and oil with appropriate ones.

•

Poor performance of air cleaner

Inspect element

•

Overheat or excessive cooling

Already described

•

Inappropriate air-fuel ratio

Inspect fuel system

•

Low oil pressure

Already described

•

Insufficient clearance

Adjust clearance to specified value.

•

Engine over temperature (Overheat)

Already described

•

Inappropriate air-fuel ratio

Inspect fuel system

ET-8

ENGINE INSPECTION AND ADJUSTMENT ENGINE INSPECTION AND ADJUSTMENT

Engine Body Related RETIGHTEN CYLINDER HEAD BOLTS Retighten the bolts in the order shown in the figure on the left while the engine is cold.

Tightening torque for cylinder head bolt: 68.6 N·m (7.0 kgf-m)

ETM0050

RETIGHTEN MANIFOLD NUTS. To prevent leakage from intake and exhaust lines Retighten the intake/exhaust manifold nuts.

Tightening torque for manifold nut: 41.2 - 48.1 N·m (4.2 - 4.91 kgf-m) (1 month or 200 operating hours) ADJUSTING VALVE CLEARANCE Perform adjustment while engine is hot.

1. Start the engine and fully warm it up. Then stop the engine.

2. Remove the rocker cover.

3. Turn the crankshaft.

(1) Set the piston for the No.1 cylinder to the compression TDC and adjust the valve clearance for (1)(2)(3)(5) in step (1) of the figure on the left.

(2) Set the piston for the No.4 cylinder to the compression TDC and adjust the valve clearance for (4)(6)(7)(8) in step (2) of the figure on the left.

MAM0143

ADJUST VALVE CLEARANCE WHEN ENGINE IS HOT Intake and exhaust : 0.38 mm (0.015 in)

SMA100

ET-9

53

ENGINE INSPECTION AND ADJUSTMENT Engine Body Related (Cont’d) INSPECT AND ADJUST ACCESSORY BELT 1. Visually check for cracks, wear, and oil smears.

(The belt must not contact with the bottom of the belt pulley.)

2. Check the belt deflection by pressing at the center between the pulleys.

Fan belt deflection: 11 - 13 mm Force: 98N (10 kgf)

ETM0046

REPLACE OIL AND OIL FILTER 1. Start the engine and fully warm it up. Then stop the engine.

2. Remove the oil filler cap and the oil pan drain plug, and discharge all oil.

3. After discharging oil, install the drain plug with the washer.

CAUTION: Be careful not to get burned when engine or engine oil is heated.

• If the oil looks milky, it is contaminated with coolant.

• If the viscosity is lower than specified, the oil is mixed with gasoline.

Tightening torque for oil pan drain plug: 29.4 - 39.2 N·m (3.0 - 4.0 kgf-m) 4. Remove the oil filter using an oil filter wrench (ST).

5. Clean the oil filter mounting face with a clean shop cloth.

•

6.

7.

Apply a small amount of engine oil to the lip of the new oil filter.

Screw in the oil filter by hand until it contacts bracket surface, and then screw in another 2/3 of a turn.

MAM0145

54

ET-10

ENGINE INSPECTION AND ADJUSTMENT Engine Body Related (Cont’d) 8.

Fill the engine with oil of the recommended specifications and check the oil level with the oil level gauge.

Engine oil amount Unit: L (US qt) With oil filter Without oil filter

SMA890

3.8 (4) 3.5 (3-3/4)

CAUTION: Verify that the oil pressure warning lamp lights up before the engine starts and turns off after the engine has started.

9.

Start the engine and check the area around the drain plug and oil filter for any leaks. If any leaks are found, the relevant part is not installed properly.

10. Warm up the engine sufficiently. Stop the engine and wait for a few minutes. Check the oil level and fill oil as necessary.

CAUTION: When checking the oil level, ensure that the engine is level.

ETM0051

CHANGING ENGINE COOLANT WARNING: Do not drain coolant when engine is still hot. It may be a cause to get burned.

CAUTION: Before mixing antifreeze with water, carefully read the instructions printed on the antifreeze package.

CLEAN RADIATOR OUTER FACE Apply compressed air to the outer face of the radiator.

CHECK COOLANT HOSES AND CONNECTIONS Check the hose connections for looseness and deterioration and retighten or replace the hose clamps as necessary.

ET-11

55

ENGINE INSPECTION AND ADJUSTMENT Engine Body Related (Cont’d) COMPRESSION PRESSURE INSPECTION 1. Warm up the engine sufficiently and then stop it.

Release the fuel pressure. (Electronic controlled specifications) 2. Remove the spark plug.

3. Apply a compression gauge correctly to the cylinder plug hole to be measured.

4. Depress the throttle pedal to the fully-open position.

5. Crank the engine and read the gauge.

• Keep the engine speed at approximately 250 rpm.

• Finish the pressure measurement in as short a time as possible.

Standard compression pressure SMA042

K21 Gasoline Combined

1.45 MPa 14.8 kgf/cm2 250 rpm

K21 LPG

1.57 MPa 16.0 kgf/cm2 250 rpm

K25 Gasoline Combined

1.51 MPa 15.4 kgf/cm2 250 rpm

K25 LPG

1.57 MPa 16.0 kgf/cm2 250 rpm

6.

56

The compression pressure differences between cylinders must not exceed 98 kPa (1 kg/cm2) [14 psi]/250 rpm. If any cylinder shows an extremely low compression pressure, put a small amount of oil into the cylinder through the spark plug hole and remeasure the pressure.

• If the pressure rises after filling oil, the piston ring is worn or damaged.

• If the pressure remains unchanged even after filling oil, the valve is stuck or inappropriately seated.

• If low compression pressure is observed in two adjacent cylinders and the pressure is not restored even after filling oil, the head gasket is leaking. In this case, oil and water may enter in the combustion chamber.

• If the engine RPM is not in the specified range: Measure the battery specific gravity.

ET-12

ENGINE INSPECTION AND ADJUSTMENT Ignition and Fuel Systems REPLACEMENT OF AIR CLEANER ELEMENT Dry filter type It requires periodical replacement. If the engine is used in a heavily contaminated environment, perform maintenance more frequently.

ETM0055

SPARK PLUG INSPECTION AND REPLACEMENT 1. Inspection • Visually check electrode for dirt and damage and insulator for burning.

• Check if the electrode gap is within the standard using a plug gap gauge.

Standard: 0.8 - 0.9 mm (0.0315 - 0.0354 in) • Adjust if outside the standard.

• Replace if necessary.

2. Installation • Install in the reverse order of removal.

Tightening torque: 19.6 - 29.4 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

ET-13

57

58

ENGINE MECHANICAL SECTION

EM

CONTENTS PRECAUTIONS ................................................... EM-2 Precautions for Draining Engine Coolant........ EM-2 Precautions for Disconnecting Fuel Piping ..... EM-2 Precautions for Removing and Disassembling................................................. EM-2 Precautions for Inspection, Correction, and Replacement................................................... EM-2 Precautions for Assembly and Installation ...... EM-2 Parts Requiring Angle Tightening ................... EM-3 Caution for Use of Power Tools ...................... EM-3 Precautions for Liquid Gasket Application ...... EM-3 ENGINE OUTSIDE DRAWINGS ......................... EM-4 MAIN SPECIFICATIONS..................................... EM-5 ADJUSTMENT VALUE ....................................... EM-7

TIGHTENING TORQUE .................................... EM-10 Standard Bolt Tightening Torque.................. EM-10 Engine Part Tightening Torque..................... EM-11 TROUBLE DIAGNOSIS .................................... EM-13 SPECIAL SERVICE TOOLS ............................. EM-15 REMOVAL AND INSTALLATION OF ENGINE ............................................................. EM-16 Removal........................................................ EM-16 Installation..................................................... EM-17 Inspection ..................................................... EM-17 ENGINE SERVICE ............................................ EM-18 Engine Disassembly ..................................... EM-18 Inspection and Correction............................. EM-25 Engine Assembly .......................................... EM-38

EM

59

PRECAUTIONS PRECAUTIONS

Precautions for Draining Engine Coolant •

Drain coolant only after the engine has cooled down.

Precautions for Disconnecting Fuel Piping • •

•

Operation should be done in a place free from fire.

Release fuel pressure before operation. (Electronic controlled specifications): Refer to “Release of Fuel Pressure” in EC section.

After disconnecting, plug the pipe to prevent fuel from draining.

Precautions for Removing and Disassembling • • • •

•

Use correct STs in the specified position. Always pay attention to safety.

Be careful not to lose surface accuracy of mating or sliding surfaces.

To prevent foreign material from entering the engine, close openings with appropriate tape as necessary.

Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or excessive wear and to ensure correct reassembly.

As a rule, nuts and bolts must be loosened in a diagonal manner starting from an outer one. If a particular tightening sequence is provided separately, follow the sequence.

Precautions for Inspection, Correction, and Replacement •

Following the inspection procedure, inspect the parts adequately and repair or replace as necessary. Perform the same inspections even for new parts and replace them if necessary.

Precautions for Assembly and Installation • •

• •

• • •

60

Always use a torque wrench when tightening nuts and bolts.

Unless otherwise specified, tighten bolts and nuts from inside to outside in a crisscross pattern. Tighten them gradually and evenly in 2 to 3 steps.

Always replace gasket, packing, oil seals, and O-rings with new ones.

For each part, perform adequate cleaning/washing and drying with a dryer. In particular, ensure that the oil and coolant passages are free from plugging and clogging.

Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine oil to sliding surfaces.

If coolant was drained, bleed air from the system.

After assembly, start engine and increase the engine speed, then check coolant, fuel, oil, grease, and exhaust gas for leakage.

EM-2

PRECAUTIONS Parts Requiring Angle Tightening • •

When tightening the following parts, use an angle wrench (ST).

Cylinder head bolt Before assembly, verify that no grease/oil and dust are present on the cylinder head, cylinder block mounting face, and head gasket. Then apply antirust oil or engine oil to the threads and head bottoms of the head bolts.

Caution for Use of Power Tools •

The use of power tools such as an air runner are only allowed for disassembly. Do not use them for assembly.

Precautions for Liquid Gasket Application REMOVING PARTS ATTACHED WITH LIQUID GASKET • Remove mounting nuts and bolts. Remove liquid gasket using a seal cutter (ST).

• • •

CAUTION: Be careful not to damage the mating surfaces.

In positions where a seal cutter is difficult to use, lightly tap with a plastic hammer, and remove.

Be careful not to scratch the mating surfaces when using a screwdriver.

GIM0061

GIM0062

LIQUID GASKET APPLICATION INSTRUCTION 1. Remove any old liquid gasket remaining on the gasket application surface and its mating surface using a scraper.

• Remove any old liquid gasket remaining in the gasket application groove and on the threads of bolts and bolt holes.

2. Wipe the gasket application surface and its mating surface using thinner or equivalent to remove any moisture, oil, and foreign material.

3. Set genuine liquid gasket to tube presser (commercial service tool).

4.

• • • • • •

GIM0063

Apply a continuous bead of liquid gasket to the specified position at the specified diameter.

Apply liquid gasket in the application groove.

Apply liquid gasket inside bolt holes as a rule. Make sure to carefully read the relevant instructions.

Attaching should be done within 5 minutes after gasket application.

Immediately wipe off any protruding liquid gasket.

Do not retighten nuts and bolts after installation.

After finishing work, wait at least 30 minutes before refilling engine oil and coolant.

CAUTION: Follow any directions specified in the text on the following pages.

EM-3

61

ENGINE OUTSIDE DRAWINGS ENGINE OUTSIDE DRAWINGS

62

ELECTRONIC CONTROLLED SPECIFICATIONS

EM-4

MAIN SPECIFICATIONS MAIN SPECIFICATIONS

ENGINE SPECIFICATIONS Engine type

K21

Engine control system

Electronic controlled specifications

Fuel specification

Gasoline

LPG

Total displacement (cc)

2,065

Shape of combustion chamber

Bathtub

Valve mechanism

OHV

Bore x stroke mm (in)

89 x 83 (3.50 x 3.27)

Compression ratio Compression pressure [MPa

Combined

(kg/cm2)

[psi]/rpm]

8.7

9.3

8.7

1.45 (14.8) [210]/250

1.57 (16.0) [228]/250

1.45 (14.8) [210]/250

Engine speed control system

Engine Control System, electronically controlled throttle

Fuel in use (Note 1)

Unleaded regular gasoline

LPG

See the left column

37.4 (50.8)/2,400

37.4 (50.8)/2,400

Maximum output [kW (PS)/rpm]

2,400 rpm SPEC.

35.9 (48.8)/2,400

2,700 rpm SPEC.

39.6 (53.8)/2,700

41 (55.7)/2,700

40.7 (55.3)/2,700

Maximum torque [N·m (kg-m)/rpm]

2,400 rpm SPEC.

149 (15.2)/2,000

151 (15.4)/2,000

150 (15.3)/2,000

2,700 rpm SPEC.

149 (15.2)/2,000

151 (15.4)/2,000

150 (15.3)/2,000

Valve opening/closing timing (degree)

Intake open (ATDC)

4

Intake close (ABDC)

40

Exhaust open (BBDC)

36

Exhaust close (ATDC) Valve clearance mm (in)

0

Intake (when engine is hot)

0.38 (0.0015)

Exhaust (when engine is hot)

0.38 (0.0015)

Firing order

1-3-4-2

Ignition timing (idling)

degree (BTDC)

On board idle speed (rpm)

ATM MTM

700

On board high-idle speed (rpm)

ATM

2,400/2,700

MTM

2,400/2,700

Allowable maximum engine speed (rpm)

0 700

Instantaneous, no load

3,600

Continuous load

3,000

PTO system Engine oil (When shipped)

Silent chain-driven/side PTO Specification

10W-30 (Class SJ)

Amount (L) (US qt)

3.8 (4) (including filter)

Engine dimensions (length x width x height) (Note 2) mm (in)

732.7 x 568 x 743 (28.846 x 22.362 x 29.252)

Engine weight (w/o coolant, w/ oil) (Note 2) N (kg) [lb]

1,470 (150) [331]

Note 1: Fuel Gasoline: Use unleaded regular gasoline with an octane rating of 91 or more.

LPG: Use a fuel of 30P or more in cold seasons. In ambient temperature of -5˚C (23˚F) or less, use a 100P fuel.

Note 2: The engine dimensions and weight differ with the customer specifications. The above data should be deemed as reference.

EM-5

63

MAIN SPECIFICATIONS ENGINE SPECIFICATIONS Engine type

K25

Engine control system

Electronic controlled specifications

Fuel specification

Gasoline

LPG

Total displacement (cc)

2,488

Shape of combustion chamber

Bathtub

Valve mechanism

OHV

Bore x stroke mm (in)

89 x 100 (3.50 x 3.94)

Compression ratio Compression pressure [MPa

Combined

(kg/cm2)

[psi]/rpm]

8.7

9.2

8.7

1.51 (15.4) [219]/250

1.57 (16.0) [228]/250

1.51 (15.4) [219]/250

Engine speed control system

Engine Control System, electronically controlled throttle

Fuel in use (Note 1)

Unleaded regular gasoline

LPG

See the left column

Maximum output [kW (PS)/rpm]

45.8 (62.2)/2,700

46.9 (63.7)/2,700

46.6 (63.5)/2,700

175 (17.8)/1,600

188 (19.2)/1,600

187 (19.1)/1,600

Maximum torque [N·m (kg-m)/rpm] Valve opening/closing timing (degree)

Intake open (ATDC)

4

Intake close (ABDC)

40

Exhaust open (BBDC)

36

Exhaust close (ATDC) Valve clearance mm (in)

0

Intake (when engine is hot)

0.38 (0.0015)

Exhaust (when engine is hot)

0.38 (0.0015)

Firing order

1-3-4-2

Ignition timing (idling)

degree (BTDC)

On board idle speed (rpm)

ATM MTM

700

On board high-idle speed (rpm)

ATM

2,700

Allowable maximum engine speed (rpm)

0 700

MTM

2,700

Instantaneous, no load

3,600

Continuous load

3,000

PTO system Engine oil (When shipped)

Silent chain-driven/side PTO Specification

10W-30 (Class SJ)

Amount (L) (US qt)

3.8 (4) (including filter)

Engine dimensions (length x width x height) (Note 2) mm (in)

732.7 x 568 x 743 (28.846 x 22.362 x 29.252)

Engine weight (w/o coolant, w/ oil) (Note 2) N (kg) [lb]

1,470 (150) [331]

Note 1: Fuel Gasoline: Use unleaded regular gasoline with an octane rating of 91 or more.

LPG: Use a fuel of 30P or more in cold seasons. In ambient temperature of -5˚C (23˚F) or less, use a 100P fuel.

Note 2: The engine dimensions and weight differ with the customer specifications. The above data should be deemed as reference.

64

EM-6

ADJUSTMENT VALUE ADJUSTMENT VALUE

VALVE MECHANISM • Valve clearance (Hot) : mm (in) Standard Intake 0.38 (0.015) Exhaust 0.38 (0.015) VALVE • Head outer diameter : mm (in) Standard Intake 38.0 - 38.3 (1.496 - 1.508) Exhaust 32.0 - 32.3 (1.260 - 1.272) • Valve total length : mm (in) Intake 98.85 - 99.45 (3.892 - 3.915) Exhaust 98.95 - 99.55 (3.896 - 3.919) • Valve stem outer diameter : mm (in) Standard Intake 6.965 - 6.980 (0.2742 - 0.2748) Exhaust 6.945 - 6.960 (0.2734 - 0.2740) • Valve spring free length : mm (in) Intake and exhaust 44.92 (1.769) Valve-opening compressed length : mm/N (mm/kg) [in/lb] Intake and exhaust 25.0/347.0 - 391.2 (25.0/35.4 - 39.9) [0.984/78.1 - 88.0] Valve spring installation length (when closed) : mm/N (mm/kg) [in/lb] Intake and exhaust 33.8/177.9 - 200.7(33.8/18.1 - 20.5) [1.331/40.0 - 45.1] Valve spring slant : mm (in) Intake and exhaust 1.5 (0.059) • Clearance between valve stem and valve guide : mm (in) Standard Intake 0.015 - 0.048 (0.0006 - 0.0019) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) Repair limit Intake 0.10 (0.0039) Exhaust 0.10 (0.0039) Valve seat width : mm (in) Intake 1.1 - 1.4 (0.043 - 0.055) Exhaust 1.8 - 2.2 (0.071 - 0.087) Valve seat angle Intake and exhaust. 44˚23' - 45˚07' Valve face angle Intake 45˚15' - 45˚45' Exhaust 44˚30' - 45˚ CAMSHAFT • Bend : mm (in) Repair limit 0.05 (0.0020) • End play : mm (in) Standard 0.15 - 0.23 (0.0059 - 0.0091) Repair limit 0.40 (0.0157) • Journal dimensions : mm (in) Standard Front 45.434 - 45.447 (1.7887 - 1.7892) Center 43.897 - 43.910 (1.7282 - 1.7287) Rear 41.218 - 41.231 (1.6228 - 1.6233) • Oil clearance at journal : mm (in) Standard Front 0.025 - 0.051 (0.0010 - 0.0020) Center 0.038 - 0.064 (0.0015 - 0.0025) Rear 0.025 - 0.051 (0.0010 - 0.0051) Repair limit Front 0.10 (0.0039) Center 0.15 (0.0059) Rear 0.10 (0.0039)

EM-7

65

ADJUSTMENT VALUE •

Camshaft height (mm) Standard 36.750 - 36.800 (For both intake and exhaust) Size reduction limit 36.5

CRANKSHAFT • Bend (mm) Repair limit 0.05 • End play (mm) Standard 0.05 - 0.18 Repair limit 0.20 • Journal dimensions (mm) Standard 62.942 - 62.955 • Pin standard dimension (mm) Standard 44.961 - 44.974 • Oil clearance at journal (mm) Standard 0.020 - 0.062 Repair limit 0.10 FLATNESS OF FLYWHEEL AND DRIVE PLATE • Flatness of flywheel (mm) Repair limit 0.10 • Runout of drive plate (mm) Repair limit 0.20 • Flatness of ring gear (mm) Repair limit 0.50 • Flatness (mm) Repair limit 0.30 CONNECTING ROD • Center distance between both end holes (mm) Standard 143.970 - 144.030 (K25) 152.47 - 152.53 (K21) • Large end hole diameter (mm) Standard 48.0 - 48.013 • Small end hole diameter (mm) Standard 19.965 - 19.978 • Bend (per 100 mm) (mm) Repair limit 0.05 • Twist (per 100 mm) (mm) Repair limit 0.05 • Large end thrust clearance Standard 0.2 - 0.3 Repair limit 0.40 • Large end oil clearance (mm) Standard 0.030 - 0.066 Repair limit 0.10 • Weight difference (piston combination) (g) Standard 5 or less PISTON • Piston (mm) Type Thermal flow type Material Aluminum alloy Outer diameter Standard 88.965 - 89.015 • Clearance to cylinder (mm) Standard 0.025 - 0.045

66

EM-8

ADJUSTMENT VALUE • • •

•

Piston pin outer diameter (mm) Standard 19.993 - 19.998 Piston pin fitting quality Standard To a degree allowing movement by hand Piston ring closed gap (mm) Standard Top 0.28 - 0.43 Second 0.45 - 0.60 Oil 0.20 - 0.60 Various limit values 1.00 Clearance between piston ring and ring groove (mm) Standard Top 0.04 - 0.08 Second 0.03 - 0.07 Oil 0.65 - 0.135 Repair limit Top 0.10 Second 0.10 Oil — Pin outer diameter (mm) 19.993 - 19.998

CYLINDER HEAD Valve guide (mm) Standard

7.000 - 7.018 (for both intake and exhaust) Valve stem-to-valve guide clearance (mm) Repair limit 0.10 (for both intake and exhaust)

CYLINDER BLOCK Cylinder bore inner diameter mm (in) Standard 89.00 - 89.05 (3.5089 - 3.5059) Wear limit 0.2 (0.0079) Cylinder bore taper and out-of-round mm (in) 0.2 (0.0008) Top face distortion limit mm (in) 0.05 (0.0020) Distortion limit (mm) Intake manifold 0.1 Exhaust manifold 0.3 Cylinder head 0.1 Cylinder block 0.1

EM-9

67

TIGHTENING TORQUE TIGHTENING TORQUE

Standard Bolt Tightening Torque Upper: Lubricated (Antirust oil is applied to abrasive faces of threads and seating faces) Lower: No lubrication (Threads and seating faces are completely degreased) Thread size

Hexagon head bolt and nut

Diameter

Pitch

M6

1

M8

1.25

1.25 M10 1.5

1

M8

1.25

Flanged bolt

M6

1.25 M10 1.5

• •

68

Unit

4T (Bolt)

7T (Bolt)

9T (Bolt)

N·m

3.82 - 4.41 (0.39 - 0.45) 5.00 - 6.47 (0.51 - 0.66) 9.32 - 10.8 (0.95 - 1.1) 12.7 - 15.7 (1.3 - 1.6) 19.6 - 22.6 (2.0 - 2.3) 25.5 - 33.3 (2.6 - 3.4) 18.6 - 21.6 (1.9 - 2.2) 24.5 - 31.4 (2.5 - 3.2) 4.9 - 5.69 (0.5 - 0.58) 5.98 - 7.65 (0.61 - 0.78) 11.8 - 13.7 (1.2 - 1.4) 14.7 - 18.6 (1.5 - 1.9) 24.5 - 29.4 (2.5 - 3.0) 30.4 - 39.2 (3.1 - 4.0) 23.5 - 27.5 (2.4 - 2.8) 29.4 - 37.3 (3.0 - 3.8)

6.37 - 7.45 (0.65 - 0.76) 8.43 - 10.8 (0.86 - 1.1) 15.7 - 17.7 (1.6 - 1.8) 20.6 - 26.5 (2.1 - 2.7) 32.4 - 38.2 (3.3 - 3.9) 43.1 - 54.9 (4.4 - 5.6) 30.4 - 36.3 (3.1 - 3.7) 41.2 - 52 (4.2 - 5.3) 8.14 - 9.51 (0.83 - 0.97) 9.81 - 12.7 (1.0 - 1.3) 19.6 - 23.5 (2.0 - 2.4) 24.5 - 31.4 (2.5 - 3.2) 41.2 - 48.1 (4.2 - 4.9) 51.0 - 64.7 (5.2 - 6.6) 39.2 - 46.1 (4.0 - 4.7) 49.0 - 61.8 (5.0 - 6.3)

9.22 - 10.8 (0.94 - 1.1) 11.8 - 15.7 (1.2 - 1.6) 22.6 - 25.5 (2.3 - 2.6) 29.4 - 37.3 (3.0 - 3.8) 47.1 - 53.9 (4.8 - 5.5) 61.8 - 78.5 (6.3 - 8.0) 44.1 - 52 (4.5 - 5.3) 58.8 - 74.5 (6.0 - 7.6) 11.8 - 13.7 (1.2 - 1.4) 14.7 - 18.6 (1.5 - 1.9) 28.4 - 33.3 (2.9 - 3.4) 35.3 - 45.1 (3.6 - 4.6) 59.8 - 69.6 (6.1 - 7.1) 73.6 - 93.2 (7.5 - 9.5) 56.9 - 65.7 (5.8 - 6.7) 69.6 - 89.2 (7.1 - 9.1)

(kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m) N·m (kgf-m)

CAUTION: Except special nuts and bolts.

The bolts applicable to this table have one of the following marks embossed on their heads.

4T......4 7T......7 9T......9

EM-10

TIGHTENING TORQUE TAPER SCREW TIGHTENING TORQUE Allowable materials for tightening

Unit

Normal size

R1/8

N·m kg-m ft-lb, in-lb* N·m kg-m ft-lb N·m kg-m ft-lb

R1/4 R3/8

Aluminum Standard 7.8 0.796 69* 19.6 2.0 14 39.2 4.0 29

Max. value 11.8 1.2 9 29.4 3.0 22 54.9 5.6 41

Cast iron Standard 15.7 1.6 12 34.3 3.5 25 53.9 5.5 40

Max. value 21.6 2.2 16 44.1 4.5 33 73.5 7.5 54

Engine Part Tightening Torque TIGHTENING TORQUE AT VARIOUS POINTS OF ENGINE Tightening point Cylinder head (lubricated) Main bearing cap (lubricated) Crankshaft pulley bolt

Flywheel bolt (lubricated)

Connecting rod nut (lubricated)

Rear plate bolt

Camshaft sprocket bolt

Oil filter stud

Oil filter element

Spark plug

Engine slinger bolt

Rocker cover nut

Water temperature gauge

Oil pressure switch

Exhaust manifold nut

Straight screw plug (For head top face)

Oil pan drain plug

Mass air flow sensor mounting screw

Fuel tube flare nut

Crankshaft position sensor plug bolt

Thermo-housing relief plug

Unit

N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m ft-lb N·m kg-m in-lb N·m kg-m ft-lb N·m kg-m in-lb N·m kg-m in-lb

EM-11

Standard Separately given Separately given 220.5 22.5 163 132 13.47 97 31.4 3.2 23 44.1 4.5 33 39.2 4.0 29 29.4 3.0 22 14.7 1.5 11 19.6 2.0 14 22.6 2.31 17 14.7 1.5 11 15.7 1.6 12 15.7 1.6 12 41.2 4.2 30 44.1 4.5 33 29.4 3.0 22 1.27 0.13 11 16.0 1.63 12 6.37 0.65 56 6.37 0.65 56

Max. value

240.1 24.5 177 142 14.49 105 37.3 3.81 28 58.8 6.0 43 49 5.0 36 39.2 4.0 29 20.6 2.1 15 29.4 3.0 22 25.5 2.6 22 16.7 1.7 13 19.6 2.0 14 21.6 2.2 16 48.1 4.91 36 58.9 5.5 40 39.2 4.0 29 1.67 0.17 15 23.0 2.35 17 7.45 0.76 66 7.45 0.76 66

69

TIGHTENING TORQUE CYLINDER HEAD Tightening torque for general service is 68.6 N·m (7.0 kgf-m) in the place of the tightening torque (5) as shown in the figure.

MAM0142

MAIN BEARING CAP : 83.4 - 93.2 N·m (8.51 - 9.51 kgf-m) • Apply antirust oil or engine oil to the bolt threads and head bottom.

• Do not use any power tools such as an air runner for assembly.

GIM0064

70

EM-12

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS Condition

Possible causes

Action

1. Engine noise Slapping noise of bearing and crankshaft

Slapping noise of piston, connecting rod

Slapping noise of camshaft

Timing chain noise

Slapping noise of valve gear

Slapping noise of water pump

Bearing looseness

Replace.

Bearing seizure

Replace.

Crankshaft bend

Repair or replace.

Uneven wear of journal

Correct.

Excessive end play

Replace center bearing.

Bearing looseness

Replace.

Bearing seizure

Replace.

Piston looseness

Replace piston pin(s) or bushing(s).

Piston looseness relative to cylinder

Reselect.

Piston ring damage

Replace.

Poor rod alignment

Realign.

Bearing looseness

Replace.

Excessive axial looseness

Replace bearing thrust plate(s).

Rough gear tooth face(s)

Correct.

Gear damage

Replace.

Inappropriate tension

Adjust.

Damaged or sagged chain

Replace.

Worn sprocket

Replace.

Damaged or loose tensioner

Replace.

Excessive camshaft-to-bearing clearance

Replace.

Inappropriate valve clearance

Adjust.

Loose adjustment screw(s)

Replace.

Worn rocker face(s)

Replace.

Worn valve guide(s)

Replace guide(s).

Loose valve spring(s)

Replace.

Valve seizure

Repair or replace.

Inappropriate end play

Replace.

Damaged impeller

Replace.

Inappropriate clearance

Adjust.

Valve stem - insufficient guide-to-guide clearance

Clean stem(s), ream guide(s).

Loose or damaged spring

Replace.

Seized or damaged valve stem(s)

Replace or clean.

Poor fuel quality

Use good fuel.

Inappropriate valve clearance

Adjust.

Deteriorated valve spring(s)

Replace.

2. Other mechanical damage Stuck valve

Burnt valve seat(s)

Edged valve end(s)

Replace Bulb.

Too narrow valve seat width

Correct valve seat(s).

Engine over temperature (Overheat)

Repair or replace.

Overrun

Operate in optimum speed range.

Stuck valve guide(s)

Correct.

EM-13

71

TROUBLE DIAGNOSIS Condition Excessive wear of cylinder piston(s)

Poor functioning of connecting rod(s)

Poor functioning of crankshaft bearing(s)

72

Possible causes

Action

Insufficient engine oil

Refill or replace oil.

Contaminated engine oil

Clean crankcase, replace oil filter.

Poor quality oil

Use specified oil.

Engine over temperature (Overheat)

Repair or replace.

Wrong combination of piston and connecting rod

Repair or replace.

Inappropriate clearance of piston ring

Reselect and adjust.

Piston ring damage

Replace.

Damaged air cleaner

Wash.

Too rich air-fuel mixture

Adjust.

Overrun

Operate in optimum speed range.

Stuck choke valve

Clean and adjust.

Excessive use of choke valve

Start engine properly.

Insufficient engine oil

Fill oil.

Low oil pressure

Repair.

Use of poor quality oil

Use specified oil.

Rough crankshaft surface(s)

Grind surface(s), replace bearing(s).

Plugged oil passage

Clean.

Wear or damage of bearing

Replace.

Inappropriate bearing

Correct.

Bearing looseness

Replace.

Poor connecting rod alignment

Repair or replace.

Insufficient engine oil

Fill or replace oil.

Low oil pressure

Correct.

Use of poor quality oil

Use specified oil.

Uneven wear of crankshaft journal(s)

Repair

Plugged oil passage of crankshaft

Wash.

Wear or damage of bearing

Replace.

Inappropriate bearing

Correct.

Damaged bearing(s)

Replace.

EM-14

SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS Tool number 91H20-09080

Tool name Engine attachment

GIM0066

91H20-09090 (1) 91H20-09091 (2) 91H20-09092

Engine stand assembly Engine stand Stand

GIM0067

91H20-09100 (1) 91H20-09110 (2) 91H20-09111 (3) 91H20-09112

Crankshaft main bearing Crankshaft main bearing cap puller Ring puller Adapter Adapter

GIM0068

91H20-09120

Valve lifter

91H20-09150 91H20-09160 91H20-09170

Front oil seal drift Rear oil seal drift Drift rod

GIM0069

GIM0071

EM-15

73

REMOVAL AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF ENGINE • • • •

CAUTION: Always pay attention to safety.

Do not remove engine until exhaust system and engine coolant have completely cooled off.

Support the vehicle at the specified lift points.

For operation procedure for components other than engine, refer to appropriate sections.

Removal [OPERATION DESCRIPTION] • The engine and transmission are installed as an assembled unit. The engine may be removed independently of the transmission, but the transmission can only be removed together with the engine.

[PREPARATION WORK] 1. Release the fuel pressure. Refer to “Release of Fuel Pressure” in EC section.

2. Remove radiator drain plug and drain engine coolant.

3. Remove the following parts.

• Undercover of battery • Radiator, shroud, and radiator hose • Engine drive belt and cooling fan 4. Disconnect accelerator cable from throttle drum and move it out of position.

[LEFT SIDE OF ENGINE ROOM] 5. Remove air duct and air cleaner case.

6. Disconnect heated oxygen sensor harness connector and ground (between exhaust manifold cover and body).

[RIGHT SIDE OF ENGINE ROOM] 7. Disconnect vacuum hose (for brake booster and for differential lock) on engine side.

8. Remove fuel hose.

CAUTION: After disconnecting hoses, plug them immediately to prevent fuel from draining.

9.

Disconnect all harness connectors on engine side, and then move harnesses to body side.

10. Remove starter motor.

11. Remove transmission.

[REMOVAL] 12. Engage chain block hook in front/rear engine slingers and support.

CAUTION: Be careful not to contact hook and chain with body and piping when engaging hook in slingers 13. Remove engine mount insulator LH/RH nuts.

14. Pull up and remove engine by adjusting the position diligently.

74

EM-16

REMOVAL AND INSTALLATION OF ENGINE • •

CAUTION: Make sure that all wires and piping were disconnected while removing.

Be careful not to contact with body side parts.

Installation Note the following, and install in the reverse order of removal.

• Do not allow oil to get on the engine mount insulator. Be careful not to damage the engine mount insulator.

• Securely insert positioning stopper pin into mating side hole.

• Make sure all mount insulators are seated properly, then tighten mount nuts and bolts.

Inspection • • •

Before starting engine, check amount of engine coolant, oil and grease. Refill as necessary.

Start engine and check for any unusual noise and vibration.

Warm up engine, and then check engine coolant, oil and grease, fuel, and exhaust gas for leakage.

EM-17

75

ENGINE SERVICE ENGINE SERVICE

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

EMM0312

Always use appropriate tools and ensure that no parts are damaged.

The following tasks can be performed more easily by using the relevant engine attachment (ST) and engine stand (ST).

1. Preparation for engine disassembly • Drain coolant and engine oil.

2. Installation of engine attachment Remove the following parts from the cylinder block and install the engine attachment (ST).

• Oil filter • Engine mount bracket (RH) • Fuel tube (and fuel pump for carburetor model) • Oil pressure switch • Release the alternator adjusting lever and remove the alternator.

• Using some of the existing holes on the engine attachment (ST), retain the attachment with the mounting bracket bolts at four points at least.

EMM0313

3.

76

Removal of exterior and electrical parts Set the engine to the engine stand (ST) and remove the following parts.

• Ignition system wiring (or high-tension cords for carburetor model) • Ignition coil unit (or distributor for carburetor model) • Spark plug • Oil level gauge • Cooling fan and pulley • Starter motor • Clutch and flywheel • Rear plate • Rocker cover • Crankshaft pulley • Remove the injector unit (for LPG, gasoline) • Remove the electric throttle control unit (or carburetor for carburetor model) • Remove the oil pump and drive shaft (for carburetor type, also remove the distributor).

EM-18

ENGINE SERVICE Engine Disassembly (Cont’d) 4.

Removal of manifold • Remove the manifold and head retaining bolts.

• Remove the intake and exhaust manifold assembly.

EMM0314

DISASSEMBLY OF INTAKE MANIFOLD Disassembly sequence. Reassembly sequence is in the reverse order of disassembly.

Electronic control system component view

EM-19

77

ENGINE SERVICE Engine Disassembly (Cont’d) 5.

Removal of rocker cover and gasket • Remove the rocker cover retaining nuts.

• Remove rocker cover.

EMM0316

6.

Removal of rocker shaft assembly • Loosen the eight valve rocker adjusting nuts and screws to remove the valve rocker shaft.

• Pull off the push rod.

• Make sure to remove the push rod and other parts by cylinder and by port (intake or exhaust), and store them in an organized manner so that the part installation locations are easily identifiable.

• When removing the valve rocker shaft, compress the coil spring slightly and tie the spring with a metal wire, as shown in the figure, before loosening the bolts. This will facilitate the reassembly work later.

7.

Removal of cylinder head assembly • Pull off the push rod.

• Loosen the cylinder head bolts according to the following sequence.

• Remove cylinder head.

EMM0317

EMM0318

78

EM-20

ENGINE SERVICE Engine Disassembly (Cont’d) 8.

Remove oil pan.

Remove any sealant.

9.

Remove oil pump with strainer.

FEM008

FEM009

10. Disassembly of PTO device

EMM0319

• • •

Remove crankshaft pulley bolt.

Remove crankshaft pulley.

Remove the sprocket bushing.

EM-21

79

ENGINE SERVICE Engine Disassembly (Cont’d) • •

Remove the front cover.

To remove the cover, remove the bolts and lightly tap on it with a plastic hammer.

Before installing the cover, apply sealant (liquid packing) to the mounting face.

EMM0320

11. Remove the sprocket and chain as an assembly from the oil pump side and the crankshaft side.

FEM012

After removing the retaining bolts, remove the signal plate bushing and remove the hydraulic pump sprocket along with the bearing by hand.

CAUTION: Ensure that the chain is not damaged.

EMM0321

12. To separate the oil pressure pumpside sprocket and the bearing, use the relevant Service Tool with a press.

91H20-09220 Bearing puller 91H20-09230 Bearing drift

FEM014

80

EM-22

ENGINE SERVICE Engine Disassembly (Cont’d) 13. Timing chain cover • Remove front oil seal.

Remove from the front cover using the front oil seal drift (ST).

Service Tools (ST): Front oil seal drift 91H20-09150 Drift rod 91H20-09170

FEM015

14.

15.

16.

17.

EMM0322

FEM017

Remove timing chain cover.

Remove chain tensioner (1).

Loosen the camshaft gear bolts.

Remove the camshaft sprocket (3) and crankshaft sprocket (2) along with the chain (4).

18. If shim(s) are attached for the crankshaft gear, also remove them.

19. Removal of camshaft • Remove locating plate.

• Turn over the cylinder block. Lower and pull off the valve lifter.

• Pull off the two bolts retaining the camshaft locating plate and remove the camshaft. Be careful not to damage the metal faces.

• Pull the piston toward the cylinder block top deck and tentatively assemble the rod cap to prevent incorrect assembly.

Place the parts in the order of cylinder arrangement.

20. Removal of piston and connecting rod • Remove connecting rod cap and push the piston out toward cylinder head side with handle of a hammer. Be careful not to drop the pistons.

• Pull the piston toward the cylinder block top deck and tentatively assemble the rod cap to prevent incorrect assembly.

Place the parts in the order of cylinder arrangement.

CAUTION: Store the connecting rod caps and bushings in the order of cylinder arrangement to prevent incorrect assembly.

21. Loosen the flywheel bolts and remove the flywheel.

22. Remove rear plate.

23. Removal of crankshaft • Remove the rear oil seal retainer.

• Remove the main bearing cap bolts. Remove the main bearing cap by lightly tapping on it with a wooden hammer.

CAUTION: Store the bearing bushings in an organized manner so that the part installation locations are easily identifiable.

EMM0323

EM-23

81

ENGINE SERVICE Engine Disassembly (Cont’d) 24. Remove the oil seal from the oil seal retainer using the rear oil seal drift (ST).

ST: 91H20-09070

EMM0324

25. Remove the crankshaft and bearing.

After removing the bearing, place the corresponding cap at a correct position on the block side face to prevent incorrect assembly.

FEM019

FEM020

26. Disassembly of cylinder head • Remove valve spring using a valve lifter (ST).

ST: 91H20-09120 • Before removing the lip seal for valve disassembly, first remove the garter spring.

This is necessary to prevent the lip seal from being damaged by sharp edges of the valve stem.

• Store the removed valves, valve collets, valve retainers, valve springs, and valve seals in an organized manner to identify which part combination corresponds to which cylinder.

27. Disassembly of piston and connecting rod • Disassemble the piston and connecting rod.

• Remove piston rings.

The oil ring is a combined type. To remove it, first remove the upper and lower rails, and then the expander.

CAUTION: Store the removed pistons, pins, connecting rods and bushings in an organized manner to identify which part combination corresponds to which cylinder.

EM102

82

EM-24

ENGINE SERVICE Engine Disassembly (Cont’d) 28. Pull off the piston pin.

The piston pin is press-fit into the connecting rod.

To remove the piston pin, first remove the snap ring, heat the piston to 80˚C, and then pull off the piston pin by using the piston pin press stand (ST).

CAUTION: Store the removed pistons, piston pins, piston rings and connecting rods in an organized manner to identify which part combination corresponds to which cylinder.

EM103

Inspection and Correction 1.

General precautions • Inspect each part for damage, distortion, bend or excessive play and repair/replace the part if the condition is unallowable.

• Before cleaning the cylinder head and block, check for any trace of water leakage.

• Completely remove any water scale, sealant, and carbon from each part.

CAUTION: Be careful not to damage the sliding faces when using a carbon scraper or brush.

•

After cleaning the oil passage of each part, verify that no plugging is present by applying compressed air.

• Make sure that any parts requiring correct combination are identified appropriately.

• For a part that is to be stored for a long time after cleaning, make sure to apply oil to the high-finished surfaces to prevent rust creation.

2. Intake manifold water jacket • Also inspect the water jacket connector. Repair or replace it if any traces of leakage are found.

• Also inspect the water hoses. If any deterioration or damages are found, replace them. If any leakage is found at the connections, retighten the clamps.

3. Cylinder head REMOVING CARBONS • Remove any carbons from the combustion chamber and mounting faces of each cylinder. At that time, also check for scratches and damages.

• Remove oil, scale, gasket, sealant, and carbon deposits from surface of cylinder head using a scraper.

CAUTION: Do not allow gasket fragments to enter oil or engine coolant passages.

FEM024

EM-25

83

ENGINE SERVICE Inspection and Correction (Cont’d) MEASURING CYLINDER HEAD DISTORTION • Visually check for any cracks and damages.

• Measure distortion at six points on the head bottom face. If the measured distortion exceeds the specified limit, correct the head bottom face with a surface grinder or an equivalent tool, or replace the head.

Surface flatness 0.1 mm or less Grinding limit 0.2 mm or less

EMM0325

VALVE SEAT CONTACT • This inspection must be done after ensuring that the dimensions of the valve guide and the valve are within the standard.

• Check valve contact by applying DICATOL PL-1 to valve seat contact surface.

• Make sure that areas around all connect surfaces are connected.

• If seating condition is not correct, reseat the valve and check again.

If seating condition cannot be corrected by reseating, replace valve seat.

EMV0149D

84

EM-26

ENGINE SERVICE Inspection and Correction (Cont’d) VALVE SEAT PROCESSING • Cut the valve seat to the specified dimensions using a valve seat cutter set and valve seat grinder (commercial service tool).

CAUTION: Tightly hold the cutter handle with both hands when using a valve seat cutter, and cut the entire periphery of the contacting face without a break while pressing the cutter.

Poor pressure onto the cutter or repeated cutting may create steps in the seat.

•

Cut the valve seat to the dimensions specified in the figure.

Standard processing dimensions D1: 35.9 - 36.1 mm D2: 37.6 - 37.8 mm D3: 41.0 mm D4: 28.6 - 28.8 mm D5: 31.4 - 31.6 mm D6: 35.0 mm

EMM0326

4.

EMM0327

Cylinder block Measure distortion of the cylinder block top face in the longitudinal and lateral directions.

Measuring cylinder block distortion.

• Remove any foreign material deposits such as carbon from the cylinder block.

• (Use a straight ruler and filler gauge for distortion measurement) • Visually check for any cracks and damages.

• Measure distortion at six points on the head top face. If the measured distortion exceeds the specified limit, correct the head top face with a surface grinder or an equivalent tool, or replace the head.

EM-27

85

ENGINE SERVICE Inspection and Correction (Cont’d) Distortion limit: 0.1mm Standard

Repair limit

Longitudinal mm (in)

0.05 (0.0020)

0.10 (0.0039)

Lateral mm (in)

0.02 (0.0008)

0.04 (0.0016)

Cylinder block face

Determine the grade based on the measurement at a point located 65 mm from the top deck in the thrust direction.

5.

Measuring cylinder bore • Take the following measurements for the directions A and B at three levels using a cylinder bore gauge.

EM124

Max. difference between A and B Max. difference among three levels

Roundness Taper (mm)

Cylinder bore inner diameter

Standard

Wear limit

89.0 - 89.05 (K21, K25)

89.20

Roundness

---

0.2

Taper

---

0.2

Difference in inner diameter between respective cylinders

---

0.2

EMM0328

6. Balling and horning (1) Select an appropriate oversize piston according to the wear of the cylinder inner surface.

Measure the piston skirt diameter. Bore the cylinder to a diameter 0.02 mm larger than the measurement.

EM126

86

EM-28

ENGINE SERVICE Inspection and Correction (Cont’d) •

Ensure that the piston-to-cylinder clearance is between 0.025 and 0.045. Make sure to perform measurement in ordinary temperature. If even one cylinder requires boring, all cylinders must be bored at once.

FEM035

(2) Calculating cylinder inner diameter • Measure the skirt diameter (dimension H) of the oversize piston.

• Based on the dimension H of the piston, determine the cylinder boring diameter.

Boring diameter: R = H + C – M Boring margin: M = 0.02 mm Piston-to-cylinder clearance : C = 0.025 to 0.045 mm (20˚C) ∴R= H + (0.005 to 0.025) mm • Bore the cylinder to the dimension R. Piston service part list Oversize STD 0.50 1.00

(3) Boring precautions • Make sure to bore the cylinder step-by-step with the boring depth of each step limited to 0.05 mm.

• Notice that the cylinder inner diameter is affected by the cutting heat.

• To prevent deformation due to cutting heat, bore the cylinders in the order of No. 2, No. 4, No. 1 and No. 3.

• Apply an appropriate mark to each piston so that which piston is for which cylinder is easily identifiable.

(4) After horning, measure the taper and roundness of the bore.

(5) Measuring piston-to-cylinder clearance Pull off the piston pin from the piston and put the piston into the cylinder upside down. Insert a filler gauge of 0.04 mm in the piston-to-cylinder clearance from the piston sliding side and pull the filler gauge with a spring scale. If the spring scale reads 0.5 kg to 1.5 kg, the clearance is normal.

EMM0329

EM-29

87

ENGINE SERVICE Inspection and Correction (Cont’d) Oversize piston Diameter mm Piston size K21, K25 STD

88.965 - 89.015

0.50 OS

89.465 - 89.515

1.00 OS

89.965 - 90.015

Standard measurements for piston and cylinder Specified clearance mm (in)

0.025 - 0.045 (0.0010 - 0.0018) [20˚C (68˚F)]

Filler gauge N (Kgf, lb) Drawing force

4.9 to 14.7 (0.5 - 1.5, 1.1 - 3.3)

Filler gauge in use Thickness mm (in)

0.04 (0.0016)

7.

Measuring piston wear • Inspect the piston sliding face. Replace it if significant sticking damage or wear is observed.

• Measuring piston ring-to-groove clearance Measure the clearance between the piston ring groove and the piston ring. If excessive wear is observed, replace the piston ring along with the piston. (mm) Standard

Limit

Top

0.045 - 0.080

0.1

Second

0.030 - 0.070

0.1

Oil

—

—

EM423

8.

Piston ring • Measuring piston ring closed gap • Put the piston ring into the cylinder bore and measure the ring closed gap. (mm) Standard

EM542

Limit

Top

0.28 - 0.43

1.0

Second

0.45 - 0.60

1.0

Combined rail

0.20 - 0.60

1.0

Measure the end gap of the piston ring with a feeler gauge. If the gap exceeds 1 mm, replace the piston ring. If the gap is 0.15 mm or less, correct the ring ends with an oil stone or replace the piston ring.

CAUTION: Always measure the ring gap near the bottom of the cylinder where the wear is relatively small when replacing the piston ring without correcting the cylinder bore.

88

EM-30

ENGINE SERVICE Inspection and Correction (Cont’d) 9. Piston pin FITTING PISTON PIN TO PISTON • In ordinary temperatures, the piston pin should rotate when turned by hand or the pin should go smoothly when inserted.

• If the piston pin behavior is unusual, replace the piston and piston assembly.

Engine type

K21, K25

Piston pin outer diameter 19.993 - 19.998

10. Connecting rod MEASURING BEND, TWIST • Measure the bend and twist using a connecting rod aligner.

If the measured bend or twist is excessive, replace the component.

Usable limit: Bend 0.05 mm (per 100 mm) Twist 0.05 mm (per 100 mm) CAUTION: The center distance between both end holes must be 143.97 to 144.03 mm (K25) 152.47 - 152.53 (K21) EM133

Bend Twist Parallelism [per 100 mm (3.94 in)] mm (in) for every 100 mm

Standard

Repair limit

0.025 (0.0010)

(B) 0.05 (0.002) (T) 0.05 (0.002)

11. Connecting rod weight WEIGHT ADJUSTMENT • When replacing the connecting rod assembly, ensure that the maximum difference in the connecting rod assembly weight between any two cylinders does not exceed 4 g.

MEASURING CONNECTING ROD THRUST CLEARANCE • Measure the thrust clearance using a feeler gauge.

• Measure the connecting rod side clearance. If the clearance exceeds the limit, replace the connecting rod.

Standard clearance: 0.2 - 0.3 mm Max. clearance: 0.4 mm

EM134

EM-31

89

ENGINE SERVICE Inspection and Correction (Cont’d) 12. Connecting rod and bushings • Check the bushings for bend, melting, or tearing and replace them if damaged.

• Measure the oil clearance using a plastigage.

EMM0330

MEASURING OIL CLEARANCE • The following paragraphs describe how to use a plastigage. a. Remove any oil and dust from the bearing inner/outer faces and journal faces. Cut off the plastigage to a length slightly shorter than the bearing width. Place the cut plastigage on the journal face so as not to cover any oil holes. b. Assemble the bearing cap and tighten it to the specified torque.

CAUTION: Do not turn the crankshaft while the plastigage is in the bearing. c. d.

Remove the cap and read the plastigage width using the scale printed on the bag.

If the clearance exceeds the limit, use an undersize bearing. At that time, grind the journal or pin.

Standard Items

Oil clearance Standard

Oil clearance Limit

Cap tightening torque

Main bearing

0.02 - 0.073

0.1

Lubricated 83.4 - 93.2 N·m (8.51 - 9.51Kgf-m)

Connecting rod bearing

0.032 - 0.066

0.1

Lubricated 31.4 - 37.3 N·m (3.2 - 3.81Kgf-m)

FEM036

•

If the oil clearance exceeds the limit, grind the journal or pin with a surface grinder and use an undersize bearing.

Undersize bearing list Connecting rod bearing Main bearing K21, K25

Pin diameter

STD

44.974 - 44.96

0.08

44.894 - 44.8

0.02

0.12

44.854 - 44.89

0.25

0.25

44.724 - 44.71

STD

0.50 0.75 1.00

90

EM-32

ENGINE SERVICE Inspection and Correction (Cont’d) 13. Crankshaft and bearing CRANKSHAFT INSPECTION • Inspect the journal and pin for damage or wear and replace them as necessary.

FEM037

To determine the diameter, measure the journal or pin at a total of four points using a micrometer.

Roundness and taper of journal and pin: Limit 0.03 mm (0.079 in) CAUTION: The roundness is represented by the difference between the dimensions X and Y in the left figure.

The taper is represented by the difference between the dimensions A and B in the left figure.

EMM0331

Standard

Repair limit

Limit

Roundness and taper mm (in)

0.01 (0.0004)

0.03 (0.0012)

MEASURING BEND • Apply the probe of a dial gauge to the center journal and take a reading while turning the crankshaft. Determine half of the reading as the bend. If the bend exceeds the specified limit, replace the crankshaft.

Bend limit: 0.05 mm

Crankshaft bend

EM137

Standard mm (in)

Usable limit mm (in)

0.02 (0.0008)

0.05 (0.0020)

MEASURING CRANKSHAFT END PLAY • Tighten to the specified torque. After that, measure end play.

• Assemble the crankshaft and measure the end play.

• If the end play exceeds the limit, replace the main bearing center bushing.

Measuring main bearing end play Standard End play mm (in)

0.05 - 0.18 (0.0020 - 0.0071)

Limit 0.2 (0.0079)

EM138

EM-33

91

ENGINE SERVICE Inspection and Correction (Cont’d) MAIN BEARING CRUSH HEIGHT • With main bearing installed, tighten bearing cap to the specified torque. Remove bearing cap and make sure that the main bearing edges protrude.

Standard: There must be crush height

EMA0558D

CRANKSHAFT MAIN BEARING • Inspect the main bearing bushing.

• As shown below, the main bearing bushings in use are classified in two types.

Nos. 1, 2, 4 and 5 are common.

No.3 (center) is provided with a thrust bushing.

Check the bearing for scratch, metal fatigue, peeling or bend and replace the upper and lower bearings together as necessary.

EMM0332

MAIN BEARING CAP AND BEARING Measuring oil clearance (1) Remove the cap and read the plastigage width using the scale printed on the bag.

(2) If the clearance exceeds the limit, use an undersize bearing. At that time, grind the journal or pin.

Standard Items

Oil clearance Standard

Oil clearance Limit

Main bearing

0.02 - 0.06

0.1

Cap tightening torque Lubricated 83.4 - 93.2 N·m (8.51 - 9.51Kgf-m)

Main bearing specifications Undersize mm (in) 0.02 (0.000787)

92

Crankshaft journal diameter mm (in) 62.922 - 62.935 (2.47724 - 2.47775)

0.25 (0.098)

62.692 - 62.705 (2.4682 - 2.4687)

0.50 (0.0197)

62.422 - 62.455 (2.4576 - 2.4589)

0.75 (0.0295)

62.192 - 62.205 (2.4485 - 2.4490)

1.00 (0.0394)

61.942 - 61.955 (2.4387 - 2.4392)

EM-34

ENGINE SERVICE Inspection and Correction (Cont’d) 14. Camshaft CAMSHAFT JOURNAL INSPECTION • Inspect the camshaft journal and replace it if any damage or uneven wear is observed.

• If the wear is found to exceed the limit by measurement with a micrometer, replace the camshaft.

Camshaft journal inspection Unit: mm (in) Camshaft journal Taper out-of-round

Standard (Shall not exceed the value)

Usable limit

0.01 (0.0004)

0.03 (0.0012)

Journal wear

0.05 (0.0020)

FEM039

MEASURING CAMSHAFT HEIGHT • Measure the camshaft height by applying calipers to the camshaft nose.

Unit: mm (in) Camshaft height

•

Standard

Intake/exhaust 36.750 - 36.800 (1.4468 - 1.4488)

Usable limit

36.5 (1.437)

Inspect the oil pump and distributor drive gear. If excessive wear or damage is observed, replace the camshaft.

FEM040

VALVE TIMING The figure on the left is applicable to all cylinders.

If any of the valves deviate from the specifications, the camshaft ridges may be worn out or damaged. The camshaft must be replaced.

Camshaft bushing inspection • Check for bend, melting, uneven contact or peeling.

• If any damage is found, replace the camshaft bushing.

Measuring camshaft journal clearance

EM-35

93

ENGINE SERVICE Inspection and Correction (Cont’d) •

Measure the inner diameter of the camshaft bushing and the outer diameter of the camshaft journal. If any nonstandard condition is found, replace the camshaft bushing. (mm) Journal No.

Standard

Usable limit

#1 #3 #2

0.025 - 0.051

0.1

0.038 - 0.064

0.15

Clearance

Bushing inner diameter

#1 #2 #3

45.472 - 45.485 43.948 - 43.961 41.256 - 41.269

Journal outer diameter

#1 #2 #3

45.434 - 45.447 43.897 - 43.910 41.218 - 41.231

FEM041

•

When installing a new camshaft bushing, always align the oil holes correctly.

15. Timing sprocket • Check camshaft gear surface for flatness.

• Place the camshaft with camshaft sprocket on a V block and measure the sprocket runout. If the deflection exceeds 0.1 mm, repair or replace the camshaft. Also inspect the gear teeth and bosses. If any excessive wear or damage is observed, replace the camshaft.

16. Front cover and timing chain housing • Inspect the housing mounting faces and oil seal. If any excessive damage is observed, replace the relevant component(s).

EM148

17. Valve lifter •

•

Inspect the contact face between the valve lifter body and camshaft. If excessive wear, damage or melting is observed, replace the component. Also inspect the installation status to the cylinder block and replace the component.

The valve lifter, if correctly installed and lubricated, should seat into the hole slowly by its weight.

Measuring valve lifter Standard (Shall not deviate from the range)

FEM042

Valve lifter and cylinder block hole Clearance mm (in)

94

EM-36

0.016 - 0.052 (0.0006 - 0.0020)

Repair limit 0.1 (0.0039)

ENGINE SERVICE Inspection and Correction (Cont’d) 18. Push rod • Inspect the push rod and replace it if excessive wear, twist or damage is observed. If a bend of 0.05 mm or more is present, repair or replace the push rod.

19. Rocker shaft • Check the rocker shaft for wear, damage or bend and replace it if wear of 0.05 mm or more is observed.

EMM0334

20. Rocker arm and adjusting bolt • Inspect the valve stem-to-rocker shaft contact face of the rocker arm and adjusting bolt. If excessive wear is found or the rocker shaft clearance exceeds the specified limit, replace the rocker arm (adjusting bolt).

Rock arm/shaft Clearance mm (in)

EMM0335

Standard

Repair limit

0.020 - 0.054 (0.0008 - 0.0021)

0.1 (0.0039)

21. Flywheel • Inspect the flywheel sliding face and the ring gear teeth.

• If excessive damage or wear is observed, repair or replace the relevant component.

• If the wear of the flywheel ring gear is relatively small, reuse the ring gear by shifting the installation position by 45 degrees.

To install a new ring gear, heat it to 180˚C and use a compression fitting method.

MEASURING FLATNESS • Measure the flatness while turning the crankshaft using a dial gauge.

• The flatness limit A is the maximum allowable flatness measured vertically to the flywheel clutch sliding face.

Flywheel flatness limit A: 0.1 mm (0.004 in) or less

EM156

EM-37

95

ENGINE SERVICE Engine Assembly 1.

2.

General assembly precautions • Apply an adequate amount of oil to the sliding faces.

• Clean the part completely. In particular, ensure that no oil passages are plugged.

• As a rule, replace all gaskets, packing and oil seals with new ones.

• Always replace the lock plates.

• Always follow the instructions about the tightening torque and tightening order. While tightening, monitor the clearance at each critical point.

• Always install the nuts, bolts and washers to their original positions.

• For sealing, use liquid packing as necessary. Make sure to apply liquid packing if so instructed.

• Always keep the tools and work benches clean from dust, dirt and oil/greases.

Assemble the piston and connecting rod.

• Install the assembled connecting rod and piston to the relevant cylinder.

• To install the piston pins, press-fit them into the relevant pistons with a force of 0.5 to 1.5 t by using the piston pin press stand (ST). When press-fitting, apply a small amount of oil to the pin and the small end of the rod.

• A round recess on the piston top is the piston’s front mark.

EM156

•

EMM0338

3.

The front of the connecting rod is determined as follows: When installed to the piston and viewed from the front, the projection should come to the right.

Assembly of piston ring • •

Securely assemble the top ring, second ring and oil ring to their relevant positions.

Make sure to assemble these parts in the following order: oil ring, second ring, top ring.

EMM0338

96

EM-38

ENGINE SERVICE Engine Assembly (Cont’d) • •

The top ring is plated with chrome on its sliding face.

When installing the compression ring, turn the manufacturer marking upward.

The upper and lower combined rings are identical.

•

EMM0339

4.

Assembly of valve and valve spring •

•

• EMM0527

Set the lip seal with the valve oil seal drift (ST) and insert the valve. Assemble the valve spring and valve spring retainer in order and insert the collet by compressing the spring with the valve lifter (ST).

CAUTION: Always assemble the valves to their original cylinders.

The wear level of the sliding face differs depending on the cylinder.

Verify that the valves are seated securely and no foreign objects are caught inside.

Rocker shaft washer (2)

Outside valve spring (2)

Snap ring (2)

Valve rocker LH (4 at mark) Valve rocker RH (4 at mark) Rocker shaft spring (3) Adjusting nut (8)

Adjusting screw Rocker shaft assembly

Mark (Upper, crankshaft pulley side)

EMM0528

5.

Rocker shaft assembly • Apply engine oil to sliding surfaces with rocker shaft of valve rocker, and assemble it as shown in the figure.

EM-39

97

ENGINE SERVICE Engine Assembly (Cont’d) 6.

Assembly of camshaft bushing • Assembly of center bushing Turn the cutout toward the distributor driving direction and drive in the bushing with the jig.

• Assembly of rear bushing Locate the bushing so that the arrow on the bushing faces upward. Align the bushing to the oil hole on the cylinder block and drive in the bushing as shown.

• The bushing has a slightly larger diameter toward its rear end. This ensures that the bushing is press fit into the cylinder block.

7.

Assembly of crankshaft • Assemble the main bearing bushing to the cap.

• As shown below, the main bearing bushings in use are classified in two types.

Nos. 1, 2, 4 and 5 are common.

No. 3 (center) is provided with a thrust bushing.

• Assemble crankshaft.

• Assemble main bearing caps.

• For the front bearing cap, align the cap to the cylinder block so that they are flush with each other.

EMM0341

EMM0332

•

•

Apply engine oil to the cap bolts and tighten them to the specified torque from inside to outside as shown in the figure on the left.

Make sure that the crankshaft can be turned with a light force every time one bolt is tightened. : 83.4 - 93.2 N·m (8.5 - 9.5 Kgf-m)

NOTE: Cranking torque EMM0342

CAUTION: For assembly, see the front of the part. An (embossed) arrow and numbers indicating the assembly position can be seen.

8.

Assembly of rear oil seal retainer • Assemble the oil seal to the rear oil seal retainer.

To drive in the oil seal, use the special service tool (91H20-09070).

EMM0343

98

1.5 kgf-m or less

EM-40

ENGINE SERVICE Engine Assembly (Cont’d) •

Install rear oil seal retainer to cylinder block.

Rear oil seal retainer retaining bolt: 2.1 - 3.7 kgf-m 20.6 - 26.5 N·m

EMM0345

• •

•

• EMM0344

•

CAUTION: Before installing the rear oil seal retainer, apply liquid packing to the retainer as shown in the figure.

Once attaching the retainer and tightening the bolts, do not make additional tightening or remove the retainer (and retighten).

For the mounting face, apply a continuous bead of sealant along the groove. For the bolt holes, apply sealant so that it does not run off the inner edges.

Make sure to finish the assembly within 5 minutes after sealant application.

After the assembly, leave the assembled parts as is for 30 minutes or more.

PRECAUTIONS BEFORE APPLICATION: • The mounting faces (both sides) shall be free from moisture, oil, grease, waste, dust and other foreign objects.

• Make sure to remove any sealant from the flange/mounting faces and threads when reassembling the part that has once been attached and disassembled.

9. Assembly of piston (1) Assemble the bearing to the connecting rod.

(2) To each cylinder, assemble the corresponding connecting rod and piston subassembly according to the cylinder number.

(3) When assembling, turn the bottom mark of the piston toward the front.

(4) Set the crankshaft pin positions to TDC or BDC. (5) Insert the pistons into the cylinder block using the piston ring compressor (ST).

CAUTION: Do not mistake the piston front.

(6) Assemble each connecting rod and connecting rod cap while aligning their matching marks.

EM164

EM-41

99

ENGINE SERVICE Engine Assembly (Cont’d) (7) Tighten connecting rod cap.

Connecting rod cap bolt: 3.2 - 3.8 Kgf-m (K21, K25)

EM166

10. Assembly of valve lifter • Fit the valve lifter in the correct position. Apply a small amount of oil and press the valve lifter into the hole on the cylinder block.

11.

Assembly of camshaft (1) Gently put the camshaft into the camshaft hole so that the bearing bushings are not damaged.

(2) Tighten locating plate bolt to the specified torque.

M6 x 16 (thread length) 7T bolt: : 8.43 - 10.8 N·m (0.86 - 1.1 kgf-m) 12. Assembly of timing chain/sprocket (1) Tighten camshaft bolts.

Tightening torque: 39.2 - 49 N·m (4.0 - 5.0 Kg-m) (2) Check the height of the camshaft gear and crankshaft gear end faces, and adjust the height by adding shims to the crankshaft side as necessary.

EMM0347

(3) Assemble the sprocket and timing chain simultaneously while aligning their matching marks.

Height difference of gear end faces

Within 0.2 mm

Shim thickness Shim part number

0.16 mm (per 1 shim) 12299 32200

EM392

100

EM-42

ENGINE SERVICE Engine Assembly (Cont’d) 13. Installation of timing chain tensioner • Assemble chain tensioner.

• When installing the chain tensioner, align the oil holes of the tensioner body to those of the cylinder block to ensure that the tensioner spindle shoe (synthetic rubber) is held parallel with the chain.

CAUTION: Assembling the shoe in the reverse position will prevent tightening of the tensioner bolt, resulting in tensioner damage.

M6 x 35 (thread length) bolt: : 8.43 - 10.8 N·m (0.86 - 1.1 kgf-m) EMM0348

14. Installation of timing chain housing • Before installing the timing chain housing, apply liquid packing to the housing as shown in the figure.

EMM0349

15. Inspection and installation of oil pump sprocket and chain PTO DEVICE Inspection • Sprocket (Oil pump side) If the gear teeth have significant scratches, excessive wear or stepped wear at the spline, replace the sprocket.

• Sprocket (Crankshaft side) If the gear teeth have significant scratches or wear, replace the sprocket.

Ball bearing • If the bearing is loose or drags, replace the sprocket.

• Chain If the link has significant scratches, stretch (unusual slapping noise is generated when tilt lever is operated) or wear, replace the sprocket.

Assembly • Assemble oil seal to front cover.

Drive in the sprocket using the front oil seal drift (91H20-09150).

CAUTION: First, apply grease to the lip of the oil seal. When driving in the sprocket, ensure that the sprocket is not inclined.

EM-43

101

ENGINE SERVICE Engine Assembly (Cont’d) •

Install the bearing to the oil pump-side sprocket.

The bearings before and after the sprocket are identical.

To install them, use a press as done for disassembly.

•

Install the sprocket and chain as an assembly.

Install the chain to the sprocket, and then install the chain and sprocket assembly to the crankshaft and timing chain housing.

Remove any old grease from the oil pump spline and apply new molybdenum grease.

Install front cover.

EMM0350

• •

EMM0351

• B B

Section B-B

A A

2.5 mm (0.098 in) dia.

Constant

Section A-A

102

C

Install the bushing crankshaft pulley for the crankshaft position sensor.

Before installing the front cover, apply liquid packing to the cover as shown in the figure. (Refer to the rear oil seal retainer installation procedure.)

M8 x 25 (thread length) 7T bolt: : 20.6 - 26.5 N·m (2.1 - 2.7 Kgf-m) [15 - 20 ft-lb]

C

Section C-C EMM0544

EM-44

ENGINE SERVICE Engine Assembly (Cont’d) 16. Installation of crankshaft pulley

(1) Set the crankshaft pulley by aligning the pulley claws to the groove of the bushing.

(2) Attach the washer, and tighten the crankshaft pulley bolt.

Crankshaft pulley bolt: : 220.5 - 240.1 N·m (22.5 - 24.5 kgf-m) [163 - 177 ft-lb] 17. Installation of cylinder head (1) Both ends of cylinder block top Drive in dowels into the head bolt holes (two positions).

(2) Place the head gasket on the block top with the copper side facing up.

(3) Set the cylinder head. Apply engine oil to the cylinder bolts and tighten them to the specified torque in the order shown in the left figure.

CAUTION: Check tightening angle with an angle wrench (ST) or a protractor. Do not simply estimate tightening angle.

For the service purposes, the following substitution torque may be used: 68.6 N·m (7.0 kgf-m).

(4) Assembly of push rod

MAM0142

EM-45

103

ENGINE SERVICE Engine Assembly (Cont’d) 18. Installation of rocker shaft assembly (1) Securely set the push rod onto the holder of the valve lifter.

FEM058

(2) Assemble the rocker shaft assembly. : 17.64 - 21.56 N·m (1.8 - 2.2 kgf-m) CAUTION: Tighten the rocker shaft retaining bolts evenly from inside to outside.

FEM059

•

For the electronic control models, install the spindle support (left figure) to the distributor installation holes.

EMM0354

(3) Adjust the valve clearance.

Valve clearance: Both intake and exhaust 0.38 mm (Engine coolant temperature: 70–90°C) CAUTION: The valve clearance must be finally adjusted when the engine is hot. However, preliminary adjustment in cold state will make the final adjustment easier.

EMM355

104

(4) Assemble the rocker cover. : 13.7 - 15.7 N·m (1.4 - 1.6 kgf-m)

EM-46

ENGINE SERVICE Engine Assembly (Cont’d) 19. Installation of engine accessories • Install the oil pressure switch.

• Installing oil pump (all models) and distributor (carburetor model) (1) Set the crankshaft position to the compression TDC for cylinder No.1.

EMM0356

(2) Locate the distributor so that the center of its flange long hole aligns to the bolt hole on the cylinder block, and insert the distributor. (Do not turn the distributor to align the holes)

EMM0357

(3) Align the drive shaft groove of the engine lubricating oil pump.

EMM0358

(4) Align the distributor gear mark to the short mark on the housing.

CAUTION: Do not align the gear mark to the gear installation pin or the long mark.

(5) Tentatively tighten the retaining bolts.

(6) After installing the distributor gear, adjust the ignition timing by using a timing light. Then, fully tighten the retaining bolts.

Idle speed and ignition timing (BTDC˚/rpm) EMM0359

EM-47

Electronic controlled specifications 0˚/700 rpm

105

ENGINE SERVICE Engine Assembly (Cont’d) (7) Installation of oil pan • Before installing the oil pan, apply liquid packing to the oil pan flange as shown in the figure.

EMM0360

•

EMM0361

Tighten the oil pan retaining bolts to the specified torque in the order shown in the left figure.

• Tightening torque for oil pan retaining bolt: : 8.43 - 10.8 N·m (0.86 - 1.1 kgf-m) M6 x 12 (thread length) 7T bolt (8) Installation of flywheel housing (or rear plate) • Install flywheel housing.

• Tightening torque for housing retaining bolt : 44.1 - 58.8 N·m (4.5 - 6.0 kgf-m) (9) Installation of flywheel •

Install flywheel.

•

Tightening torque for flywheel (Apply engine oil to the bolt seat face and threads) : 132 - 142 N·m (13.47 - 14.49 kgf-m) Check the flywheel runout with a dial gauge by turning the crankshaft.

EMM0362

•

Measurement position

Repair limit

Section A

0.1 mm (0.079 in)

EMM0363

106

EM-48

ENGINE SERVICE Engine Assembly (Cont’d) 20. Other parts • Install the oil filter. For the installation procedure, refer to page ET-10.

• Install thermostat.

• •

EMM0364

• • • • • • •

Install thermal transmitter, engine coolant temperature sensor, and heater connector.

Install spark plugs. : 18 - 24 N·m (1.8 - 2.4 kg-m) Installation of low-voltage distribution cord Remove from the engine attachment.

Install engine mount bracket LH. Install engine mount bracket RH. Install the alternator and adjusting bar.

Install the fan belt and fan.

Adjust the fan belt. Refer to MA section for the adjustment procedure.

EM-49

107

108

ENGINE CONTROL SECTION

EC

CONTENTS PRECAUTIONS ................................................... EC-2 On Board Diagnostic (OBD) System of Engine......................................................... EC-2 Precaution....................................................... EC-2 PREPARATION ................................................... EC-5 Special Service Tools ..................................... EC-5 DESCRIPTION .................................................... EC-6 Description ...................................................... EC-6 TROUBLE DIAGNOSIS .................................... EC-11 Component Parts Location ........................... EC-11 ECM Component .......................................... EC-12 Circuit Diagram ............................................. EC-14 ECM Terminal ............................................... EC-15 How to Proceed with Trouble Diagnosis ....... EC-22 Diagnosis Chart by Symptom ....................... EC-25 Description .................................................... EC-31 Fail-Safe Function......................................... EC-31 Table of DTC................................................. EC-32 Service Tool .................................................. EC-36 Self-Diagnosis Function (Without Service tool).................................... EC-39 ECM Input/Output Monitor ............................ EC-40 ECM Active Test ........................................... EC-40 BASIC INSPECTION ......................................... EC-41 Inspection of Idle Speed and Ignition Timing............................................... EC-41 Throttle Valve Closed Position Learning and Idle Air Volume Learning........................ EC-42 Accelerator Pedal Released Position Learning .......................................... EC-43 Fuel Pressure Inspection .............................. EC-43 Fuel Pressure Release ................................. EC-44

COMPONENT PARTS INSPECTION ................EC-45 Crankshaft Position Sensor (POS) ................EC-45 Camshaft Position Sensor (PHASE)..............EC-45 Mass Air Flow Sensor....................................EC-45 Engine Coolant Temperature Sensor ............EC-45 Throttle Position Sensor 1, 2 (Electric throttle control actuator assembly)...EC-46 Accelerator Pedal Position Sensors 1, 2 (Accelerator work unit)...................................EC-46 Intake Air Temperature Sensor (Joined with mass air flow sensor).................EC-47 Stop Lamp Switch..........................................EC-47 Spark Plug .....................................................EC-47 Ignition Coil ....................................................EC-48 Injector ...........................................................EC-48 Fuel Pump .....................................................EC-49 Electric Throttle Control Motor (Electric throttle control actuator assembly).................EC-49 Heated Oxygen Sensor .................................EC-49 LPG Injector...................................................EC-50 LPG Assistance Injector ................................EC-50 PTC Heater (Integrated with vaporizer) .........EC-50 PCV GAS RECIRCULATION DEVICE...............EC-51 System Diagram ............................................EC-51 Component Parts Inspection .........................EC-51 ECM COMPONENTS .........................................EC-52 Removal and Installation ...............................EC-52

EC

109

PRECAUTIONS PRECAUTIONS

On Board Diagnostic (OBD) System of Engine The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration.

•

•

•

•

•

•

CAUTION: Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MIL to light up.

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.)

Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector.

Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MIL to light up due to the short circuit.

Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to the malfunction of fuel injection system, etc.

Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.

Precaution • • •

•

Always use a 12 volt battery as power source.

Do not attempt to disconnect battery cables while engine is running.

Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect battery ground cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned OFF. Before removing parts, turn ignition switch OFF and then disconnect battery ground cable.

SEF0289H

• •

Do not disassemble ECM. If a battery cable is disconnected, the memory will return to the ECM value. The ECM will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.

• If the battery is disconnected, the following emissionrelated diagnostic information will be lost within 24 hours.

– Diagnostic trouble codes – 1st trip diagnostic trouble codes

110

EC-2

PRECAUTIONS PREPARATION

Precaution (Cont’d) •

When connecting ECM harness connector, fasten it securely with levers as far as they will go as shown in the figure.

•

When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break).

Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors.

Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep engine control system harness at least 10 cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of ICs, etc.

Keep engine control system parts and harness dry.

Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly.

Handle mass air flow sensor carefully to avoid damage.

Do not disassemble mass air flow sensor.

Do not clean mass air flow sensor with any type of detergent.

Do not disassemble electric throttle control actuator.

Even a slight leak in the air intake system can cause serious incidents.

Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS).

After performing each TROUBLE DIAGNOSIS, perform DTC Confirmation Procedure or Overall Function Check.

The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Overall Function Check should be a good result if the repair is completed.

•

•

• •

• • • • • MEF040D

• •

EC-3

111

PRECAUTIONS Precaution (Cont’d) •

•

When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor.

Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

SEF348N

• •

Do not operate fuel pump when there is no fuel in lines.

Tighten fuel hose clamps to the specified torque.

• •

Do not depress accelerator pedal when starting.

Immediately after starting, do not rev up unnecessarily.

Do not rev up engine just prior to shutdown.

•

SEF709Y

112

EC-4

engine

PREPARATION PREPARATION

Special Service Tools Description

Application

EGI fuel pressure indicator 91H20-09010

For measuring fuel pressure gauge

Heated oxygen sensor wrench 91H20-09020

Removing and installing heated oxygen sensor

GSE kit 16A68-11500

For system inspection and diagnosis

Check adapter V 91H20-09030 (for SMJ 150-pin connector)

For control unit input/output signal inspection

ECM0013

ECM0014

ECM0015

ECM0016

Harness adapter 91H20-09040 (150-pin to 121-pin conversion adapter)

ECM0017

EC-5

113

DESCRIPTION DESCRIPTION

Description •

• •

Adopts Engine Control Module (ECM). Fuel injection control, ignition timing control, idle speed control, and electronically controlled governor control etc. are all performed by a single control unit.

Adopts electric throttle control actuator system to control electronically controlled governor.

Adopts Hall IC type crankshaft position sensor (POS) and camshaft position sensor (PHASE).

Items

Description

Electric throttle control actuator

•

Adopts electronic throttle control actuator with integrated throttle control motor to adjust throttle valve opening optimally according to driving conditions or to improve safety and operability by electronically controlled governor.

Fuel injection control

•

With fuel injection control, air-fuel ratio is optimized to improve exhaust performance and response.

Using feedback control through learning of air-fuel ratio compensation, the system corrects the ratio during transitional conditions, such as sudden sharp changes in the ratio, in order to improve driveability.

•

Ignition timing control

•

•

Uses Hall IC crankshaft position sensor (POS) and camshaft position sensor (PHASE) to perform controls so that optimum ignition timing is obtained for every operating condition.

Optimum ignition timing setup according to each fuel is also enabled at the time of a combined use formula.

Adopts electronic distribution system (NDIS) in which each cylinder is equipped with an ignition coil incorporating a power transistor for better ignition performance.

Idle speed control

•

Adopts electronic throttle control actuator that continuously regulates intake air amount required for idling.

Governor speed control

•

Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal.

Maximum speed regulation control

•

Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum speed by changeover switch.

Idling area torque up control

•

Performs torque up control in idling area by engine speed signal in order to also enable cargo work at idling.

Overheat prevention control

•

Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening when engine coolant temperature reaches approximately 110˚C (230˚F).

Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine coolant temperature reaches approximately 135˚C (275˚F).

• Power/soft mode control

•

Changes throttle opening characteristic of throttle position by power/soft mode control switch, and then minute operation of engine speed is enabled. (Option setting)

Fuel pump control (gasoline)

•

Turns fuel pump relay ON/OFF depending on engine speed signal.

LPG interception valve control

•

Turns interception valve relay ON/OFF depending on engine speed signal and fuel pressure sensor signal.

Fail-safe function

•

Ensures vehicle’s safe operation and enables vehicle to be driven in an emergency when any of the major system components (mass air flow sensor, engine coolant temperature sensor, etc.) have malfunctioned.

Diagnostic system

•

Adopts self-diagnosis system for easier trouble diagnosis.

114

EC-6

DESCRIPTION Description (Cont’d) K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (GASOLINE)

EC-7

115

DESCRIPTION Description (Cont’d) K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (LPG)

116

EC-8

DESCRIPTION Description (Cont’d) K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (COMBINED USE)

EC-9

117

DESCRIPTION Description (Cont’d)

std

std

std

std

std

opt

LPG

std

std

std

—

std

std

std

std

opt

Fuel

Control Item

Fuel injection control

A/F feedback control

Fuel cut off

Fuel pump control

Ignition timing control

Idle speed control

Maximum engine speed control

Maximum vehicle speed control

Fuel injection control

Crankshaft position sensor (POS, PHASWE)

⊕

⊕

⊕

⊕

⊕

⊕

⊕

⊕

Mass air flow sensor

⊕

⊕

♦

Intake air temperature sensor

♦

Engine coolant temperature sensor

♦

⊕: Significant impact to control ♦: Impact to control

Sensors

⊕

♦

♦

♦

♦

♦

♦

Throttle position sensor

♦

♦

⊕

Accelerator pedal position sensor

♦

♦

♦

Ignition switch

⊕

⊕

⊕

Neutral SW signal

♦

♦

♦

♦ ♦ ⊕

♦

♦

♦

♦

♦

♦

♦ ♦

♦

♦

♦

♦

♦

♦

♦

♦

♦

♦

♦

⊕

⊕

⊕

⊕

♦

♦ ♦ ♦

Headlamp (electrical load) switch

⊕

Power/soft mode switch (opt)

Actuators

std

⊕ ♦

Stop lamp switch

118

std

♦

Vehicle speed sensor

Battery voltage

♦

LPG fuel pressure sensor

♦

⊕

Fuel changing switch

⊕

⊕

⊕

Gasoline injector

⊕

⊕

⊕

Ignition system

std

♦

⊕

Heated oxygen sensor

std

Fail-safe

std

Self-diagnosis

std

Combined

std

Fuel changing (Gasoline and LPG) Combined

Gasoline

Power/soft mode control

SENSORS AND ACTUATORS CONTROL ITEMS Main sensors and actuators related to the ECM are listed below.

♦

♦

♦

♦ ♦

⊕

⊕

Power transistor

⊕

Ignition coil

⊕

♦

Throttle control motor relay

⊕

⊕

♦

Throttle control motor

⊕

⊕

♦

Gasoline fuel pump relay

⊕

⊕

Gasoline fuel pump

⊕

♦

♦

⊕

Ignition relay EGI relay

⊕

⊕

⊕

LPG injector

⊕

⊕

⊕

LPG assistance injector

⊕

⊕

⊕

LPG interception valve relay

⊕

⊕

LPG interception valve

⊕

♦

EC-10

⊕

⊕

⊕

⊕

⊕

⊕

⊕ ♦ ♦ ♦

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS

Component Parts Location

Specifications Main component part

Type

Location Gasoline

Actuators Gasoline injector

LPG

Combined

High resistance

Intake manifold

LPG injector

Gas injection

Integrated in injector holder (on intake manifold)

Fuel pump

Electric motor/turbine

Integrated in fuel tank

Fuel pressure regulator

Diaphragm

Throttle control motor

Electric DC motor (DC motor)

Integrated in electronic throttle control actuator

Ignition coil

Mold (built-in power transistor)

Cylinder head (On each spark plug)

EC-11

119

TROUBLE DIAGNOSIS Component Parts Location (Cont’d) Specifications Main component part Sensors

Crankshaft position sensor

Type

Crankshaft position sensor (POS)

Location

Hall IC (element)

Camshaft position sensor (PHASE)

Gasoline

LPG

Combined

Front cover

Chain housing

Mass air flow sensor

Hot wire

Air horn

Accelerator pedal position sensors 1 and 2

Variable resistance

Integrated in accelerator work unit (accelerator pedal assembly)

Integrated in electronic throttle control actuator

Water outlet

With air flow meter

Zirconia (with heater)

Exhaust manifold

ECM

121-pin digital control

Vehicle side

EGI & IGN coil relay

Compact general relay (1M X 2)

Vehicle side

Throttle position sensors 1 and 2 Engine coolant temperature sensor

Thermistor

Intake air temperature sensor Heated oxygen sensor

ECM Component Specifications Component

Gasoline Intake manifold

LPG injector

Integrated in injector holder (on intake manifold)

Throttle control motor

Integrated in electronic throttle control actuator

Ignition coil

Cylinder head (on each spark plug)

Crankshaft position sensor (POS)

Front cover

Camshaft position sensor (PHASE) Front housing Mass air flow sensor

Air horn

Intake air temperature sensor

With air flow meter

Engine coolant temperature sensor Water outlet Accelerator pedal position sensors 1 and 2

Integrated in accelerator work unit (accelerator pedal assembly)

Fuel pump

Integrated in fuel tank

(Vehicle side)

Vehicle speed sensor

(Vehicle side)

ECM

(Vehicle side)

EGI & IGN coil relay

(Vehicle side)

Stop lamp switch

(Vehicle side)

Throttle control motor relay

(Vehicle side)

Fuel pump relay

(Vehicle side)

Vaporizer

(Vehicle side)

LPG interception valve

(Vehicle side)

120

Fuel pressure regulator Heated oxygen sensor

LPG

Combined

Actuator

Gasoline injector

Throttle position sensors 1 and 2

NOTE

Location

EC-12

Sensor

Other

TROUBLE DIAGNOSIS ECM Component (Cont’d)

EC-13

121

TROUBLE DIAGNOSIS Circuit Diagram K-ENGINE ELECTRONIC CONTROLLED ECM CIRCUIT DIAGRAM (COMBINED GASOLINE AND LPG)

122

EC-14

TROUBLE DIAGNOSIS ECM Terminal

REFERENCE VALUE LIST Voltage is measured with a circuit tester, and the sample waveforms obtained with an oscilloscope are shown below for each ECM terminal. Measurement data varies depending on variation in parts as well as many other factors. Such factors include vehicle history, driving conditions, environmental conditions, maintenance status, measuring instrument/method, etc. Data shown below are reference values.

Terminal signal

Description

Measurement condition

Measured value

1 2 115 116

ECM ground

Always

Approx. 0V

66

Sensor ground (Throttle position sensor)

At idle after warming up

Approx. 0V

At approx. 2,000 rpm 67

Mass air flow sensor ground

Always

Approx. 0V

78

Heated oxygen sensor ground

Always

Approx. 0V

82

Accelerator pedal position sensor 1 ground

Always

Approx. 0V

83

Accelerator pedal position sensor 2 ground

Always

Approx. 0V

32

Fuel changing switch 2 (Gasoline)

Changing switch ON (At gasoline side)

Approx. 5V

Changing switch ON (At LPG side)

Approx. 0V

At normal speed setting

Approx. 0V

At low speed setting

Battery voltage

Changing switch ON (At LPG side)

Approx. 5V

56 70

Governor control switch Fuel changing switch 1 (LPG)

Changing switch ON (At GAS side)

Approx. 0V Approx. 0V

84

Headlamp switch

Lighting switch OFF Lighting switch ON

Battery voltage

101

Brake switch

Brake pedal released

Approx. 0V

Brake pedal depressed

Battery voltage

102

Neutral switch

N position

Approx. 0V

Other than above

Battery voltage

Ignition switch OFF

Approx. 0V

Ignition switch ON

Battery voltage

109 (IGN)

Ignition switch

EC-15

123

TROUBLE DIAGNOSIS ECM Terminal (Cont’d) Terminal signal 13

Description Crankshaft position sensor (POS)

Measurement condition At cranking

Measured value Approx. 2.6V

ECM0052

At idle after warming up

Approx. 3V

ECM0053

At approx. 2,000 rpm

Approx. 3V

ECM0054

14

Camshaft position sensor (PHASE)

At cranking

Approx. 0.15V

ECM0055

At idle after warming up

Fluctuates between approx. 1.5 - 2V.

ECM0056

At approx. 2,000 rpm

Approx. 2V

ECM0057

24

Heated oxygen sensor heater

At idle after warming up

Approx. 0.3V

31

LPG fuel pressure sensor

At idle after warming up

Approx. 0.78V

124

EC-16

TROUBLE DIAGNOSIS ECM Terminal (Cont’d)

Terminal signal 35

Description Heated oxygen sensor

Measurement condition At idle after warming up

Measured value Changes between approx. 0.1 0.4V⇔;approx. 0.6 - 0.9V

ECM0058

At approx. 2,000 rpm

Changes between approx. 1 0.4V⇔;approx. 0.6 - 0.9V

ECM0059

50

51

69

Throttle position sensor 1

Mass air flow sensor

Throttle position sensor 2

At idle after warming up

Approx. 0.6V

Ignition switch ON with engine stopped Accelerator pedal is fully depressed

Approx. 0.5V

Ignition switch ON with engine stopped Accelerator pedal is released

Approx. 4.3V

At approx. 2,000 rpm

Approx. 0.7V

Ignition switch ON

Approx. 1V

At cranking

Approx. 1.5V

At idle after warming up

Approx. 1.3V

At approx. 2,000 rpm

Approx. 1.5V

At idle after warming up

Approx. 4.5V

Ignition switch ON with engine stopped Accelerator pedal is fully depressed

Approx. 4.5V

Ignition switch ON with engine stopped Accelerator pedal is released

Approx. 0.7V

At approx. 2,000 rpm

Approx. 4.4V

EC-17

125

TROUBLE DIAGNOSIS ECM Terminal (Cont’d) Terminal signal 98

106

Description Accelerator pedal position sensor 2

Accelerator pedal position sensor 1

Measurement condition

Measured value

At Idle

Approx. 0.335 - 0.435V

Ignition switch ON with engine stopped Accelerator pedal is fully depressed

Approx. 0.335 - 0.435V

Ignition switch ON with engine stopped Accelerator pedal is released

Approx. 2.2 - 2.3V

At approx. 2,000 rpm

Approx. 0.35V

At Idle

Approx. 0.67 - 0.87V

Ignition switch ON with engine stopped Accelerator pedal is fully depressed

Approx. 0.67 - 0.87V

Ignition switch ON with engine stopped Accelerator pedal is released

Approx. 4.4 - 4.6V

At approx. 2,000 rpm

Approx. 0.65V

PTC heater relay (Except North America)

At idle after warming up

Approx. 0V

Ignition switch ON when the engine coolant temperature is 30˚C (86˚F) or less (except for cranking)

Battery voltage

104

Throttle control motor relay

Ignition switch ON, engine running

Approx. 1V

112

LPG interception valve relay

Engine running

Battery voltage

Ignition switch OFF

Approx. 0V

For approximately 1 second after ignition switch ON

Approx. 1V

After that

Battery voltage

27

113

Gasoline F/P relay

At cranking, engine running

Approx. 1V

3

Throttle control motor relay power supply Always

Battery voltage

48

Sensor power supply

Ignition switch ON, engine running

Approx. 5V

49

Fuel changing switch power supply

Changing switch ON

Approx. 5V

Changing switch ON (At neutral)

Approx. 0V

90

Accelerator pedal position sensor 1 power supply

Ignition switch ON, engine running

Approx. 5V

91

Accelerator pedal position sensor 2 power supply

Ignition switch ON, engine running

Approx. 2.5V

110

Power supply for ECM (backup)

Always

Battery voltage

118 121

Power supply for ECM

Ignition switch ON, engine running

Battery voltage

4

Throttle control motor (Close)

At idle after warming up

Approx. 2 - 2.5V

At approx. 2,000 rpm 5

Throttle control motor (Open)

At idle after warming up

Approx. 0.1 - 0.15V

At approx. 2,000 rpm 11

126

LPG assistance injector

At idle after warming up

EC-18

Battery voltage

TROUBLE DIAGNOSIS ECM Terminal (Cont’d)

Terminal signal 22 23 41 42

Description Injector drive signal

Measurement condition At cranking

Measured value Approx. 10.5V

ECM0060

At idle after warming up

Battery voltage

ECM0061

At approx. 2,000 rpm

Relatively lower than battery voltage

ECM0062

34

Intake air temperature sensor signal

Intake air temperature is approx. 20˚C (68˚F).

Approx.

3.5V

Intake air temperature is approx. 80˚C (176˚F).

Approx.

1.2V

Ignition switch ON, engine running

Approx. 5V

ECM0499

47

Electric throttle control actuator open

EC-19

127

TROUBLE DIAGNOSIS ECM Terminal (Cont’d) Terminal signal 61 62 80 81

Description Ignition signal (power transistor drive signal)

Measurement condition At cranking

Measured value Approx. 0.2V

ECM0047

At idle after warming up

Approx. 0.1V

ECM0048

At approx. 2,000 rpm

Approx. 0.1V

ECM0049

73

Engine coolant temperature sensor signal

Engine coolant temperature is approx.

20˚C (68˚F).

Approx.

3.5V

Engine coolant temperature is approx.

80˚C (176˚F).

Approx.

1.2V

Approx. 6.6 - Battery voltage

ECM0500

85 (K LINE)

Signal line for service

When connected to Service tool When not connected to Service tool

Approx. 6V

86

CAN communication line L

Always

Approx. 2.2V (Varies depending on communication status.)

ECM0051

128

EC-20

TROUBLE DIAGNOSIS ECM Terminal (Cont’d)

Terminal signal 94

Description CAN communication line H

Measurement condition Always

Measured value Approx. 2.4V (Varies depending on communication status.)

ECM0050

111

Self shut-off

For approximately 10 seconds with ignition switch ON and after ignition switch OFF

Approx. 1V

Approximately 10 seconds on more after ignition switch OFF

Battery voltage

119

LPG injector drive (H)

Battery voltage Time axis may change according to setting data and driving condition.

120

LPG injector drive (L)

Battery voltage Time axis may change according to setting data and driving condition.

NOTE: Numerical values are obtained using an analog circuit tester.

EC-21

129

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS

How to Proceed with Trouble Diagnosis 1.

The most important point in performing trouble diagnosis of malfunctions is to thoroughly understand the vehicle systems (both control and mechanical).

An ECM-based engine controls actuators such as injectors and the ignition coil according to information from sensors. Then through actuator operation, the engine (mechanical system) runs. Sensors transmit information on the running condition, which changes constantly, to ECM. It is important to understand these cycles.

2.

It is also important to clarify customer concerns before starting the inspection.

First of all, reproduce the symptom, and understand it fully.

Ask the customer about his/her concerns carefully. In some cases, it will be necessary to check the symptoms by driving the vehicle with the customer.

ECM0031

ECM0032

CAUTION: Customers are not professionals. Do not assume “maybe the customer means ...” or “maybe the customer mentioned this symptom”.

3.

ECM0033

4.

5.

It is essential to confirm symptoms right from the beginning in order to ensure all malfunctions are completely repaired.

For an intermittent malfunction, it is important to reproduce the symptom based on an interview with the customer and past examples. Do not perform an inspection on an ad hoc basis.

Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake the suspected harness or connector by hand. When repairs are performed without any symptom check, no one can judge if the malfunction has actually been eliminated.

The next important thing is to find which system among the following is causing the malfunction: ECM control signal system, or a mechanical system (such as the engine main body and auxiliary component). It is important to inspect the system using Service tool or by checking the ECM input/output signals.

When checking the ECM input/output signals, connect a check adapter (Service tool) to ECM in order to prevent misdiagnosis.

Special Service Tools (Service tool): Check adapter V (91H20-09030) (for SMJ 150-pin connector) Harness adapter (91H20-09040) (150-pin → 121-pin conversion adapter) Use the reference value of input/output data (guideline) in this manual in order to judge the ECM input/output signals. Measure the data of another vehicle of the same model under the same conditions when it is difficult to judge, and compare the data. It is advisable to collect sufficient data of a normally operating vehicle.

ECM0034

130

EC-22

TROUBLE DIAGNOSIS How to Proceed with Trouble Diagnosis (Cont’d) TROUBLE DIAGNOSIS FLOW CHART There are many different malfunction symptoms. So there is no perfect trouble diagnosis technique applicable to all malfunctions.

Experience is also important to achieving an accurate trouble diagnosis.

Nonetheless, an accurate trouble diagnosis can be performed by applying similar procedures, regardless of the malfunction symptom.

Perform trouble diagnosis following the flow chart shown below.

ECM0035

DIAGNOSTIC WORK SHEET Description • In order to clarify the malfunction symptom, it is important to ask the customer and collect information about their concerns.

• Ask the customer about what symptoms are present under what conditions. Use the information to clarify the symptom.

• Use the trouble diagnosis sheet to be certain not to miss any vital information.

ECM0036

EC-23

131

TROUBLE DIAGNOSIS How to Proceed with Trouble Diagnosis (Cont’d)

ECM0037

132

EC-24

TROUBLE DIAGNOSIS Diagnosis Chart by Symptom

No initial combustion Impossible to start Initial combustion When engine is cold Poor starting When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Other Poor fuel consumption efficiency Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOMS AND THE SENSOR CIRCUIT The table below shows the possible symptoms caused by the malfunction of each sensor circuit.

Symptoms

Poor idle

Sensor malfunction ⊕: Highly possible ♦: Possible Crankshaft position sensor (POS, PHASE)

Mass air flow sensor

Signal

OPEN

Poor driving control

⊕

♦

• An open circuit in either REF or POS signal makes it impossible for the vehicle to start.

• Control signals for fuel system and ignition system are not output.

♦ ♦ ♦ ♦

⊕ ♦ ♦ ♦

♦

• The symptom depends on the duration of momentarily open circuit and the operating conditions. Slight shocks and surges may be sensed during driving, while engine stall may be caused during idle.

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦

♦ ♦

OPEN

♦ ♦

High output

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

Low output

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Ground

OPEN

Power supply

OPEN

♦ ♦

⊕ ♦ ♦

⊕

• It will be in fail-safe condition, and vehicle runs at an engine speed from 800 rpm to 1,600 rpm.

♦ ♦ ♦ ♦

♦ ♦

• The air-fuel ratio becomes rich.

Black smoke may accompany.

Poor connection of grounding may be a possible cause.

♦ ♦ ♦ ♦

♦ ♦

• The air-fuel ratio becomes lean.

Contaminated hot wire or suction of air may be suspected.

⊕ ⊕ ⊕ ⊕

♦

• It will be over-rich.

♦

♦

• It will be in fail-safe condition, and vehicle runs at an engine speed from 800 rpm to 1,600 rpm.

♦

OPEN/ SHORT

Engine coolant temperature sensor

OPEN/ SHORT

♦ ♦ ♦

♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Resistance is large.

♦ ♦ ♦

♦

♦ ♦ ♦ ♦ ♦ ♦

Resistance is small.

♦ ♦ ♦ ♦

OPEN/ SHORT

♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

Intake air temperature sensor

Heated oxygen sensor

Description/notable characteristics of the symptom

⊕ ⊕ ⊕ ⊕

Momentarily open

⊕

Engine stall

♦ ♦

♦ ♦

• It will be in fail-safe condition, and then Engine Warning lamp turns ON. This malfunction tends to occur when engine is cold or when the engine coolant temperature is high.

♦ ♦ ♦ ♦ ♦ ♦ ♦

• The engine coolant temperature is judged as low. This malfunction tends to occur after warming up.

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦

♦

EC-25

♦

♦ ♦

♦ ♦

• The engine coolant temperature is judged as high. This malfunction tends to occur when engine is cold.

♦ ♦

• It will be base air-fuel ratio.

133

TROUBLE DIAGNOSIS

No initial combustion Impossible to start Initial combustion When engine is cold Poor starting When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Other Poor fuel consumption efficiency Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.

Diagnosis Chart by Symptom (Cont’d)

Symptoms

Poor idle

Sensor malfunction ⊕: Highly possible ♦: Possible

♦

Vehicle speed sensor

OPEN/ SHORT

Throttle position sensor

OPEN/ SHORT

♦

♦ ♦

Output fluctuation

♦

♦ ♦

Ignition switch

IGN

Neutral SW

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦

OPEN/ SHORT

♦

♦ ♦

♦ ♦ ♦

Output fluctuation

♦

♦ ♦

♦ ♦

OPEN

♦

♦

• Duration of fuel cut becomes shorter or fuel may not be cut.

♦ ♦

♦ ♦

• Idle will be base rpm. No addition for acceleration.

♦

♦

• Possible interruption by unnecessary fuel injection. Poor ground or control unit connection may be the cause.

♦

• Idling is judged as OFF during idle. Turning ignition switch repeatedly to ON and OFF will set the system to normal.

♦ ♦ ♦

⊕

♦ ⊕ ⊕ ⊕ ⊕

♦

OPEN

⊕ ♦ ⊕ ♦ ♦

• Impossible to start without outputs for fuel and ignition systems.

♦

• Neutral switch is judged as OFF, and the target cold engine speed in N/P position is lowered.

SHORT

• Neutral switch is judged as ON, and fast idle is effective for cold engine in positions other than N/ P position, making the creep larger.

Stop lamp switch

OPEN/ SHORT

Headlamp (electrical load) switch

OPEN/ SHORT

CAN communication line

OPEN/ SHORT

Power supply for ECM

OPEN

Sensor ground (coolant temperature sensor, throttle position sensor)

OPEN/ SHORT

Control unit and connector

Poor connection, water entry?

LPG fuel pressure sensor

OPEN/ SHORT

Fuel changing switch

OPEN

⊕

LPG fuel pressure sensor

OPEN

⊕

134

Description/notable characteristics of the symptom

♦ ♦

♦

Poor adjustment

Accelerator pedal position sensor

Engine stall

Poor driving control

♦

♦ ♦

⊕

⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦

♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

♦

♦ ♦

♦

• Impossible to start without outputs for fuel and ignition systems.

♦

• The same as the open circuit in the applicable sensor.

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

• A slightly raised connector often results in poor connection. Entry of water causes engine stall, and afterwards it is momentarily impossible to restart engine. In some cases, restarting is possible after a short wait.

♦ ♦ • Fuel changing cannot be done.

⊕ ⊕ ⊕ ⊕

EC-26

♦ ♦

• LPG interception valve OFF.

TROUBLE DIAGNOSIS Diagnosis Chart by Symptom (Cont’d)

No initial combustion Impossible to start Initial combustion When engine is cold Poor starting When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Other Poor fuel consumption efficiency Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.

RELATIONSHIPS BETWEEN MALFUNCTIONING SYMPTOMS AND ACTUATOR CIRCUITS The table below shows the possible symptoms caused by the malfunction of each actuator circuit.

Symptoms

Poor idle

Actuator malfunction ⊕: Highly possible ♦: Possible Gasoline injector

Power supply circuit Coil

OPEN

♦ ♦ ♦ ♦

Poor driving

⊕ ⊕ ♦ ♦ ♦ ♦

OPEN

♦ ♦ ♦ ♦

Nozzle hole

Ground circuit (ECM)

OPEN

♦ ♦ ♦ ♦

♦ ⊕ ⊕ ♦ ♦ ♦ ♦

SHORT

♦ ♦ ♦ ♦

⊕ ⊕ ♦ ♦ ♦ ♦

Foreign material intrusion

♦ ♦ ♦ ♦

⊕ ♦ ♦ ♦

Clogging

♦ ♦ ♦ ♦

OPEN

♦

♦

⊕ ⊕ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦

♦ ♦ ♦ ♦

♦ ♦

♦

OPEN

Coil

OPEN

♦ ♦

♦

Ground circuit

OPEN

♦ ♦

♦

♦ ♦ ♦ ♦ ♦

• Continuous fuel injection to cylinder with short circuit, resulting in OVER-RICH and misfiring.

• Starting engine is impossible when the circuits for all the cylinders are open.

♦ ♦ ♦ ♦ ♦

• The cylinder with foreign material will keep injecting.

♦ ♦ ♦ ♦

• The symptom depends on clogging status. The correction factor of air-fuel ratio becomes larger.

♦ ♦ ♦ ♦

• Shocks may be sensed and engine stall may be occur depending on the duration of the operation conditions.

♦

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦

Power supply circuit

♦ ♦ ♦ ♦ ♦ ♦

♦ ♦

♦

• Slight shocks and surges may be sensed depending on the duration of momentarily open circuit and the operating conditions.

♦ ♦ ♦ ♦ ♦ ♦

♦ ♦

• Engine stall may occur if duration of momentarily open circuit is too long.

♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦

• Shocks may be sensed and engine stall may be occur depending on the duration of the operation conditions.

♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦

• Injects fuel toward spark plug on the cylinder with open circuit.

Momentarily open

Momentarily open

♦ ♦

♦

Momentarily open Ignition coil

♦ ♦

♦

Momentarily open

OPEN

♦

Description/notable characteristics of the symptom

• No fuel injection to cylinder with open circuit, resulting in LEAN output of heated oxygen sensors.

• Starting engine is impossible when the circuits for all the cylinders are open.

♦ ♦ ♦ ♦ ♦

Momentarily open Ignition signal circuit

♦

⊕ ⊕ ♦ ♦ ♦ ♦

Momentarily open Drive circuit (ECM side)

♦ ♦ ♦ ♦ ♦

Momentarily open

Engine stall

♦

EC-27

♦ ♦

135

TROUBLE DIAGNOSIS

No initial combustion Impossible to start Initial combustion When engine is cold Poor starting When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Other Poor fuel consumption efficiency Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.

Diagnosis Chart by Symptom (Cont’d)

Symptoms

Poor idle

Actuator malfunction ⊕: Highly possible ♦: Possible

⊕

OPEN

Throttle control motor circuit

OPEN/ SHORT

♦

♦ ♦

♦ ♦

Throttle motor relay circuit

OPEN

♦

♦ ♦

♦ ♦ ♦ ♦

Heated oxygen sensor heater circuit

OPEN

• Fuel pump relay circuit • Fuel pump circuit • Ignition relay circuit

OPEN

Fuel pump Pressure regulator

OPEN/ SHORT HI side circuit

⊕

♦ ♦

⊕ ⊕ ⊕ ⊕

• Impossible to start

♦

• Impossible to start

♦ ♦

⊕ ⊕ ⊕ ⊕

♦ ♦

• LPG interception valve OFF

♦ ♦

• LPG interception valve OFF

⊕ ⊕ ⊕ ⊕

♦ ♦

• LPG interception valve OFF

⊕ ⊕ ⊕ ⊕

♦ ♦

• LPG interception valve OFF

♦ ♦

• LPG interception valve OFF

⊕

OPEN

⊕

SHORT

⊕

⊕ ⊕ ⊕ ⊕ ♦

OPEN

♦

Control unit side short

♦

♦ ♦

♦

♦ ♦

♦

⊕

⊕ ⊕ ⊕ ⊕

⊕

⊕ ⊕ ⊕ ⊕

Control unit side short LPG interception valve

OPEN OPEN

Improper TAS learning

OPEN

136

• The same malfunction may occur as power supply open of throttle control motor and throttle position sensor.

⊕ ⊕ ⊕ ⊕

OPEN

Malfunction indicator lamp

♦

⊕

LO side circuit

OPEN

♦

♦ ♦ ♦ ♦

Coil

LPG interception valve relay

♦ ♦

♦ ♦

SHORT

LPG assistance injector

♦

⊕

Momentarily open

OPEN

Description/notable characteristics of the symptom

♦ ⊕ ⊕ ⊕ ⊕

EGI relay circuit

LPG injector

Engine stall

Poor driving

♦ ♦ ♦ ♦ ♦

♦ ♦

EC-28

TROUBLE DIAGNOSIS Diagnosis Chart by Symptom (Cont’d)

⊕: Highly possible ♦: Possible ∇: Not very possible

Other

Poor starting

Engine stall

♦ ∇

♦ ♦

∇

∇

∇

Air sucked from oil filler cap

♦ ∇

♦ ♦

∇

∇

∇

Description/notable characteristics of the symptom

Air sucked from PCV hose (downstream of PCV)

♦ ∇

♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇

♦ ♦

♦

∇

Air sucked from intake manifold and gasket

♦ ∇

♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇

♦ ♦

♦

∇

• Air-fuel ratio becomes LEAN. • High air-fuel correction factor.

• Low suction power (vacuum pressure) of intake manifold. * Check the suction using a pressure gauge. * Generally applicable to air suction in air intake system

♦

• Noise (high hissing tone)

♦

• Symptom depends on clogging status.

This tends to happen during high-speed or high load operation.

♦

PCV kept open

♦ ∇

♦ ∇

♦ ♦ ♦ ♦

♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦

∇ ♦

♦

♦ ♦ ♦ ♦ ♦

Clogged air cleaner element

Fuel mixture

Poor driving

Air sucked from oil level gauge

Clogged fuel strainer

Malfunctioning gasoline pressure regulator

∇ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

Poor quality gasoline

∇ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇

♦ ♦ ♦ ♦

∇

• Symptom varies depending on oil quality.

Improper LPG fuel (cold area and propane ratio)

♦ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇

♦ ♦ ♦ ♦

∇

• Starting ability in cold area is changed depending on propane ratio.

• Use LPG with proper propane ratio.

Malfunctioning LPG vaporizer pressure adjusting valve

∇ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

• If the pressure is low, it is caused by poor output during high-speed or high load operation.

• If the pressure is excessively high, relief valve operates and engine stalls at rich.

Clogged LPG vaporizer hot water circuit

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

• Symptom depends on fuel temperature.

This tends to happen during engine stall and is impossible to restart during engine warming up.

Clogged LPG interception valve filter

♦ ∇

♦ ∇ ♦ ♦ ♦ ♦ ♦

∇ ♦

• Symptom depends on clogging status.

This tends to happen during high-speed or high load operation.

Valve deposit

♦ ♦

♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

∇

• Air-fuel ratio becomes LEAN. High airfuel correction factor.

Improper connection of wire connector

∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇

∇ ∇ ∇ ∇ ∇

∇

• Check that wiring route is proper.

♦ ♦ ♦ ♦ ♦

♦

• Check that connector is slightly raised.

Poor starting if slightly raised connectors are in all cylinders.

♦

—

Poor connection of wire connector

Sparking

Poor idle

No initial combustion Initial combustion When engine is cold When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Poor fuel consumption efficiency

Symptoms

Impossible to start

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOM AND THE ENGINE MAIN BODY/AUXILIARY COMPONENT The table below shows the possible symptoms caused by the malfunction of engine main body system. It will be helpful in malfunction trouble diagnosis. (The table lists general symptoms and some may not be applicable.)

∇ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

∇

Improper ignition timing adjustment

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Malfunctioning spark plug

♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

∇

∇ ♦ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦

Leakage from high-pressure parts

EC-29

• Symptom varies depending on combustion pressure.

∇ ∇

♦

• Check that the gap is proper. Check spark plug for electric wear, soil (fuel injection, smoking), and damaged insulator.

♦

• Symptom varies depending on the level of leakage.

137

TROUBLE DIAGNOSIS

Compression pressure

⊕: Highly possible ♦: Possible ∇: Not very possible

Poor driving

Description/notable characteristics of the symptom

Improper bulb contact

∇ ♦ ⊕ ⊕

⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕

♦ ♦ ♦ ♦ ♦

• Symptom varies depending on contact condition and the number of cylinders.

Worn piston ring

∇ ♦ ⊕ ⊕

⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕

♦ ♦ ♦

• Symptom varies depending on degree of wear and the number of cylinders.

∇ ♦ ♦

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

∇ ∇

♦ ♦ ♦ ♦

Clogged three-way catalytic converter /exhaust system Low idle base speed

∇ ∇

♦

• Engine stall may occur by power steering load and cargo load during deceleration or at idling.

• Tires/wheels are hot.

♦ ♦ ♦ ♦

♦

—

∇

♦ ∇

♦

• Insufficient ATF amount, improper oil specification (This symptom may especially occur in the cold.)

∇ ∇ ∇ ♦ ♦ ∇ ∇

∇

♦

• Malfunctioning oil pressure relief valve, improper oil specification (This symptom may especially occur in the cold.)

♦ ♦ ♦ ♦ ♦ ♦ ♦

♦ ♦ ♦ ♦

∇

High A/T load

High HYD PUMP load (PS, Cargo)

∇ ♦ ♦ ♦

• In some cases, after engine stall, restarting is possible.

♦

Belt tension too high (excessive tension)

Foreign material in fuel tank (such as dust)

♦

♦ ♦ ♦

Dragging of brakes

Other

Engine stall

Other

Poor starting

Poor idle

No initial combustion Initial combustion When engine is cold When engine is warming up Fast idle is not effective High idle rpm Low idle rpm Inconsistent idle when engine is cold.

Inconsistent idle when warming up Poor power output Poor acceleration Engine rpm does not increase smoothly.

During surge and acceleration During surge and constant speed driving Knocking Backfire After-burn At Idle Driving During deceleration During a heavy load Engine over temperature (Overheat) Poor fuel consumption efficiency

Symptoms

Impossible to start

Diagnosis Chart by Symptom (Cont’d)

• With low fuel, this may easily occur.

Damaged fan, malfunctioning water pump

♦

• Noise

Clogged/restricted radiator/ condenser

♦

—

Also check the following items other than the above: • Check harness tension.

• Check each connector connection.

• Check ground wire for looseness.

• Check battery connection for looseness or corrosion.

• Check water and oil condition.

• Check fan belts for looseness.

138

EC-30

TROUBLE DIAGNOSIS Description •

• •

“When” a malfunction occurs that is caused by the sensors of engine or the air-fuel ratio control, “{ }” of the meter panel illuminates. Then, Diagnostic Trouble Code (DTC) is displayed on the meter. At this time, the possible cause is displayed by operating the button.

For DTC, refer to Table of DTC (EC-32).

When a malfunction has occurred, check the symptom and perform the trouble diagnosis using “Diagnosis history”, “ECM input/output monitor” and “Active test” in the meter.

NOTE: • For “Diagnosis history”, refer to EC-32.

• For “ECM Active Test”, refer to EC-40.

Fail-Safe Function When any of the critical sensors or systems sends a malfunction message, the fail-safe function estimates the driving conditions with other input signals and selects safer conditions for engine (vehicle) control, based on data previously stored in ECM. Related sensors

Malfunction condition

Mass air flow sensor

Same as self-diagnosis malfunction detection conditions.

Fail-safe •

•

Engine Warning lamp

Selects fuel injection pulse width depending on engine speed and throttle position so the vehicle can be driven. However, fuel injection will be inhibited (fuel cut off) when engine speed exceeds approximately 800 - 1,600 rpm.

Idle speed is 800 rpm.

ON

Engine coolant temperature sensor

•

Uses the estimated engine coolant temperature (varies with elapsed time after start) to perform controls so the vehicle can be driven.

ON

Accelerator pedal position sensor

•

Fuel injection will be inhibited when 1 circuit is opened. Release valve mechanically until it can drive at low speed when disconnecting connector.

ON

Throttle position sensor

•

Fixes output to a preset value so the vehicle can be driven. However, fuel injection will be inhibited (fuel cut off) when engine speed exceeds approximately 2,500 rpm.

ON

EC-31

139

TROUBLE DIAGNOSIS Table of DTC SELF-DIAGNOSIS RESULTS When a malfunction occurs in ECM input/output signal circuit, the malfunctioning circuit is recorded and displayed. Also, the malfunction item that is occurred is displayed.

Display sample [Example: When there is a malfunction in mass air flow sensor] Display DTC and the malfunction item in the alarm monitor screen.

DTC

Name

— E-03

NO DTC VCM communication signal circuit malfunction

E-04

E-05

E-07

ECM communication signal circuit malfunction DCM communication signal circuit malfunction MP communication signal circuit malfunction

Engine warning lamp —

U1001 —

U1001 —

U1001 —

E-22

140

P0102

ON

Engine coolant temperature signal circuit malfunction

— U1001

—

Mass air flow sensor signal circuit malfunction

E-21

DTC for GST

ON

Malfunction return condition

Diagnosis outline

Trip

— • Malfunction occurs in CAN communication transmit/receive data or in VCM, and data transmission/reception cannot be confirmed.

• CAN communication data is transmitted/ received for predetermined period.

• Malfunction occurs in CAN communication transmit/receive data or in ECM, and data transmission/reception cannot be confirmed.

• CAN communication data is transmitted/ received for predetermined period.

• Malfunction occurs in CAN communication transmit/receive data or in DCM, and data transmission/reception cannot be confirmed.

• CAN communication data is transmitted/ received for predetermined period.

• Malfunction occurs in CAN communication transmit/receive data or in MP, and data transmission/reception cannot be confirmed.

• CAN communication data is transmitted/ received for predetermined period.

When the engine is running and the mass air flow sensor output voltage has been 0.5V or less (open or shorted) for a predetermined period.

— —

— 2

—

2

—

2

—

2

Detect disconnection and short circuit and make MIL go on.

1

Detect disconnection and short circuit and make MIL go on.

1

P0103

When the engine is stopped (ignition switch ON) and the mass air flow sensor output voltage has been approx. 4.9V or more (open or shorted) for a predetermined period.

P0117

Engine coolant temp. sensor output voltage has been less than 0.06V (open or shorted) for a predetermined period.

P0118

Engine coolant temp. sensor output voltage has been approx. 4.8V or more (open or shorted) for a predetermined period.

EC-32

TROUBLE DIAGNOSIS Table of DTC (Cont’d) DTC

Name

Engine warning lamp

Throttle position sensor signal circuit malfunction

DTC for GST P0122

P0123

P0222

E-23

ON*

P0223

P1225 P1226 P2135

Accelerator pedal position sensor signal circuit malfunction

P2122

P2123

P2127

E-24

—

P2128

P2138

E-25

E-26

Heated oxygen sensor signal circuit malfunction

—

P0132

Heated oxygen sensor heater signal malfunction

—

P0134 P0031

P0032

Malfunction return condition Throttle position sensor 2 output voltage has been approx. 0.3V or less (open) for a predetermined period.

Throttle position sensor 2 output voltage has been approx. 4.8V or more (shorted) for a predetermined period.

Throttle position sensor 1 output voltage has been approx. 0.3V or less (open) for a predetermined period.

Throttle position sensor 1 output voltage has been approx. 4.8V or more (shorted) for a predetermined period.

When the throttle valve closed position learning value is excessively low.

When the throttle valve closed position learning cannot be performed.

A malfunction occurs in the relation between throttle position sensors 1 and 2.

Accelerator pedal position sensor 1 output voltage has been approx. 0.15V or less (open) for a predetermined period.

Accelerator pedal position sensor 1 output voltage has been approx. 5V or more (shorted) for a predetermined period.

Accelerator pedal position sensor 2 output voltage has been approx. 0.15V or less (open) for a predetermined period.

Accelerator pedal position sensor 2 output voltage has been approx. 5V or more (shorted) for a predetermined period.

A malfunction occurs in the relation between accelerator pedal position sensors 1 and 2.

Heated oxygen sensor output voltage is higher than normal (1.4V or more).

Heated oxygen sensor signal circuit is open.

Heated oxygen sensor heater control voltage has been approx. less than 0.12V (open or shorted) for a predetermined period.

Heated oxygen sensor heater control voltage has been approx. 4.7V or more (shorted) for a predetermined period.

EC-33

Diagnosis outline

Trip

Detect disconnection and short circuit and make MIL go on.

1

Compare inconsistency between two separate circuits which are installed for redundancy and judges abnormal condition and make MIL go on.

Detect disconnection and short circuit and make MIL go on.

Compare inconsistency between two separate circuits which are installed for redundancy and judges abnormal condition and make MIL go on.

Detect disconnection and short circuit and make MIL go on.

Detect disconnection and short circuit of an oxygen sensor heater circuit and make MIL go on.

1

2

2

141

TROUBLE DIAGNOSIS Table of DTC (Cont’d) DTC

Name

E-27

Crankshaft position sensor signal circuit malfunction

E-28

E-29

Camshaft position sensor (PHASE) signal circuit malfunction

Self shut off malfunction

Engine warning lamp

P0335

ON

P0340

ON

—

ECM circuit malfunction

E-30

DTC for GST

ON*

Electric throttle control actuator control signal circuit malfunction

P0605

E-33

E-34

142

Overheat signal (STEP1) Overheat signal (STEP2) Ignition signal circuit malfunction

Detect abnormal crank angle sensor signal and make MIL go on.

2

Detect abnormal cam angle sensor signal and make MIL go on.

2

—

1

Detect abnormal condition in CPU or an engine control module circuit and make MIL go on.

Detect insufficient power supply for ECM and make MIL go on.

Detect improper voltage output for sensors and make MIL go on.

Detect disconnection and short circuit of a motor driving circuit and make MIL go on.

1 or 2 (Note)

Compare the difference between target throttle position and actual throttle position, judge abnormal condition and make MIL go on.

Locked ON: 1 Locked OFF: 2

Power is not supplied to ECM for some time.

P1229

Sensor power supply voltage has been 5.6V or more or less than 4.6V for a predetermined period.

Electric throttle control motor power supply circuit is shorted.

Electric throttle control motor power supply circuit is open.

Electric throttle control motor signal circuit is shorted.

When an abnormal occurs for the target of throttle position.

Because of mechanical malfunction of the electric throttle control actuator, the electric throttle control actuator does not operate normally.

• When a malfunction occurred due to the correlation between the target throttle position and the actual throttle position.

• Over current flows into throttle motor control circuit.

Engine coolant temp. sensor output voltage has been approx. 0.35V or less for a predetermined period (with the coolant temp. sensor normal)

P1126 P1128

P1121

P1218 — P1217 ON* P0350 —

• The crankshaft position sensor (POS) signal is not detected for a predetermined time at engine start or during engine running (during camshaft position sensor (PHASE) signal input).

• A crankshaft position sensor (POS) signal irregular waveform is detected for a predetermined time during engine running (during camshaft position sensor (PHASE) signal input).

• At start-up, no camshaft position sensor (PHASE) signal has been detected for more than a predetermined period.

• The camshaft position sensor (PHASE) signal is not detected for a predetermined time during engine running (during crankshaft position sensor (POS) signal input).

• A camshaft position sensor (PHASE) signal irregular waveform is detected for a predetermined time during engine running (during crankshaft position sensor (POS) signal input).

Self shut off of ECM doesn’t operate normally.

P1065

P1122

E-32

Trip

CPU system or circuits in ECM have a malfunction.

P1124

—

Diagnosis outline

P0605

P0605 E-31

Malfunction return condition

Engine coolant temp. sensor output voltage has been approx. 0.35V or less for a predetermined period (with the coolant temp. sensor normal) Ignition signal has not been continuously generated while the engine is running.

EC-34

1

—

1

Detect overheat condition by water temperature sensor and make MIL go on.

Detect electric current in an ignition coil circuit, judge abnormal ignition interval and make MIL go on.

1

1

TROUBLE DIAGNOSIS Table of DTC (Cont’d) DTC

E-35

Name LPG fuel injection open circuit malfunction

Engine warning lamp

—

LPG vaporizer malfunction E-38

E-41

DTC for GST

—

GAS air-fuel ratio malfunction

E-42

ON*

LPG air-fuel ratio malfunction

E-43

ON*

Detect abnormal electric current in an LPG injector driving circuit and make MIL go on.

1

P1241

Over current flows into LPG injector 1 (no injection area).

P1249

• LPG fuel pressure sensor circuit Detect abnormally higher fuel is open. pressure by LPG fuel pressure • LPG fuel pressure in fuel piping sensor and make MIL go on. from LPG Vaporizer to injector has been excessively increased for a predetermined period.

Brake switch signal circuit is open — or shorted.

P1805 P1814

After engine warmed with gasoline fuel, when oxygen sensor signal is stuck and does not reverse at a condition of A/F ratio is excessively lean or rich.

P1148

After engine is started with gasoline fuel, when closed-loop control does not start within a predetermined period.

P1815

After engine warmed with LPG fuel, when oxygen sensor signal is stuck and does not reverse at a condition of A/F ratio is excessively lean or rich.

After engine is started with LPG fuel, when closed-loop control does not start within a predetermined period.

ON*

LPG fuel pressure sensor malfunction

Trip

Over current flows into LPG injector 1 (injection area).

P1817

E-36

Diagnosis outline

P1240

—

Stop lamp switch malfunction

Malfunction return condition

P1245

1

Air-fuel ratio does not cross stoichiometry for a long time during intended closed-loop operation. (written in 40CFR Parts 1048.110.)

1

Air-fuel ratio does not cross stoichiometry for a long time during intended closed-loop operation. (written in 40CFR Parts 1048.110.)

1

LPG fuel pressure sensor circuit is Detect disconnection and short shorted. circuit and make MIL go on.

EC-35

1

1

143

TROUBLE DIAGNOSIS Service Tool Trip 1: If a malfunction is detected by self-diagnosis between the time ignition switch is turned ON (engine is running) and then turned OFF (this is defined as “trip”), Engine Warning lamp is lit. The corresponding DTC is recorded immediately after detection.

Trip 2: When a malfunction is detected by self-diagnosis for the first time in the first trip, a tentative DTC is recorded. If the same malfunction is detected again by self-diagnosis in the next trip (second trip), Engine Warning lamp is lit and the corresponding final DTC is recorded.

Self-diagnostic results timing • For items of trip 1, timing “0” is displayed immediately after detection of a malfunction.

• For items of trip 2, when a malfunction is detected for the first time (trip 1), timing “1t” is displayed. When a malfunction is detected again in the next trip (trip 2), it is displayed as “0”.

Accumulative counting is performed at the end of warming-up operation.

Conditions to turn off Engine Warning lamp • The Engine Warning lamp, marked with *, is turned off when ignition switch is turned ON (engine starts) again after normal state is resumed.

• For other self-diagnostic items, self-diagnostic results shall be erased by turning ignition switch to OFF after normal operation is resumed.

144

EC-36

TROUBLE DIAGNOSIS Service Tool (Cont’d) OBD SYSTEM COUNTER (FOR TRIP 2 DETECTION DIAGNOSIS WHEN MIL TURNS ON) Relation of MIL, first trip DTC, DTC and possible detection items • When the malfunction is detected for the first time, ECM records first trip DTC. • When the same malfunction is detected twice continuously, ECM records DTC and MIL turns ON. • MIL turns OFF after driving the vehicle by 3 trips without the malfunction. If the same malfunction occurs while counting, the counter is reset.

• DTC is displayed until the vehicle is driven by 40 trips while the same malfunction is not reproduced.

• If the self-diagnosis result is OK at the second trip, the first trip DTC is not displayed.

Table of counter systems Unit: Trip Items

Trips

Driving conditions

MIL (OFF)

3

B

DTC (CLEAR)

40

A

First trip DTC (CLEAR)

1

B

Driving conditions • Driving condition A Driving condition A is the condition that the engine can be warmed up.

Specifically, count up the counter if all of the following conditions are satisfied.

• The engine speed becomes 400 rpm or more.

• The engine coolant temperature rises 20°C (68°F) or more after the engine is started.

• The engine coolant temperature becomes 70°C (158°F) or more.

• The ignition switch turns OFF from ON. NOTE: • When the same malfunction is detected regardless of the driving condition, the A counter is reset.

• Count up the A counter when the above conditions are satisfied while the same malfunction not detected.

• When the A counter reaches 40, DTC is not displayed.

• When the A counter counts once while the same malfunction is not detected after ECM records first trip DTC, first trip DTC is cleared.

EC-37

145

TROUBLE DIAGNOSIS Service Tool (Cont’d) • Driving condition B Driving condition B is the condition that all diagnosis can be performed just once.

Specifically, count up the counter if all of the following conditions are satisfied.

• The engine speed becomes 400 rpm or more.

• The engine coolant temperature becomes 70°C (158°F) or more.

• The vehicle speed of 6 - 40 km/h (4 - 25 MPH) continues for 3 seconds or more at closed loop control.

• The vehicle speed of 4 km/h (2 MPH) or less and the idle determination ON continue for 5 seconds or more at closed loop control.

• Allow 6 minutes or more to pass after starting the engine.

NOTE: • When the same malfunction is detected regardless of the driving condition, the B counter is reset.

• Count up the B counter when the above conditions are satisfied while the same malfunction is not detected.

When the B counter reaches 3 without the malfunctions, MIL turns OFF.

146

EC-38

TROUBLE DIAGNOSIS Self-Diagnosis Function (Without Service tool)

DIAGNOSTIC TEST MODE II - SELF-DIAGNOSTIC RESULTS • In this mode, the MIL blinks (indicating the DTC) to identify the system that returned a malfunction.

• If no DTC is detected, DTC “0000” is displayed.

EC-39

147

TROUBLE DIAGNOSIS ECM Input/Output Monitor Heated oxygen sensor output voltage

At idle: Changes between approx. 0.1 - 0.4V⇔0.6 - 0.9V Maintain at approx. 2,000 rpm: Changes between approx.

0.1 - 0.4V⇔0.6 - 0.9V

Intake air temperature sensor

Values according to intake air temperature

LPG fuel pressure sensor

Ignition switch ON: Approx. 29 kPa (0.3 kg/cm2) [4 psi]

ECM Active Test ECM active test has the following items.

• Idle Air Volume (Normal) • Air-fuel ratio adjustment • Air-fuel ratio clear • Ignition timing adjustment • Fuel pressure clear • Power balance • Self-diagnosis clear (1) Idle Air Volume Learning If the idle speed or the ignition timing is outside the standard (engine status is malfunctioning) or if the electronic throttle control actuator or ECM is replaced, perform Idle Air Volume Learning.

Standard Idle speed: 700±50 rpm Ignition timing: 0±2/700 (°BTDC/rpm) (2) Air-fuel ratio adjustment If the values of “Air-fuel ratio” in ECM input/output monitor are outside the standard, adjust the air-fuel ratio.

Proper value: 100% Adjustment range: 75 - 125% (3) Ignition timing adjustment If the values of “Ignition timing” in ECM input/output monitor are outside the standard, adjust the ignition timing.

Proper value: 0° Adjustment range: 0 - 10° (4) Fuel pressure clear Relieve fuel pressure before removing fuel piping to secure safety.

For relieving procedure of fuel pressure, refer to “Fuel pressure clear”.

(5) Power balance When the engine does not run smoothly or the misfires occur in some cylinders, forcibly stop each cylinder in “Power balance”, and then check which cylinder has the malfunction.

148

EC-40

BASIC INSPECTION BASIC INSPECTION

Inspection of Idle Speed and Ignition Timing SERVICE DATA AND SPECIFICATIONS (SDS)

Fuel pressure kPa (kg/cm2) [psi]

353 (3.6) [51]

Idle speed (rpm)

A/T model (at N position)

700±50

Ignition timing (˚BTDC/rpm)

A/T model (at N position)

0±2/700

Manufacturer/type/gap mm (in)

NGK/FR2A-D/0.8 - 0.9 (0.0031 - 0.035)

Firing order Spark plug

1-3-4-2

Ignition advance device

Electrically controlled ignition advance

Density of CO at idle speed (%)/Density of HC at idle speed (ppm)

0.1/50 or less

• •

•

Turn ignition switch ON, and then make sure that no malfunction is detected by self-diagnosis.

Make sure that engine is free of oil pressure pump loads and any electrical loads. Perform the inspection with the shift lever in the neutral or N position.

Warm up engine and transmission to the normal operating temperature.

EC-41

149

BASIC INSPECTION Throttle Valve Closed Position Learning and Idle Air Volume Learning DESCRIPTION When electric throttle control actuator or ECM connector is removed, it is necessary for ECM to learn throttle valve closed position (throttle position sensor output with throttle valve fully closed) after reinstallation. Thus, throttle valve closed position learning is performed.

When electric throttle control actuator or ECM is replaced, the minimum required idle air volume needs to be learned. Thus, throttle valve closed position learning and idle air volume learning are performed.

Idle air volume learning is necessary even when idle speed or ignition timing is outside the standard. Note that idle air volume learning is equivalent to the base idle speed adjustment by conventional throttle adjusting screw of carburetor or LPG mixer.

OPERATION PROCEDURE FOR THROTTLE VALVE CLOSED POSITION LEARNING 1. Turn ignition switch ON → OFF. (And hold it for approximately 5 seconds after turning it OFF.) 2. Make sure that throttle valve operates. (Check for operating sound.)

3. Upon completion of the above, learning is complete.

CAUTION: Throttle valve closed position learning cannot be performed with Service tool.

OPERATION PROCEDURE FOR IDLE AIR VOLUME LEARNING 1. Perform throttle valve closed position learning.

2. Fully warm up engine, transmission, and lubricant. [Engine coolant temperature: 70 to 90˚C (158 to 194˚F)] 3. Set the selector lever to neutral or N position. Make sure that the engine is free of electrical loads, such as air conditioner, oil pressure pump, and other electrical components.

4. Perform “Idle Air Volume Learning” of “ECM Active Test”.

CAUTION: “IDLE AIR VOL LEARN (PLANT)” is the original setting on the vehicle. Do not use it.

150

EC-42

BASIC INSPECTION Throttle Valve Closed Position Learning and Idle Air Volume Learning (Cont’d) CAUTION: It will take approximately 20 seconds to complete the idle air volume learning. Do not turn OFF the ignition switch until completion.

• •

Complete “Idle Air Volume Learning”, then make sure that idle speed and ignition timing are within the standard.

Perform “Idle Air Volume Learning” again if values are outside the standard.

Accelerator Pedal Released Position Learning DESCRIPTION When the accelerator pedal assembly has been replaced or the accelerator pedal position sensor connector has been disconnected, the accelerator pedal released position needs to be learned after being repaired, so learn accelerator pedal in fully-released position.

OPERATION PROCEDURE 1. Turn ignition switch ON and wait at least 2 seconds.

2. Turn ignition switch OFF and wait at least 10 seconds.

3. Then turn ignition switch ON again and wait at least 2 seconds (learning completed).

Fuel Pressure Inspection QUICK INSPECTION With Active Test 1. Perform “Fuel pressure clear” of ECM Active Test.

2. Pinch the fuel feed hose with the fingers. Hose should not feel hard.

Without Active Test • When the fuel feed hose is squeezed while fuel pump is operating (for 1 second after the ignition switch is turned ON or while cranking), the hose should be swelling with pressure or pulsating.

FUEL PRESSURE INSPECTION CAUTION: • Safely and securely remove and install fuel hose.

• Use the fuel pressure gauge for fuel pressure inspection.

• Do not inspect fuel pressure while other systems are operating. Malfunctions may occur in fuel pressure value.

1. Release the fuel pressure.

2. Install fuel pressure gauge using fuel hose for fuel pressure inspection.

3. Remove fuel hose, and then install fuel hose for fuel pressure inspection.

CAUTION: Usable period of fuel hose for fuel pressure inspection is 30 times or less. (Fuel hoses that are damaged and allow fuel leakage are not contained above.)

EC-43

151

BASIC INSPECTION Fuel Pressure Inspection (Cont’d) 4.

5.

6.

Turn ignition switch ON, and then make sure that there is no fuel leakage.

Start engine, and check for fuel leakage.

Make sure that fuel pressure is within the standard.

At idle: 353 kPa (3.6 kg/cm2) [51 psi]

•

If the vehicle shows poor starting, check fuel pressure with fuel pump operating for approximately 1 second after ignition switch is turned ON, and during cranking.

For 1 second after ignition switch is turned ON and during cranking: 353 kPa (3.6 kg/cm2) [51 psi]

•

Check the following items if a malfunction is detected.

CAUTION: Also check fuel pressure at increased engine speed.

• • • •

Malfunctioning pressure regulator (integrated with fuel pump) Clogged fuel piping Clogged fuel filter (with fuel pump) Poor fuel pump discharge

Fuel Pressure Release CAUTION: Relieve fuel pressure before removing fuel piping to secure safety.

With Active Test 1. Perform “Fuel pressure clear” of ECM Active Test.

2. Crank engine 2 or 3 times to consume the fuel in the fuel line after it stalls.

3. Turn ignition switch OFF. Without Active Test 1. Disconnect fuel pump fuse.

2. Start engine.

3. Crank engine 2 or 3 times to consume the fuel in the fuel line after it stalls.

4. Turn OFF the ignition switch, and install the fuel pump fuse.

152

EC-44

COMPONENT PARTS INSPECTIONS COMPONENT PARTS INSPECTION

Crankshaft Position Sensor (POS) Check resistance between terminals using an analog circuit tester.

At room temperature (+) - (-) Resistance 3-1 : Not 0 Ω nor ∞ Ω 2-1 : Not 0 Ω nor ∞ Ω 3-2 : Not 0 Ω nor ∞ Ω

ECM0086

CAUTION: Measurement values will vary depending on the measurement range of circuit tester. Note that the higher the range is, the larger the resistance is.

Camshaft Position Sensor (PHASE) Check resistance between terminals using an analog circuit tester.

At room temperature (+) - (-) Resistance 3-1 : Not 0 Ω nor ∞ Ω 2-1 : Not 0 Ω nor ∞ Ω 3-2 : Not 0 Ω nor ∞ Ω

ECM0091

CAUTION: Measurement values will vary depending on the measurement range of circuit tester. Note that the higher the range is, the larger the resistance is.

Mass Air Flow Sensor 1.

2.

Remove mass air flow sensor.

Turn ignition switch to ON. While blowing air into the mass air flow sensor from the air cleaner case side, check output voltage between terminal 3 and ground.

No air blowing: Approx. 1V With air blowing: Approx. 1.3V (The more the air is blown, the higher the voltage is.)

CAUTION: If air is blown from the air duct side, the voltage becomes lower.

Engine Coolant Temperature Sensor Check resistance between terminals 1 and 2 on the engine coolant temperature sensor.

Resistance Coolant temperature at approx. 20˚C (68˚F): Approx.

2.5 k Ω Coolant temperature at approx. 80˚C (176˚F): Approx.

0.3 k Ω

EC-45

153

COMPONENT PARTS INSPECTION Engine Coolant Temperature Sensor (Cont’d) (k

)

Resistance

20 10 2.5 1 0.3 0.1

20 (68)

80 (176)

Coolant temperature

C ( F) ECM0383

Throttle Position Sensor 1, 2 (Electric throttle control actuator assembly) Check voltage between ECM terminal 50, 69 and ground.

Terminal signal

At idle after warming up

At approx.

2,000 rpm

50 - (-)

Throttle position sensor 1

Approx. 0.6V

Approx. 0.7V

69 - (-)

Throttle position sensor 2

Approx. 4.5V

Approx. 4.4V

• ECM0101

• •

•

COMPONENT PARTS INSPECTION

Signal name

CAUTION: Make sure that there is no moisture around connector when removing and installing throttle position sensor connector. If there are any water drops, completely wipe them off.

Do not apply voltage to throttle position sensor terminal.

Perform “Throttle Valve Closed Position Learning” if disconnecting connector. Perform “Throttle Valve Closed Position Learning and Idle Air Volume Learning” if replacing electric throttle control actuator. (Refer to EC-42, “Throttle Valve Closed Position Learning and Idle Air Volume Learning”.)

Do not disassemble electric throttle control actuator.

Accelerator Pedal Position Sensors 1, 2 (Accelerator work unit) Check voltage between ECM terminal 106, 98 and ground.

Terminal

ECM0103

At Idle

106

Accelerator pedal position sensor 1

Approx. 0.67 0.87V

Approx. 0.65V

98

Accelerator pedal position sensor 2

Approx. 0.335 - 0.435V

Approx. 0.35V

• •

154

At approx.

2,000 rpm

Signal name

CAUTION: Do not apply voltage to accelerator pedal position sensor terminal.

Do not disassemble accelerator work unit.

EC-46

COMPONENT PARTS INSPECTION Intake Air Temperature Sensor (Joined with mass air flow sensor) Check resistance between intake air temperature sensor (mass air flow sensor connector) terminals 3 and 5.

Resistance Intake air temperature at approx. 20°C (68°F): Approx. 2.5 kΩ Intake air temperature at approx. 80°C (176°F): Approx. 0.3 kΩ

(k

)

Resistance

20 10 2.5 1 0.3 0.1

20 (68)

80 (176)

Intake air temperature

C ( F) ECM0384

Stop Lamp Switch Check continuity between stop lamp switch terminals 1 and 2.

Brake pedal released: Continuity should not exist.

Brake pedal depressed: Continuity should exist.

ECM0108

Spark Plug 1.

2.

• • • • ECM0117

Check electrode for dirt, damage, and wear and insulator for damage.

Replace spark plug if necessary.

CAUTION: Check terminals for looseness.

Check insulator for cracks or damage.

Check for contamination by oil, water, and dust.

Make sure that the spark plug gap is normal, using a feeler gauge.

Spark plug gap: 0.8 - 0.9 mm (0.031 - 0.035 in)

EC-47

155

COMPONENT PARTS INSPECTION Ignition Coil Check the resistance between terminals of the power transistor by applying and exchanging (+ and -) the inspection rods of an analog circuit tester. (+) - (-) Resistance (at room temperature) 1-2 : Not 0 Ω nor ∞ Ω 2-1 : Not 0 Ω nor ∞ Ω 3-1 : Except 0 Ω 1-3 : Except 0 Ω 3-2 : Except 0 Ω 2-3 : Except 0 Ω ECM0118

CAUTION: Do not use a digital circuit tester because the standard is different.

Injector Check resistance between each cylinder injector terminals 1 and 2.

Standard resistance (all cylinders): Approx. 14.5 Ω (at room temperature)

ECM0123

WITH ECM INPUT/OUTPUT MONITOR 1. Check “INJ PULSE GAS” (gasoline) or “INJ PULSE LPG” (LPG) in Input/Output monitor, and increase the engine speed to approximately 2,500 rpm after warming up engine.

2. Make sure that “INJ PULSE GAS” (gasoline) or “INJ PULSE LPG” (LPG) instantly drops when accelerator pedal is released.

WITHOUT SERVICE TOOL 1. Warm up the engine sufficiently.

2. Disconnect harness connector of the injector and connect a test lamp.

3. Release the accelerator pedal at the engine speed of approximately 2,500 rpm or more, and confirm test lamp goes off for a moment.

ECM0147

156

EC-48

COMPONENT PARTS INSPECTION Fuel Pump Check resistance between terminals 3 and 6.

Resistance: Approx. 1 Ω (at room temperature)

Electric Throttle Control Motor (Electric throttle control actuator assembly) Check resistance between electric throttle control motor (throttle position sensor connector) terminals 3 and 6.

Resistance: Approx. 1 -15 Ω [at 25˚C (77˚F)] •

• •

•

CAUTION: Make sure that there is no moisture around connector when removing and installing throttle position sensor connector. Completely wipe off water drops if there are any.

Do not apply voltage to electric throttle control motor terminal.

Perform “Throttle Valve Closed Position Learning” if disconnecting connector. Perform “Throttle Valve Closed Position Learning and Idle Air Volume Learning” if replacing electric throttle control actuator. (Refer to EC-42, “Throttle Valve Closed Position Learning and Idle Air Volume Learning”.)

Do not disassemble electric throttle control actuator.

Heated Oxygen Sensor Check resistance between heated oxygen sensor terminals 2 and 3.

Resistance: Approx. 3.3 - 3.5 Ω

EC-49

157

COMPONENT PARTS INSPECTION LPG Injector 1.

2.

Check resistance between terminals 1 and 2.

Resistance: Approx. 1Ω (at room temperature) Remove fuse cover, and then check fuse for open.

CAUTION: Do not apply voltage to LPG injector.

LPG Assistance Injector Check resistance between terminals 1 and 2.

Resistance: Approx. 27Ω (at room temperature) Apply battery voltage directly to terminals 1 and 2, and then check solenoid operation.

• Apply battery voltage directly between terminals 1 and 2: Continuity should exist.

• No voltage: Continuity should not exist.

PTC Heater (Integrated with vaporizer) Check the resistance between PTC heater terminal and ground.

Resistance: 1.5 - 2.0Ω (Engine coolant temperature 25°C (77°F))

158

EC-50

PCV GAS RECIRCULATION DEVICE PCV GAS RECIRCULATION DEVI

System Diagram

Component Parts Inspection PCV valve 1. At idle, remove PCV valve together with hoses from rocker cover.

2. Check if hissing sound is heard from the air passage when PCV valve is operating normally.

ECM0144

3.

Check air flow through the PCV valve and sucking air to/from the INT end.

Blowing air: No air flow Sucking air: Air flow exists

ECM0145

EC-51

159

ECM COMPONENTS ECM COMPONENTS

Removal and Installation ECM CAUTION: Disconnect the negative battery cable from the battery.

1.

2.

3.

4.

Disconnect ECM connector.

Remove ECM together with ECM bracket.

Remove ECM bracket.

Install in the reverse order of removal.

CAUTION: Perform “Throttle Valve Closed Position Learning and Idle Air Volume Learning” after installation if replacing ECM. (Refer to EC-42, “Throttle Valve Closed Position Learning and Idle Air Volume Learning.”)

Crankshaft position sensor (POS)

5.4 - 7.4 N m (0.55 - 0.75 kg-m, 48 - 65 in-lb)

NOTE: • Make sure that there is no foreign material on sensor flange, Orings, and cylinder block.

• Keep away from magnetized objects.

O-ring

: Engine oil : Not reusable

CRANKSHAFT POSITION SENSOR (POS) 1. Remove fan.

2. Remove harness connector.

3. Remove crankshaft position sensor (POS).

Front cover

•

ECM0385

Chain housing 5.4 - 7.4 N m (0.55 - 0.75 kg-m, 48 - 65 in-lb)

O-ring

: Engine oil : Not reusable

Camshaft position sensor (PHASE) ECM0386

Make sure that the sensor is inserted securely into front cover before tightening bolts.

CAMSHAFT POSITION SENSOR (PHASE) 1. Remove fan.

2. Remove harness connector.

3. Remove camshaft position sensor (PHASE).

NOTE: • Make sure that there is no foreign material on sensor flange, Orings, and chain housing.

• Keep away from magnetized objects.

•

Make sure that the sensor is inserted securely into cylinder head front cover before tightening bolts.

MASS AIR FLOW SENSOR 1. Remove harness connector.

2. Remove mass air flow sensor assembly from air horn.

160

EC-52

ECM COMPONENTS Removal and Installation (Cont’d) ENGINE COOLANT TEMPERATURE SENSOR 1. Disconnect radiator drain plug, and drain coolant.

Engine coolant temperature sensor 12 - 16 N m (1.2 - 1.6 kg-m, 9 - 12 ft-lb)

CAUTION: Make sure to drain when the coolant temperature is cold.

Copper washer

: Liquid gasket : Not reusable

2.

3.

Remove harness connector.

Remove coolant temperature sensor using a socket specially designed for removing and installing coolant temperature sensors [commercially available: Thermosensor Socket manufactured by KTC (part No.: B20T-19)] and similar parts.

ECM0387

HEATED OXYGEN SENSOR (WITH HEATED OXYGEN SENSOR HEATER) 1. Remove harness connector from heated oxygen sensor.

2. Remove heated oxygen sensor using a socket designed for heated oxygen sensor removal and installation (Service tool).

CAUTION: Handle it carefully and avoid impacts.

EC-53

161

SERVICE DATA AND SPECIFICATIONS (SDS)

162

ENGINE LUBRICATION & COOLING SYSTEMS SECTION

LC

CONTENTS LUBRICATION SYSTEM .....................................LC-2 Specifications................................................... LC-2 Adjustment Value............................................. LC-2 Oil Pressure ..................................................... LC-2 Tightening Torque............................................ LC-2 Trouble Diagnosis ............................................ LC-3 Lubrication Schematic Diagram ....................... LC-4 Oil Pump .......................................................... LC-5

ENGINE COOLANT SYSTEM..............................LC-6 Specifications................................................... LC-6 Adjustment Value............................................. LC-6 Tightening Torque............................................ LC-6 Trouble Diagnosis............................................ LC-6 Cooling System Configuration ......................... LC-7 Water Pump..................................................... LC-8 Thermostat....................................................... LC-9

LC

163

LUBRICATION SYSTEM LUBRICATION SYSTEM

Specifications MAIN SPECIFICATIONS Lubrication method

Pressured supply

Oil pump

Spur gear type

Oil filter

Total flow, cartridge type

Adjustment Value Oil pump Unit: mm Clearance between pump gear and main body

0.4 or less

Backlash of pump gear

0.5 or less

Pump gear clearance in vertical direction

0.3 or less

Oil Pressure Oil pressure Unit: kPa (kgf/cm2) Discharge pressure At Idle

Oil temperature 80˚C 98 (1.0)

At 2,000 rpm

274 - 313 (2.8 - 3.2)

Tightening Torque

164

N·m

kgf-m

Oil pump bolt

15.7 - 17.7

1.6 - 1.81

Oil pump cover bolt

6.37 - 7.45

0.65 - 0.76

Oil pump

6.37 - 7.45

0.65 - 0.76

Oil pan drain plug

29.4 - 39.2

3.0 - 4.0

LC-2

LUBRICATION SYSTEM Trouble Diagnosis Condition Oil leakage

MWL ON

Noise

Possible causes

Action

•

Cracks or damages in pump body cover

Replacement

•

Oil leakage from gasket and oil seal

Replacement

•

Oil leakage from near spindle support

Replace the O-ring seals or inspect the pump body and replace it as necessary.

•

Oil leakage from near distributor

Replace the O-ring seals or inspect the pump body and replace it as necessary.

•

Oil leakage between timing chain housing and cylinder block

Disassemble and reassemble/apply liquid packing again.

•

Loose rocker cover retaining nuts and oil leakage.

Additionally tighten.

•

Loose oil pan mounting bolts and oil leakage

Additionally tighten.

•

Oil leakage from crankshaft front oil seal

Replacement

•

Oil leakage from crankshaft rear oil seal

Replacement

•

Oil leakage from regulator valve

Additionally tighten or replace.

•

Oil leakage from plugs in lubrication system

Replace or additionally tighten.

•

Loose oil filter

Additionally tighten.

•

Use of inappropriate quality of oil

Replace with specified oil.

•

Engine over temperature (Overheat)

Already described

•

Oil pump regulator valve malfunction

Overhaul or replace the oil pump.

•

Oil pump malfunction

Overhaul or replace the oil pump.

•

Inappropriate oil pump installation

Additionally tighten.

•

Damaged oil pump gasket

Replacement

•

Oil filter malfunction

Replacement

•

Enlarged clearance between sliding parts

Disassemble and replace the relevant sliding parts.

•

Loose mounting of rocker shaft bracket

Tighten bolts.

•

Clogged oil strainer

Wash.

•

Malfunction of oil pressure gauge pressure switch

Replacement

•

Oil pressure switch malfunction

Replacement

•

Insufficient oil in oil pan

Fill oil and identify/repair the factor causing nonstandard condition.

•

Loose oil pan drain plug or damaged gasket

Additionally tighten or replace.

•

Incident in electrical system

Inspect the electric circuits.

•

Excessive backlash of pump rotor

Replacement

LC-3

165

LUBRICATION SYSTEM Lubrication Schematic Diagram

LCM0022

166

LC-4

LUBRICATION SYSTEM Oil Pump COMPONENT PARTS LOCATION

LCM0023

INSPECTION 1. Check the following items for wear or damages.

• Pump body and cover • Pump gear section • Driving spindle The pump gear section and main body have no internal components that can be serviced separately. If the pump gear or main body is worn or damaged, replace the drive shaft assembly or oil pump assembly.

2. Inspect the clearance at the following points using a feeler gauge.

If the clearance exceeds the specified limit, replace the drive shaft assembly or oil pump assembly.

Clearance between pump gear and main body: 0.4 mm or less Backlash of pump gear: 0.5 mm or less Pump gear clearance in vertical direction: 0.3 mm or less

SLC136

3.

Inspect the regulator valve spring of the oil pump.

If damaged, replace the spring or pump assembly.

Free length 41.5±1 mm Repair limit 40.0 mm

LCM0024

LC-5

167

ENGINE COOLANT SYSTEM ENGINE COOLANT SYSTEM

Specifications Cooling method

Water cooled, controlled circulation

Water pump

Centrifugal

Thermostat

Wax pellet

Adjustment Value WATER PUMP Fan belt deflection When pushed with a force of 98N (10 kg) [mm]

11 - 13

THERMOSTAT Standard specification Valve opening temperature (˚C)

76.5

Maximum lift (mm/˚C)

8/90

Tightening Torque N·m

kgf-m

Water pump retaining bolt M8

15.7 - 17.7

1.6 - 1.81

Water pump retaining bolt M6

6.37 - 7.45

0.65 - 0.76

Thermostat housing bolt

15.7 - 17.7

1.6 - 1.81

Trouble Diagnosis Condition Water leakage

Insufficient circulation of coolant

Corrosion

168

Possible causes

Action

•

Water leakage from water pump shaft seal

Replace the water pump assembly.

•

Water leakage from water pump mounting face packing

Additionally tighten. If the leakage still remains, replace the packing.

•

Water leakage from radiator cap

Replace the packing or assembly.

•

Coolant leakage from engine coolant temperature sensor

Additionally tighten or replace.

•

Loose connection

Additionally tighten.

•

Damaged head gasket

Replace and check engine oil for contamination.

•

Cracks in cylinder block

Replace and check engine oil for contamination.

•

Cracks in cylinder head

Replacement

•

Loose head bolt

Additionally tighten.

•

Insufficient flow rate in coolant circuit

Remove any contamination and rust from the coolant circuit, and inspect the hose clamps.

•

Insufficient amount of coolant

Fill.

•

Water pump malfunction

Replacement

•

Loose fan belt.

Belt tension adjustment

•

Thermostat malfunction

Replacement

•

Excessive amount of impurities in coolant

Use clean softened water.

•

Insufficient cleaning of coolant circuit

Perform cleaning/flushing more frequently.

LC-6

ENGINE COOLANT SYSTEM Trouble Diagnosis (Cont’d) Condition Engine over temperature (Overheat)

Overcool

Noise

Possible causes

Action

•

Thermostat malfunction

Replacement

•

Radiator fins plugged with dirt and dust

Clean with compressed air.

•

Inappropriate ignition timing and valve timings

Adjust the ignition timing and valve clearances.

•

Contamination and sludge deposits in engine oil

Clean inside the engine and refill it with oil.

•

Water pump malfunction

Replacement

•

Loose fan belt.

Belt tension adjustment

•

Plugged radiator

Clean inside the radiator.

•

Poor accuracy of coolant temperature gauge

Replacement

•

Insufficient amount of coolant

Fill.

•

Air in coolant circuit

Bleeding

•

Contaminated engine coolant

Use clean softened water.

•

Thermostat malfunction

Replacement

•

Malfunctioning coolant temperature sensor

Replacement

•

Noise from water pump mechanical seal

Replacement

•

Wear or damage of water pump bearing

Replacement

Cooling System Configuration

LCM0025

LC-7

169

ENGINE COOLANT SYSTEM Water Pump 1.

Open the drain of the radiator and extract coolant into an appropriate container.

CAUTION: Do not drain coolant when engine is still hot. It may be a cause to get burned.

2.

3.

Remove the radiator shroud.

Loosen the fan belt.

• Loosen the alternator adjusting bolt.

• Fully put aside the alternator toward the engine.

• Remove fan and fan pulley.

• Remove the water pump together with the gasket.

SLC190

INSPECTION Do not disassemble water pump. If any non-standard condition is found, replace the water pump.

1.

Check the water pump vanes for rust and pitching.

2.

Check the water pump bearing for proper end play and smooth operation.

SLC070

SLC071

ASSEMBLY 1. Install the water pump in the reverse order of removal. Always use a new gasket.

2. Adjust the fan belt tension. For the adjustment value, refer to page MA-section.

• • 170

CAUTION: Before filling with coolant, always loosen the air purge plug.

After refilling, make sure to tighten the plug.

LC-8

ENGINE COOLANT SYSTEM Thermostat REMOVAL 1. Remove the radiator upper hose from the water outlet and extract coolant.

WARNING: Do not drain coolant when engine is still hot. It may be a cause to get burned.

2.

Remove water inlet and remove thermostat.

INSPECTION Inspect the thermostat as instructed below and replace it as necessary.

1. Inspect valve seating status under ordinary temperature. The valve must be seated firmly.

2. Inspect the opening temperature and maximum valve lift by heating the valve in a container.

CAUTION: if may be a cause to get burned. Do not touch the thermostat, container or hot water inside until the temperature lowers sufficiently.

3.

make sure that the valve closing temperature is approx. 5˚C lower than the opening temperature. Also perform the same inspection before installing a new thermostat.

CO097

INSTALLATION Install in the reverse order of removal.

Always use a new water inlet gasket.

LC-9

171

172

ENGINE FUEL SECTION

EF

CONTENTS EMISSION CONTROL SYSTEM .......................... EF-2 ENGINE OUTSIDE DRAWINGS .......................... EF-3 SYSTEM DIAGRAM ............................................. EF-4 UNIT LAYOUT ...................................................... EF-7 SERVICE DATA AND SPECIFICATIONS (SDS) .................................................................... EF-8 Electronic Control System Specifications ........ EF-8 LPG FUEL SYSTEM TROUBLE DIAGNOSIS ..... EF-9 DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM ............................................................. EF-10 Removal and Installation of Electronic Control Throttle Assembly .......................................... EF-10 Removal and Installation of Gasoline Fuel Injector (Electronic Controlled Gasoline and Combined Use) ............................................................... EF-11

LPG device (Specifications for LPG and combined use)................................................................ EF-13 Vaporizer Mechanism and Operation ............ EF-15 DISASSEMBLY AND ASSEMBLY OF INJECTOR HOLDER............................................................. EF-17 LPG Fuel Injector........................................... EF-17 LPG Assist Fuel Injector ................................ EF-18 LPG Fuel Pressure Sensor............................ EF-18 Relief Valve (2 Relief Valves) ........................ EF-18 DISASSEMBLY AND ASSEMBLY OF VAPORIZER ....................................................... EF-19 Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer .................................. EF-19

EF

173

EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM Engine type Standard type of fuel device

K21, K25 Gasoline LPG

Electronic controlled fuel injection device (Single point injection)

Air-fuel ratio control type

Air-fuel ratio feedback control

Starting auxiliary device

Electronic controlled fuel injection

Ignition device Catalytic device Braking device PCV gas recirculation device

174

Electronic controlled fuel injection device (Multi-point injection)

Ignition coil electronic controlled distributor integrated with power transistor for each cylinder Three-way catalyst (Monolith) With fuel cut device Closed type

EF-2

ENGINE OUTSIDE DRAWINGS ENGINE OUTSIDE DRAWINGS

ELECTRONIC CONTROLLED SPECIFICATIONS

EF-3

175

SYSTEM DIAGRAM SYSTEM DIAGRAM

176

K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (GASOLINE)

EF-4

SYSTEM DIAGRAM K-ENGINE SYSTEM DIAGRAM (LPG)

EF-5

177

SYSTEM DIAGRAM K-ENGINE SYSTEM DIAGRAM (COMBINED USE)

178

EF-6

UNIT LAYOUT UNIT LAYOUT

FUEL PIPING DIAGRAM

EF-7

179

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS)

180

Electronic Control System Specifications Gasoline electronic injection (injection from each cylinder port) LPG electronic injection (injection from single point on this side of electric throttle control actuator) Vaporizer (water heater) ......

Fuel discharge pressure: Approx. 31.9 KPa (0.33 kgf/cm2) [4.6 psi] Throttle body and injector holder bolts tightening torque (Air horn also secures.)

M6 bolt [thread length : 90 mm (3.54 in): 11.8 - 13.7 N·m (1.2 - 1.4 kg-m) [9 - 10 ft-lb]

EF-8

LPG FUEL SYSTEM TROUBLE DIAGNOSIS LPG FUEL SYSTEM TROUBLE DIAGNOSIS Condition Fuel leakage

Excessive fuel consumption

Low output

Cause

Action

Looseness of piping connection

Tighten

Operating malfunction of vaporizer

Repair, adjust or replace

Poor connection or some foreign object is caught in between plunger rubber seat and valve seat of solenoid valve

Clean, rub or replace

Looseness of piping connection

Retighten and adjust

Primary chamber side pressure at idle is excessively high

Wash, adjust or replace

Operating malfunction of vaporizer

Repair, adjust or replace

Looseness of piping connection or clogged filter Clean, additionally tighten or replace

Inconsistent or rough idle

Engine hesitation or hunting

Poor starting engine

Operating malfunction of vaporizer

Adjusting malfunction of primary chamber pressure of vaporizer

Adjust or replace

Use of improper fuel

Use proper fuel

Engine coolant temperature is excessively high

Investigate and repair the cause of rise of the engine coolant temperature

Clogged fuel passage

Clean

Clogged air cleaner

Wash

Operation malfunction of electric throttle control actuator

Replace

Operation malfunction of LPG injector

Clean or replace

Operating malfunction of vaporizer

Repair, adjust or replace

Operating malfunction of vaporizer valve (It is closed improperly.)

Clean, adjust or replace

Looseness of vacuum hose

Connect proper vacuum hose

Operating malfunction of vaporizer

Repair, adjust or replace

Adjusting malfunction of idle speed

Adjust (Refer to Idle Air Volume Learning; EC section.)

Operation malfunction of LPG injector

Clean or replace

Insufficient fuel

Refill fuel

Operating malfunction

Check that LPG tank manual valve is opened

Operating malfunction of solenoid valve

Check and repair of wiring, switch and solenoid valve

Operating malfunction of vaporizer

Repair, adjust or replace

Blown fuse for LPG injector

Replace

Operation malfunction of LPG injector

Clean or replace

LPG injector control signal malfunction

Check harness and ECM

Adjusting malfunction of idle speed

Adjust (Refer to Idle Air Volume Learning; EC section.)

Adjusting malfunction of primary chamber pressure of vaporizer

Adjust or replace

Leakage from primary valve seat of vaporizer

Clean, adjust or replace

Foreign materials enter vaporizer inside

Clean, adjust or replace

Leakage by looseness of setscrew

Tighten

Overcool of vaporizer (Scale deposit, damage of hose, poor coolant circulation)

Check, wash and adjust

Tar deposit in valve

Remove tar and clean

EF-9

181

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

Removal and Installation of Electronic Control Throttle Assembly REMOVAL 1. Remove air duct.

2. Remove harness connector. (Mass air flow sensor, LPG injector, LPG assistance injector, LPG fuel pressure sensor and electric throttle control actuator) 3. Loosen air horn bolts in turns, and then remove them.

4. Loosen injector holder bolts in turns, and then remove them.

5. Also loosen chamber bolt of electronic control throttle, and then remove the chamber.

ELECTRONIC CONTROLLED SYSTEM COMPONENT VIEW

182

EF-10

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM Removal and Installation of Gasoline Fuel Injector (Electronic Controlled Gasoline and Combined Use) PREPARATION • Air hose • Moving engine harness connector REMOVAL AND INSTALLATION OF FUEL HOSE Removal • Release the fuel pressure. Refer to “Release of Fuel Pressure” in EC section.

CAUTION: After removal, plug the fuel hose to prevent the fuel from draining.

Installation • Insert hose until its end reaches 25 mm (0.98 in) or more from fuel tube end. Install a clamp and securely tighten it. Do not install the clamp on top of the bulge.

• Start engine, increase the engine speed, and make sure that there is no fuel leakage after repairing.

REMOVAL AND INSTALLATION OF FUEL TUBE AND FUEL INJECTOR Removal CAUTION: Fuel remaining in the tube leaks during operation. This operation should be done in a place free from fire.

• • EFM0098

•

Remove fuel gallery bolt.

Remove fuel gallery. Remove fuel injector and fuel gallery as a set.

Remove clips (4) using long-nose pliers. Disconnect fuel injector and fuel gallery.

CAUTION: Do not reuse clips.

EF-11

183

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM Removal and Installation of Gasoline Fuel Injector (Electronic Controlled Gasoline and Combined Use) (Cont’d)

EFM0101

184

INSTALLATION OF FUEL INJECTOR Install fuel injector to fuel tube as shown in the figure.

Precautions for installation of fuel injector 1. Make sure that there is no contamination and damage in O-ring contact area caused by dirt. Do not clean O-ring with solvent.

2. Do not reuse removed O-ring.

3. Handle O-ring with bare hands.

4. Apply engine oil into O-ring and holder for assembly. (Do not apply engine oil into fuel passages of fuel injector.)

5. Do not use damaged O-ring.

6. Do not apply excessive force to damage O-ring.

7. Press clips into fuel injector when assembling. Securely fit clips to fuel injector locating grooves (a) and (b). (Do not reuse clips.)

8. Always replace O-ring when clips contact with O-ring.

9. Assemble fuel injector to fuel tube after installing clips to fuel injector.

10. Fuel injector is pressed by a force of 196 N (20 kg) [44 lb] or less.

[Stop operation if a force of 147 N (15 kg) [33 lb] or more is necessary.]

11. Insert fuel injector to fuel tube while aligning fuel tube stopper (c) with clip cutout (d) before installing. Securely fit (c) to (d) and holder rib (e) to clip hole (f) after inserting.

12. Make sure that fuel injector is securely installed without rotation and disconnection after installing to fuel tube.

EF-12

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM LPG device (Specifications for LPG and combined use) Inject the proper amount of fuel supplied from vaporizer based on ECM command.

COMPONENT PARTS LOCATION It includes mechanical relief valve with LPG injector, LPG assistance solenoid valve, and fuel pressure sensor.

It is composed of injector holder and drive unit. The drive unit operates vaporizer and injector that depress and perform carburetion of high-pressure fuel flow from LPG tank to approximately 29 kPa (0.3 kg/cm2) [4 psi].

(1) LPG injector It is used for LPG gas injection.

(2) LPG assistance solenoid valve Engine output may be insufficient in high-speed and high load area when using LPG injector only. LPG assistance solenoid valve helps LPG injector to keep maximum engine output in high-speed and high load area.

(3) Fuel pressure sensor Sends a signal to control fuel injection at low fuel pressure (e.g. in low temperature).

(4) Mechanical relief valve Operates when fuel pressure is over set pressure. It opens fuel circuit, and sends fuel to intake manifold, and protects fuel piping at lower fuel pressure. It is provided in holder fuel passage.

•

Repair each component specified in (1), (2), (3), and (4) as an assembly if a malfunction is detected in the above components.

Refer to EC section for inspection procedure.

EF-13

185

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM LPG INJECTION SYSTEM

LPG INJECTION SYSTEM DRIVE METHOD

186

EF-14

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM Vaporizer Mechanism and Operation

PRIMARY (DECOMPRESSION) ROOM (1) Primary side valve (2) Primary side valve seat (3) Primary (decompression) room (4) Primary side diaphragm (5) Primary side diaphragm spring (6) Hook (claw) (7) Primary side valve lever (8) Balance diaphragm Fuel is supplied from LPG tank to vaporizer via LPG solenoid valve.

Fuel from solenoid valve is supplied to primary decompression room through primary side valve (1) and primary side valve seat (2).

Fuel pressure supplied to primary room is 29 kPa (0.3 kg/cm2) [4 psi] or more. Primary diaphragm (4) pushes up diaphragm spring and hook (6) working together. It causes the operation that one side of primary valve lever (7) is lifted up. Therefore, the power that pushes primary valve (1) toward valve seat side (2) is increased, and fuel flow is cut off.

Primary diaphragm is pushed down by increasing the tension of diaphragm spring (5) higher than the fuel pressure when the fuel of primary room is consumed and the pressure of primary room inside is decreased to 29 kPa (0.3 kg/cm2) [4 psi] or less, and hook (6) is working together to push primary valve lever (7) down. Therefore, primary valve (1) opens and fuel flows in.

Repeat above operations to keep primary room pressure approximately 29 kPa (0.3 kg/cm2) [4 psi].

Variation of pressurization can be suppressed by balance diaphragm (8) even if pressure in LPG tank changes.

CAUTION: The vaporizer is not serviced by a repair kit. Complete assembly must be replaced.

EF-15

187

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM Vaporizer Mechanism and Operation (Cont’d)

14 - 15 mm (0.55 - 0.59 in)

EFM0123

Set primary valve lever as shown in the figure.

PRESSURE INSPECTION Check primary room pressure with the following procedure: 1. Remove primary room test hole plug, and install pressure gage using appropriate connector.

2. Start engine, and check for primary room fuel leakage at idle after warming up.

Standard: 30.7 - 33.1 kPa (0.31 - 0.34 kgf/cm2) [4.4 - 4.8 psi] 3. Rotate pressure adjusting screw if measured pressure is outside the standard.

CAUTION: Apply sealant and keep air tightness when reinstalling test hole plug.

IDLE ADJUSTMENT IN ELECTRIC CONTROLLED LPG SPECIFICATIONS It is not necessary because it is performed with control unit.

REMOVAL OF IMPURITIES LPG includes incombustible materials (e.g. tar).

These materials will be collected in vaporizer. This may cause operating malfunctions of fuel system.

It is necessary to periodically release and drain with engine warmed up.

188

EF-16

DISASSEMBLY AND ASSEMBLY OF INJECTOR HOLDER DISASSEMBLY AND ASSEMBLY OF INJECTOR HOLDER

INJECTOR HOLDER ASSEMBLY

LPG Fuel Injector REMOVAL AND INSTALLATION • Disassemble and assemble as shown in the figure.

• Install LPG fuel injector and check LPG leakage using soapy water after assembly.

• Insert straight and assemble O-ring and seal rubber on top after changing to new ones and applying engine oil to the circumference lightly.

• O-ring may be damaged when tilting and inserting forcibly.

• Do not use silicon oil when inserting.

• Use correct injector specified for each engine type. (Check part number on fuel injector body label.)

• Tightening torque of securing screw: 3.9 - 7.8 N·m (0.4 0.8 kg-m) [3 - 5 ft-lb] INSPECTION AND CLEANING • Perform continuity test of harness connector.

If it is approximately 1 Ω (at room temperature) with a tester, it is normal.

If continuity should not exist, check for blown fuse.

• If fuse is blown, replace it with proper fuse (5A). Check signal wave of related harnesses. When a non-standard signal flows, a malfunction may occur again.

• Clean injector.

Clean injector from fuel inlet side with compressed air for approximately 5 minutes.

• Do not use cleaner such as cab cleaner because it negatively affects rubber parts of inside.

EF-17

189

DISASSEMBLY AND ASSEMBLY OF INJECTOR HOLDER LPG Assist Fuel Injector REMOVAL AND INSTALLATION • Rotate and remove hexagonal part of body using a spanner.

• When removing hexagonal part of body, inside spring, plunger, and washer are removed together. Do not drop and lose them.

• Install after assembling inner components in their original position. Replace aluminum washer with new ones.

• Tightening torque: 11.8 - 26.5 N·m (1.2 - 2.7 kg-m) [9 - 19 ft-lb] INSPECTION AND CLEANING • If foreign materials such as tars are applied or collected on plunger or its inside, remove them with compressed air.

LPG Fuel Pressure Sensor REMOVAL AND INSTALLATION • If foreign materials are applied in the top, remove them with compressed air.

• Replace O-ring with a new one and apply engine oil to the circumference of O-ring lightly. And then, insert LPG fuel pressure sensor straight to holder and install.

Relief Valve (2 Relief Valves) • •

2 relief valves are built into holder.

Relief valve (1) setting pressure is 0.08 MPa (0.8 kg/cm2) [11 psi].

Relief valve (2) setting pressure is 0.12 MPa (1.2 kg/cm2) [17 psi].

INSPECTION AND CLEANING • Seal necessary part of each holder.

Apply compressed air from fuel connector.

Raise air pressure from 0.00 MPa (0 kg/cm2) [0 psi] (gauge pressure) gradually. Check continuity of the passage at nearly above the setting pressure.

Clean with compressed air up to 0.49 MPa (5 kg/cm2) [71 psi] if continuity should not exist.

Replace holder with a new one if continuity should not exist after applying compressed air of 0.49 MPa (5 kg/cm2) [71 psi].

• Do not replace relief valve only.

190

EF-18

DISASSEMBLY AND ASSEMBLY OF VAPORIZER DISASSEMBLY AND ASSEMBLY OF VAPORIZER

Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer

TAR DRAIN • Start and warm up the engine using LPG. • Close tank cock, and then consume LPG in fuel line.

• Remove drain plug, and then drain tar from vaporizer.

• Put the tray below so as not to make engine room dirty.

• Apply sealant to drain plug and assemble after finishing work.

• Install LPG fuel injector and check LPG leakage using soapy water after assembly.

REMOVAL • Close tank cock, and then consume LPG in fuel line.

• Disconnect battery cable at negative terminal.

• Drain coolants from radiator drain plug.

• Disconnect hot water hose. Use shop cloth and tray because water may come out.

• Disconnect vacuum hose.

• Disconnect fuel hose and fuel tube.

• Handle each hose so that foreign materials do not enter the inside.

Or, be careful to prevent each tube insertion part from being damaged.

• Remove mounting bolt to bracket of vaporizer.

EF-19

191

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) INSTALLATION • Install in the reverse order of removal.

• Install vaporizer bracket.

Tightening torque: 16 - 21 N·m (1.6 - 2.1 kg-m) [12 - 15 ft-lb] • Connect each hose and tube.

• Securely tighten each clamp.

• Connect battery cable at negative.

• Check LPG leakage.

Start the engine and apply soapy water to each connection of vacuum hose and drain plug. Check for LPG leakage.

Apply soapy water to mating surface of case and cover. Check for LPG leakage.

DISASSEMBLY OF PRIMARY CHAMBER SIDE • Remove mounting screws (2) of bracket for tamperproof using SST. • Remove primary adjusting screw lock nut (WAF: 23 mm (0.91 in)).

• Remove primary adjusting screw.

• Remove primary chamber cover screws (2) using SST. • Remove other screws (8) using commercial service tool.

• Remove fuel connector (inlet side) screws (2) using commercial service tool.

•

The figure shows the condition that primary chamber cover is removed.

Be careful not to lose primary pressurization spring that is on back of cover when removing.

•

The figure shows the condition that primary chamber cover is removed.

Remove the diaphragm while sliding it in the arrow direction shown in the figure.

Check primary diaphragm for breakage or damage. Replace if necessary.

•

192

EF-20

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) •

The figure shows the condition that lever and valve seat are removed.

When removing lever mounting screws (2) shown in the above figure, lever and valve seat can be removed as a set. Do not lose the lever because it is fixed with only the pin.

•

The figure shows the condition that valve lever, valve seat and pin are removed.

•

Furthermore, the figure shows the condition that valve is removed.

•

The figure shows the condition that balance diaphragm is removed.

Balance diaphragm can be removed by loosening 4 screws of plate.

EF-21

193

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) DISASSEMBLY OF SECONDARY CHAMBER SIDE • The figure shows that secondary chamber side is assembled.

• Secondary chamber cover is fixed by 6 screws.

Secondary chamber cover can be removed by loosening each screw.

•

The figure shows the condition that secondary chamber cover is removed.

DISASSEMBLY OF HIGH-PRESSURE SIDE COVER • Loosen and remove high-pressure side cover mounting screws (8).

INSPECTION OF PRIMARY SIDE VALVE • Check around primary side valve and valve seat.

• Check valve lever for smooth operation.

• Check valve and lever assembly if necessary.

INSPECTION OF DIAPHRAGM • Check for cracks, damage and hardening.

• Replace each diaphragm if necessary.

194

EF-22

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) ASSEMBLY OF HIGH-PRESSURE SIDE COVER • Clean disassembled parts completely.

• Clean filter from inside with compressed air.

• Replace O-ring with a new one.

• Tighten mounting bolts (6) evenly.

• Tightening torque N·m (kg-m) [ft-lb]: 6.3 - 8.3 (0.64 - 0.85) [5 - 6]

ASSEMBLY OF SECONDARY CHAMBER SIDE • Clean disassembled parts other than seal rubber completely.

• Replace seal rubber with a new one.

Securely insert circumference O-ring of seal rubber into groove.

• Gently place secondary chamber cover (steel), and then install with securing screws (6).

• Tightening torque N·m (kg-m) [ft-lb]: 3.8 - 5.1 (0.39 - 0.52) [2.8 3.7]

ASSEMBLY OF PRIMARY CHAMBER SIDE • Clean disassembled parts other than diaphragm completely.

• Set balance diaphragm and plate in this order, and then secure them using screws.

• Tightening torque N·m (kg-m) [ft-lb]: 1.0 - 2.9 (0.1 - 0.3) [1 - 2] • Lastly, put the rod on center.

Top convex side faces to lever side.

• • • • •

Assemble primary side valve.

Clean disassembled parts completely.

Install valve to lever as shown in the figure.

Face convex part of wave washer to clip side.

Check for looseness after installing.

Bend and adjust the wave washer if necessary.

EF-23

195

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) • • •

Assemble primary side valve.

Replace O-ring with a new one.

Tightening torque N·m (kg-m) [ft-lb]: 1.0 - 2.9 (0.1 - 0.3) [1 - 2]

•

Measure dimension H of lever.

• •

Measure dimension H using vaporizer height gauge (SST).

Measure while inserting L-part of height gauge into tip of lever.

Standard: 13.6 - 14.1 mm (0.535 - 0.555 in)

•

If it is outside the standard, insert both end grooves of vaporizer height gauge (SST) into lever, and then bend and adjust the lever.

CAUTION: Be careful not to damage valve.

196

EF-24

DISASSEMBLY AND ASSEMBLY OF VAPORIZER Tar drain, Removal, Installation, Disassembly and Inspection of Vaporizer (Cont’d) • Check primary valve airtightness.

(1) Put vaporizer into oil tank. Apply air pressure of 0.29 - 0.49 MPa (3 - 5 kg/cm2) [43 - 71 psi] from fuel inlet connector.

(2) Under the above condition, close primary valve by pulling primary valve lever by hand, and then make sure that air does not leak from primary valve and O-ring.

•

•

• •

• • • •

•

In the reverse order of disassembly, place primary diaphragm over the body, slide it to the center, and then secure primary diaphragm.

Place primary chamber cover over the body.

(At this time, be careful not to drop primary adjusting spring from primary chamber cover.)

Tighten 2 screws of mounting bolts using SST, and then tighten the other 8 screws using commercial service tool.

Tightening torque N·m (kg-m) [ft-lb]: 3.8 - 5.1 (0.39 - 0.52) [2.8 3.7] Perform primary chamber adjustment.

Remove plug of primary oil pressure output port, install adopter (SST), and then set LPG pressure gauge (SST).

Install #100 JET to fuel outlet connector. (Flow: approx. 10L/ min) Apply air pressure of 0.29 MPa (3 kg/cm2) [43 psi] from fuel inlet connector.

Standard: 32.1 - 33.5 kPa (0.327 - 0.342 kg/cm2) [4.6 - 4.8 psi] If the value is outside the standard, adjust it as described below.

Adjust primary chamber with the following procedure if adjustment with vaporizer only is difficult.

• Install vaporizer to the vehicle.

• Remove plug of primary oil pressure output port, install adopter (SST), and then set LPG pressure gauge (SST).

• Start and warm up the engine.

• Check pressure of pressure gauge at idle after warming up.

Standard: 30.7 - 33.1 kPa (0.313 - 0.338 kg/cm2) [4.4 - 4.8 psi] • If the value is outside the standard, adjust it as described below.

• Vaporizer primary pressure setting value is different between the unit condition and the condition of installing vaporizer to engine and having hot water flowing (approximately 80 °C (176 °F)).

EF-25

197

DISASSEMBLY AND ASSEMBLY OF VAPORIZER • • • • • •

198

Tighten lock nut after setting to standard pressure by rotating primary pressure adjusting screw.

Tighten primary pressure adjusting screw using double spanner.

Tightening torque N·m (kg-m) [ft-lb]: 11.8 - 26.5 (1.2 - 2.7) [9 19] Apply soapy water to mating surface of cover. Check for leakage.

Place tamperproof bracket over primary chamber cover, and then tighten mounting screw using SST. Tightening torque N·m (kg-m) [ft-lb]: 3.8 - 5.1 (0.39 - 0.52) [2.8 3.7]

EF-26

ENGINE ELECTRICAL SYSTEM SECTION

EE

CONTENTS ADJUSTMENT VALUE ........................................EE-2 TROUBLE DIAGNOSIS .......................................EE-3 STARTER MOTOR...............................................EE-4 Starter Motor Specifications.............................EE-4 Component Parts Location ..............................EE-5 Overhaul ..........................................................EE-6

Assembly Inspection........................................EE-8 ALTERNATOR .....................................................EE-9 Components of Alternator................................EE-9 Disassembly ..................................................EE-10 Inspection ......................................................EE-12

EE

199

ADJUSTMENT VALUE ADJUSTMENT VALUE Component Starter motor

Alternator

200

Items

Description

•

Brush dimensions

10.0 - 18.0 mm (0.394 - 0.709 in) (Wear margin 8 mm (0.31 in))

•

Brush spring pressure

13.7 - 17.7 N (1.4 - 1.8 kg) [3.1 - 4.9 lb]

•

Stator

Resistance between respective lead wires: 1 Ω or less Resistance between stator core and lead wire: ∞

•

Rotor coil

Standard resistance between slip rings: 2.9 Ω Standard resistance between slip ring and rotor core: ∞

•

Snap ring

Snap ring outer diameter: Standard: 14.4 mm (0.567 in) Repair limit: 14.0 mm (0.551 in)

•

Brush

Projected length from holder: Standard: 10.0 mm (0.394 in) Repair limit: 2.0 mm (0.079 in)

EE-2

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS Condition No or slow cranking

Engine is cranked but not started.

Possible causes

Action

•

Battery is discharged

Check and repair the charging system, check and adjust the fan belt for tension, or replace the battery

•

Incident in starter system wiring

Check and repair or replace the starter switch.

•

Starter motor malfunction

Repair or replace.

(Starter circuit diagnosis procedure) If the light turns off or dims when the starter switch is turned to “ON” with the headlights on: a: Check the battery. b: Check the electric connections and wiring. c: Check the starter motor.

If the light remains bright when the starter switch is turned to “ON” with the headlights on: a: Check the wiring between battery and starter motor. b: Check the starter switch. c: Check the starter motor.

• Incident in ignition system (Another possible cause is an incident in the fuel system. Refer to the section about the fuel system)

(Ignition system diagnosis procedure) Inspect the spark plug following the steps below Disconnect the IGN/coil from the No. 1 plug and keep the cord 10 mm (0.394 in) away from the engine metal portions. Then crank the engine. If there is difficulty in identifying a spark, use the following approach: connect the IGN/ coil to a new spark plug that is separately prepared, contact the thread of the plug to the engine metal and check for a spark by activating the starter.

If a good spark is available: a: Check the spark plug. b: Check the ignition timing. c: Check the fuel system. d: Check the cylinder compression.

If no spark is available: a: Check the primary coil current. b: If the current is too large, a short circuit may be present, replace. c: Check coil malfunction, replace. d: If the IGN/coil has an open circuit, replace.

EE-3

201

STARTER MOTOR STARTER MOTOR

CAUTION: Before starting any electrical system service, make sure to turn off the key switch and disconnect the battery cable.

Starter Motor Specifications Items Part type

Specification 91H20-03330

Type

Integrated reduction gears

Output

1.2 kW

EEM0122

202

EE-4

STARTER MOTOR Component Parts Location Major components of starter motor Symbol

Description

(1)

Front bracket

(2)

Overrunning clutch

(3)

Lever

(4)

Internal gear

(5)

Packing

(6)

Shaft gear

(7)

Gear assembly

(8)

Packing

(9)

Armature

(10)

Yoke assembly

(11)

Connector brush holder assembly

(12)

Rear blanket

(13)

Switch assembly

(14)

Hexagon head bolt

(15)

Flange screw

EE-5

203

STARTER MOTOR Overhaul

EEM0124

RELATED TO MAGNET SWITCH • Plunger sliding face (rust, contamination, deformation) • Broken or worn return spring • Rough surface of main contact (burnout) • Operation check of magnet switch (Proper performance of magnet coil) 1. Plunger’s drawing operation (Series coil operation) Wire the plunger as shown in the figure on the left. The plunger should be drawn strongly by the series coil and shunt coil.

2. Plunger’s holding operation (Shunt coil operation) In the above circuit, disconnect the wiring from the terminal M. If the shunt coil is normal, the plunger should be held in place.

EEM0125

PINION MECHANISM • Damage or wear of pinion gear tooth tops • Visually check for damage or wear. Replace the gear if the damage/wear is excessive.

• Pinion gear sliding face (rust, contamination, damage on spline) • Check the pinion gear sliding motion. Replace the gear(s), if the gear(s) drag excessively.

• Broken or worn pinion spring • Check the pinion spring(s) and replace them if excessive damage is present.

• Pinion spring (lever fulcrum) sliding motion • Check the pinion spring(s) and replace them if excessive damage is present.

• Overrunning clutch operation (slippage, seizure) Turn the pinion gear by hand. If it turns freely in both directions or will not turn in either direction, the overrunning clutch has lost its proper functionality. Replace it.

FIELD COIL Check the field coil for continuity.

Judgement If there is continuity, the field coil is normal.

If there is no continuity, the field coil has an open circuit.

Replace it.

EEM0126

204

EE-6

STARTER MOTOR •

Check for continuity between the field coil and a ground.

Judgement If continuity is present, the field coil is shorted. Replace it.

If there is no continuity, the coil is normal.

CAUTION: Note that, however, a compound-wound motor structurally grounds the field coil. This means that the tester will show continuity between the field coil and a ground.

EEM0127

ARMATURE COIL • Check the continuity between the commutators.

Judgement If there is continuity, the armature coil is normal.

If there is no continuity, the coil has an open circuit. Replace it.

EEM0128

•

Check for continuity between the armature coil and a ground.

Judgement If continuity is present, the field coil is shorted. Replace it.

If there is no continuity, the coil is normal.

EEM0129

BRUSH COMMUTATOR RELATED Brush wear: mm (in)

10.0 - 18.0 (0.394 - 0.709) (Wear margin: 8 (0.31) max.)

Brush spring pressure (kg) [lb]

13.7 - 17.7 (1.4 - 1.8) [3.1 - 4.0]

• •

If the commutator has a rough surface, grind it using sandpaper of #500 or #600.

If the insulator (high mica) of the commutator is 0.5 - 0.8 mm (0.020 - 0.031 in) or less in thickness, replace the commutator.

EEM0130

EE-7

205

STARTER MOTOR Assembly Inspection • •

Inspection for abrasion between the armature core and the ball core.

Starter motor inspection (performance with no load)

EEM0131

PROCEDURE • Connect an ammeter to the battery positive terminal and the B terminal.

• Connect a test wire to the B terminal and S terminal.

• Connect a voltmeter to the B terminal and the starter motor body.

• Connect a test wire to the battery negative terminal and the starter motor body.

JUDGEMENT • The pinion gear should pop out and the starter motor should rotate.

206

EE-8

ALTERNATOR ALTERNATOR

Components of Alternator

C144F038

EE-9

207

ALTERNATOR Disassembly PULLEY • Secure shaft hexagonal part with a box wrench, loosen pulley nut, and remove pulley.

CAUTION: Hexagonal box wrench must be used. Twelve-fold box wrench may crush shaft head and slip.

C144F030

REAR END COVER • Remove screw and terminal B nut, and then remove rear end cover.

C144F031

BRUSH HOLDER • Remove screw, and then remove brush holder.

C144F032

IC REGULATOR • Remove screw, and then remove IC regulator.

CAUTION: Lengths of screws are different. Arrange removed screws, and securely install them in the original position.

C144F033

208

EE-10

ALTERNATOR Disassembly (Cont’d) RECTIFIER • Remove screws securing wires of rectifier and stator, and remove rectifier.

C144F034

REAR END FRAME • Remove bolts and nuts, and then remove rear end frame.

C144F035

ROTOR • Keep drive end frame level using blocks, and then press out rotor.

C095F148

RETAINER PLATE • Remove screws, and remove retainer plate.

C144F036

EE-11

209

ALTERNATOR Disassembly (Cont’d) BEARING Drive end side Keep drive end frame level using blocks, and then press out bearing using a jig.

Slip ring side Pull out bearing using a puller.

C095F149

CAUTION: Bearing for high speed is specified to be used. Always use it when replacing, and do not impact it.

C095F150

Inspection BEARING • Rotate bearing by hand.

• Check for noise or binding.

• Replace if necessary.

C095F151

STATOR • Measure resistance between each lead wire using a circuit tester.

Standard: 1 Ω or less • Measure resistance between stator core and lead wire.

Standard: ∞ • Replace if necessary.

O109F317

210

CAUTION: Opening of stator coil itself is not considerable. Check the connection part of wires if continuity should not exist.

EE-12

ALTERNATOR Inspection (Cont’d) ROTOR COIL • Measure resistance between each slip ring using a circuit tester.

Standard: 2.9 Ω • Measure resistance between slip ring and rotor core using a circuit tester.

Standard: ∞ • Replace if necessary.

C095F153

SLIP RING • Check slip ring for dirt and damage.

• Wipe it clean with a cloth that has been dipped in alcohol if dirty.

• Polish with sandpaper (#500 to 600) if there is slight damage.

• Measure slip ring outer diameter.

Slip ring outer diameter: Standard 14.4 mm (0.567 in) Repair limit 14.0 mm (0.551 in) • Replace if outside the repair limit.

C095F154

BRUSH • Measure excessive brush length from brush holder.

Excessive length of brush: Standard 10.0 mm (0.394 in) Repair limit 2.0 mm (0.079 in) • Replace if outside the repair limit.

• Make sure that brush is slightly moving in brush holder.

C095F155

RECTIFIER • Check continuity between each rectifier diode with circuit tester in kΩ range.

• It is normal that continuity should exit in one side of diode and continuity should not exist in another side of diode.

CAUTION: Do not use 500V mega tester that breaks rectifier.

C144F037

EE-13

211

ALTERNATOR Inspection (Cont’d) NOTE: Rectifier condition cannot be judged by forward resistance. One of the characteristics of a diode is that forward current is greatly changed by battery voltage. Indication of tester changes with differences of tester type and resistance range. Rectifier condition is judged by resistance differences between forward and reverse currents.

O109F322

IC REGULATOR Check continuity between IC regulator terminal B and F with circuit tester in kΩ range.

• It is normal that continuity should exit in one side and continuity should not exist in another side.

CAUTION: Do not use 500V mega tester that breaks IC regulator.

O109F323

NOTE: IC regulator can be checked with the following procedure if there is constant voltage power supply that can change voltage between 10 to 20V range.

CAUTION: Regulator may be destroyed if IC regulator misconnects only for a moment. Perform inspection after checking wiring.

• • • • • •

Connect IC regulator unit with constant voltage power supply, circuit tester, and lamps.

(SW1 and SW2 must remain OFF.) Set a power supply voltage to 12V. Set SW1 setting to ON. Make sure that L1 turns ON brightly, and L2 turns ON dimly at this time.

Next, turn SW2 to NO while leaving SW1 at ON. Make sure that L1 turns OFF, and L2 turns ON brightly at this time.

Raise battery voltage from 12V gradually. Make sure that L2 may turn OFF when battery voltage is approximately 14.5±0.6V.

C095F158

212

EE-14

TECHNICAL PUBLICATIONS FEEDBACK Date:___________ (Please print)

Dealer name: Address: City: Zip code:

Submitted by: P. O. Box: State: Country:

The following discrepancy or omission has been discovered in: Operation & Maintenance Manual Option Bulletin Part List/Manual

Special Instruction

Service Manual

Service Data Manual

Electronic Manual

Other:

Publication #

Engine model #

Truck model #

Issue date #

Truck serial #

Page #

(Please print)

Explanation of discrepancy or omission:

Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P. O. Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277

Cat Lift Trucks

Service Manual

K21, K25 Gasoline Engine

99789-65120

Mitsubishi Caterpillar Forklift Europe B.V. Hefbrugweg 77 1332 AM Almere, The Netherlands

99789-65120

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CATERPILLAR and CAT are registered trademarks of Caterpillar Inc.

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