197

CONTENTS
EMISSION CONTROL SYSTEM (ONLY FOR
ELECTRONIC CONTROLLED TYPE) ................ EF-2
UNIT LAYOUT .................................................... EF-3
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 LPG Injector Drive Unit
Connector ..................................................... 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
Injector Holder ...............................................EF-15
VAPORIZER MECHANISM AND OPERATION EF-16
Primary (Decompression) Room ...................EF-16
Description ....................................................EF-19
ENGINE FUEL
SECTION EF
EF
198
EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED
TYPE)
Engine type K21, K25
Standard type of fuel device
Gasoline Electronic controlled fuel injection device (Multi-point injection)
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 Ignition coil electronic controlled distributor integrated with power transistor for
each cylinder
Catalytic device Three-way catalyst (Monolith)
Braking device With fuel cut device
PCV gas recirculation device Closed type
EF-2
EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED TYPE)
199
UNIT LAYOUT
EFM0089
EF-3
UNIT LAYOUT
200
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(GASOLINE)
EFM0090
EF-4
UNIT LAYOUT
201
K-ENGINE SYSTEM DIAGRAM (LPG)
EFM0091
EF-5
UNIT LAYOUT
202
FUEL PIPING DIAGRAM
EFM0093
EF-6
UNIT LAYOUT
203
K-ENGINE SYSTEM DIAGRAM (COMBINED USE)
EFM0094
EF-7
UNIT LAYOUT
204 EF-8
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECI-
FICATIONS (SDS)
Electronic Control System Specications
Gasoline electronic injection (injection from each cylinder port)
LPG electronic injection (injection from single point on this side of
electric throttle control actuator)
Vaporizer (integrated with electrical PTC heater, water heater) ......
Fuel discharge pressure: Approx. 0.3 kgf/cm
2
Throttle body and injector holder bolts tightening torque (Air horn
also secures.)
M8 bolt (thread length : 85, 90, 100 mm): 15.7 - 17.6 Nm (1.6 - 1.8
kg-m)
205
LPG FUEL SYSTEM TROUBLE DIAGNOSIS
Condition Cause Action
Fuel leakage Looseness of piping connection Tighten
Operating malfunction of vaporizer Repair and adjust
Poor connection or some inclusion is caught in between plunger
rubber seat and valve seat of solenoid valve
Clean and rub
Operating malfunction of lock off mechanism Adjustment
Excessive fuel consumption Looseness of piping connection Retighten and adjust
Primary side room pressure at idle is excessively high. Clean and adjust
Clogged air cleaner Washing
Adjusting malfunction of LPG mixer main adjusting screw Adjustment
Low output Operating malfunction of vaporizer Repair and adjust
Looseness of piping connection or clogged lter Clean and retighten
Adjusting malfunction of vaporizer primary and secondary room
pressures
Adjustment
Adjusting malfunction of LPG mixer main adjusting screw Adjustment
Use improper fuel. Use proper fuel.
Clogged fuel passage Clean
Inconsistent or rough idle Improper position of vaporizer idle adjustment screw or carburetor
throttle valve, or operating malfunction of electric throttle control
actuator
Adjustment
Operating malfunction of vaporizer Repair and adjust
Operating malfunction of vaporizer valve (It is closed improperly.) Clean, adjustment, or replacement
Engine hesitation or hunting Operating malfunction of vaporizer Adjustment
Adjusting malfunction of idle speed Adjustment
Poor starting engine Insufcient fuel Rell 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 Replacement
Water pump malfunction Repair and adjust
Adjusting malfunction of idle speed Adjustment
Operating malfunction of
vaporizer
Adjusting malfunction of vaporizer primary and secondary room
pressures
Adjustment
Leakage from primary and secondary valve seats of vaporizer Clean, adjust, or replace
Damage of diaphragm Replacement
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
EF-9
LPG FUEL SYSTEM TROUBLE DIAGNOSIS
206
DISASSEMBLY AND
ASSEMBLY OF FUEL
SYSTEM
Removal and Installation of LPG Injector
Drive Unit Connector
REMOVAL
1. Pull center of lever forward, and then disconnect tab from lever
and lift it up.
2. Raise the lever until it clicks, and fully press the lever to drive
unit side.
3. Pull connector forward, and then disconnect it from unit.
INSTALLATION
1. Press the lever in drive unit connector while pressing it to
connector end.
2. Press in the lever until it clicks.
3. Raise the lever until it clicks, engage the tabs to the back of the
lever and connector, and then securely connect them.
Removal and Installation of Electronic
Control Throttle Assembly
REMOVAL
1. Remove air cleaner case and air duct.
2. Remove harness connector.
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. Remove fuel tube.
EFM0095
EFM0096
EFM0097
EFM0098
EF-10
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
207
Removal and Installation of Electronic
Control Throttle Assembly (Contd)
INSTALLATION
Caution for installation
Uniformly tighten bolts diagonally in several steps.
CAUTION:
Make sure that there is no moisture around connector
when removing and installing throttle position sensor con-
nector. Completely wipe off water drops if there are any.
Do not apply voltage to throttle position sensor terminal.
Perform "Throttle Valve Closed Position Learning" if dis-
connecting connector. Perform "Throttle Valve Closed Posi-
tion Learning and Idle Air Volume Learning" if replacing
electric throttle control actuator.
Do not disassemble electric throttle control actuator.
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.
EFM0099
EFM0100
EF-11
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
208
Removal and Installation of Gasoline Fuel
Injector (Electronic Controlled Gasoline and
Combined Use) (Contd)
Installation
Insert hose until its end reaches 25 mm 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 re.
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 injec-
tor and fuel gallery.
CAUTION:
Do not reuse clips.
INSTALLATION OF FUEL INJECTOR
Install fuel injector to fuel tube as shown in the gure.
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 t 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 kgf) or less. [Stop
operation if a force of 147 N (15 kgf) or more is necessary.]
11. Insert fuel injector to fuel tube while aligning fuel tube stopper
(c) with clip cutout (d) before installing. Securely t (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.
EFM0101
EF-12
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
209
Removal and Installation of Gasoline Fuel
Injector (Electronic Controlled Gasoline and
Combined Use) (Contd)
FUEL TUBE INSTALLATION
Install fuel tube to intake manifold as shown in the gure.
Precautions for installation of fuel tube
1. Satisfy precautions 1. to 6. for installation of fuel injector.
2. Insertion of fuel injector is performed by a force of 196 N (20
kgf) or less. [Stop operation if a force of 147 N (15 kgf) or more
is necessary.]
3. Do not contact O-ring with the edge that is made by each
process of intake manifold for assembly.
4. First tighten fuel tube bolt in position a in the gure, and then
tighten it in position b in the same gure.
:
First tightening: 9.3 - 20.6 Nm (0.9 - 2.1 kgf-m)
Second tightening: 20.6 - 26.5 Nm (2.1 - 2.7 kgf-m)
Check for fuel leakage after installation
Check for fuel leakage by racing several times after idling for 5 to 10
minutes.
EFM0102
EFM0103
EF-13
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
210
Removal and Installation of Gasoline Fuel
Injector (Electronic Controlled Gasoline and
Combined Use) (Contd)
FUEL HOSE
Install fuel hose with the following procedure:
1. Tighten clamp in the position that the fuel hose is inserted to the
clamp 1 mm or more (from hose end) while holding hose end as
shown in the gure.
2. The inserted length of hose is 28 mm or more.
3. Tighten clamp in the position that is 1 mm or more from hose
end with fuel tube assembly installed to engine.
4. Make sure that hose winding radius is R70 or more after
installing fuel hose.
5. There must be no twisting on the hose after assembling fuel
hose.
6. Difference between pipes (offset) is within 3 mm after
assembling fuel hose.
Precautions for tightening of clamp
Do not tighten clamp on bulge of fuel tube.
(Stop operation if the clamp is placed on the bulge.)
EFM0104
EFM0105
EFM0106
EF-14
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
211
Injector Holder
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.
(1) LPG injector
It is used for LPG gas injection.
Arrow mark: Fuel ow
(2) LPG assistance solenoid valve
Engine output may be insufcient 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 pip-
ing at lower fuel pressure. It is provided in holder fuel passage.
Repair each component specied 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.
EFM0108
EF-15
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
212
VAPORIZER MECHANISM
AND OPERATION
Primary (Decompression) Room
This is decompressed and carbureted high-pressure fuel ow from
LPG tank to approximately 0.3 kgf/cm
2
.
(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
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 0.3 kgf/cm
2
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 ow 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 0.3 kgf/cm
2
or less, and hook (6) is working together
to push primary valve lever (7) down. Therefore, primary valve (1)
opens and fuel ows in.
Repeat above operations to keep primary room pressure
approximately 0.3 kgf/cm
2
.
CAUTION:
The vaporizer is not eld-serviceable. Consult with specialized
shop for servicing.
EFM0112
EF-16
VAPORIZER MECHANISM AND OPERATION
213
Primary (Decompression) Room (Contd)
Set primary valve lever as shown in the gure.
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.
Standard: 0.20 - 0.36 kgf/cm
2
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.
IDLE ADJUSTMENT IN CARBURETOR LPG SPECIFICATIONS
1. Rotate vaporizer idle adjusting screw so that idle speed is the
highest.
2. Adjust idle speed to the specied range using carburetor throttle
adjusting screw.
3. Repeat above steps 1. and 2. to set idle speed properly.
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.
EFM0113
EF-17
VAPORIZER MECHANISM AND OPERATION
214
Primary (Decompression) Room (Contd)
DISASSEMBLY, ASSEMBLY, AND INSPECTION
Make sure that there is no leakage from all connections after
assembling all parts.
DISASSEMBLY OF PRIMARY ROOM
1. Remove primary cover screw and remove cover.
2. Remove primary diaphragm spring.
3. Remove primary diaphragm carefully to reverse the direction of
LPG owing in.
4. Remove primary side valve lever as an assembly.
5. Remove dust or dirt on all removed parts with dry compressed
air.
6. Wipe off sulfurs or tars.
7. Assemble in the reverse order of disassembly.
CAUTION:
Make sure that diaphragm hook is securely engaged with
the lever.
Pulling up the lever (7), blow approximately 4 kgf/cm
2
of
compressed air from vaporizer inlet to make sure that pri-
mary side valve is placed in the proper position. Replace it
with new one if there is some leakage.
EFM0114
EF-18
VAPORIZER MECHANISM AND OPERATION
215
Description
Vaporizer has three functions of fuel carburetion, decompression,
and conservation of pressure.
Vaporizer uses radiator water to prevent vaporizer from freezing by
latent heat of fuel carburetion.
The gure shows vaporizer of carburetor specications. Electronic
controlled vaporizer consists of primary room only. PTC heater
(electric heating) is integrated for electronic controlled specications
to help the carburetion when engine starts cold.
EFM0115
VAPORIZER MECHANISM AND OPERATION
EF-19