ENGINE FUEL

SECTION

EF

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

EF

197

EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED TYPE)

EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED
TYPE)
Engine type

K21, K25

Standard type of fuel device

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

198

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

UNIT LAYOUT
UNIT LAYOUT

EFM0089

EF-3

199

UNIT LAYOUT
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(GASOLINE)

EFM0090

200

EF-4

UNIT LAYOUT
K-ENGINE SYSTEM DIAGRAM (LPG)

EFM0091

EF-5

201

UNIT LAYOUT
FUEL PIPING DIAGRAM

EFM0093

202

EF-6

UNIT LAYOUT
K-ENGINE SYSTEM DIAGRAM (COMBINED USE)

EFM0094

EF-7

203

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

204

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 (integrated with electrical PTC heater, water heater) ......
Fuel discharge pressure: Approx. 0.3 kgf/cm2
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)

EF-8

LPG FUEL SYSTEM TROUBLE DIAGNOSIS

LPG FUEL SYSTEM TROUBLE DIAGNOSIS
Condition
Fuel leakage

Excessive fuel consumption

Low output

Inconsistent or rough idle

Engine hesitation or hunting

Poor starting engine

Operating malfunction of
vaporizer

Cause

Action

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

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

Operating malfunction of vaporizer

Repair and adjust

Looseness of piping connection or clogged filter

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

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

Operating malfunction of vaporizer

Adjustment

Adjusting malfunction of idle speed

Adjustment

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

Replacement

Water pump malfunction

Repair and adjust

Adjusting malfunction of idle speed

Adjustment

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

205

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

DISASSEMBLY AND
ASSEMBLY OF FUEL
SYSTEM

Removal and Installation of LPG Injector

Drive Unit Connector
REMOVAL
1.
2.
3.

EFM0095

Pull center of lever forward, and then disconnect tab from lever
and lift it up.
Raise the lever until it clicks, and fully press the lever to drive
unit side.
Pull connector forward, and then disconnect it from unit.

INSTALLATION
1.
2.

Press the lever in drive unit connector while pressing it to

connector end.
Press in the lever until it clicks.

EFM0096

3.

Raise the lever until it clicks, engage the tabs to the back of the
lever and connector, and then securely connect them.

EFM0097

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.

EFM0098

206

EF-10

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

Removal and Installation of Electronic
Control Throttle Assembly (Contd)

EFM0099

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 connector. 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 disconnecting connector. Perform "Throttle Valve Closed Position Learning and Idle Air Volume Learning" if replacing
electric throttle control actuator.

Do not disassemble electric throttle control actuator.

EFM0100

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.

EF-11

207

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

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 fire.

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.
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 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 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.
EFM0101

208

EF-12

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

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 figure.
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.

EFM0102

4.

First tighten fuel tube bolt in position a in the figure, and then
tighten it in position b in the same figure.
:
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.
EFM0103

EF-13

209

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

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 figure.
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.

EFM0104

6.

Difference between pipes (offset) is within 3 mm after

assembling fuel hose.

EFM0105

Precautions for tightening of clamp

Do not tighten clamp on bulge of fuel tube.
(Stop operation if the clamp is placed on the bulge.)

EFM0106

210

EF-14

DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM

Injector Holder
Inject the proper amount of fuel supplied from vaporizer based on
ECM command.

EFM0108

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 flow
(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-15

211

VAPORIZER MECHANISM AND OPERATION

VAPORIZER MECHANISM
AND OPERATION

Primary (Decompression) Room

This is decompressed and carbureted high-pressure fuel flow from
LPG tank to approximately 0.3 kgf/cm2.

EFM0112

(1)
(2)
(3)
(4)
(5)
(6)
(7)

Primary side valve

Primary side valve seat
Primary (decompression) room
Primary side diaphragm
Primary side diaphragm spring
Hook (claw)
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/cm2 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 0.3 kgf/cm2 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 0.3 kgf/cm2.
CAUTION:
The vaporizer is not field-serviceable. Consult with specialized
shop for servicing.

212

EF-16

VAPORIZER MECHANISM AND OPERATION

Primary (Decompression) Room (Contd)
Set primary valve lever as shown in the figure.

EFM0113

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/cm2
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 specified 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.

EF-17

213

VAPORIZER MECHANISM AND OPERATION

Primary (Decompression) Room (Contd)
DISASSEMBLY, ASSEMBLY, AND INSPECTION
Make sure that there is no leakage from all connections after
assembling all parts.

EFM0114

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 flowing 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/cm2 of

compressed air from vaporizer inlet to make sure that primary side valve is placed in the proper position. Replace it
with new one if there is some leakage.

214

EF-18

VAPORIZER MECHANISM AND OPERATION

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.

EFM0115

The figure shows vaporizer of carburetor specifications. Electronic

controlled vaporizer consists of primary room only. PTC heater
(electric heating) is integrated for electronic controlled specifications
to help the carburetion when engine starts cold.

EF-19

215