1FS RM.

book 1 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-1

FUEL SYSTEM

SST LIST .......................................................................... 3-2

THROTTLE BODY ......................................................... 3-4 0
COMPONENTS ............................................................... 3-4
1
REMOVAL, INSPECTION AND INSTALLATION............ 3-6
2
GASOLINE INJECTOR................................................. 3-8
3
COMPONENTS ............................................................... 3-8
REMOVAL, INSPECTION AND INSTALLATION............ 3-9 4
FUEL PRESSURE REGULATOR INSPECTION .......... 3-12 5
LPG ADAPTER ............................................................ 3-13 6
INSPECTION ................................................................. 3-13 7
LPG INJECTOR ............................................................ 3-14
8
INSPECTION ................................................................. 3-14
9
LPG INJECTOR CLEANING......................................... 3-14
LPG REGULATOR ....................................................... 3-15
10
GENERAL ..................................................................... 3-15 11
COMPONENTS ............................................................. 3-16 12
REMOVAL, INSPECTION AND INSTALLATION.......... 3-17 13
LPG main solenoid ..................................................... 3-27 14
INSPECTION ................................................................. 3-27
LPG PROPERTY .......................................................... 3-27
REQUIRED CONDITIONS FOR LPG FUEL .......... 3-28
1FS RM.book 2 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-2

SST LIST
Illustration Part No. Part Name

09268-76007-71
Injection measuring tool set
(09268-41047)

09842-76001-71
EFI inspection wire
(09842-30070)

09813-26600-71 Gauge

09814-22000-71 Tool

09815-22000-71 Tool

09817-23600-71 Union

09819-22000-71 Gauge

09819-23600-71 Gauge

09820-23600-71 Tester SUB-ASSY

1FS RM.book 3 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-3

23627-22000-71 Spring

80339-76026-71 Automatic choke pipe plug

1FS RM.book 4 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-4

THROTTLE BODY
COMPONENTS
2103

2103-095
27

02A

GT
02

JV
27A

GT
1302-091

KZ
BV

03
KZ

1104
2103-093
28

02A
02

JV
28A

1302-091
JV
BV
1FS RM.book 5 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-5

1302

2103-094
27

02A

GT
02

JV
27A

GT
1302-091

KZ
BV

03
KZ 1302

2103-098
1701-BY

1302-091
KX
KV
75

KO
1FS RM.book 6 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-6

REMOVAL, INSPECTION AND INSTALLATION

T = N·m

T = 12 to 16

T = 7 to 11

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery negative terminal
2 Air cleaner hose
3 Intake pipe
Adapter (LPG or combination specification)
4
Air intake connector (gasoline specification)
5 Throttle body [Point 1]
6 Vacuum sensor
1FS RM.book 7 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-7

Point operation
[Point 1]
Throttle Inspection:
shaft Inspect the throttle body.
Clearance 1. Check the throttle shaft for backlash.
2. Push the throttle valve hard with a finger to open/close.
3. While the throttle valve is free, an appropriate angle to the air
horn and a clearance should be maintained.
[Reference] Throttle angle around 16°

Air horn 16°

Inspection:
Inspect the throttle motor.
Measure the resistance between terminals.
Standard: Between M(+) and M(-): 0.3 to 100 Ω
M(-) M(+)
1FS RM.book 8 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-8

GASOLINE INJECTOR
COMPONENTS
1701

54

11 BV AL
54

54
BL
BQ
54

AV

AV

AH
AG AH BQ
AH AG
24
AH

2302-02
2302-AQ
23
AH
AH
AG
2101-064
1FS RM.book 9 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-9

REMOVAL, INSPECTION AND INSTALLATION

T = N·m

T = 17 to 25

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery negative terminal
2 Throttle body See page 3-6  
3 Removal of fuel pressure from fuel system See page 2-5  
4 Pressure regulator [Point 4]
5 Delivery pipe, spacer, injector [Point 1] [Point 3]
6 Insulator [Point 2]

Note:
Use new gaskets and O-rings for assembling.
1FS RM.book 10 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-10

Point operation
O-ring
[Point 1]
Inspection:
Inspect the injector for injection amount and leakage.
1. With the O-ring and grommet attached to the injector, install
SST as shown in the left figure and connect the fuel filter on
Grommet
the vehicle and pressure regulator.
SST SST 09268-76007-71
(09268-41047)
WARNING:
• Use a cloth or the like to prevent splashing of fuel.
• Keep the working area away from fire.
2. Disconnect the connector of C/OPN RLY in the ECU box.
3. Make the terminal 1 and 2 in the disconnected relay block
Terminal 2 short-circuited.

Terminal 1

C/OPN RLY

SST 4. Connect SST to the injector.

SST 09842-76001-71
(09842-30070)
5. Turn the ignition key switch ON to function the fuel pump.
6. Connect SST to the battery and measure the amount delivered
from the injector.
Standard: 78 to 82 cc/15 seconds
Note:
To measure the injection amount, attach a vinyl hose with an
inner diameter of 9 to 10 Ø to the end of the injector nozzle and
Battery place a measuring cylinder to measure the amount.
7. Check the nozzle for leakage while keeping the fuel pressure
applied condition.
Standard: One drop maximum/12 minutes
Inspection:
Check the injector resistance.
Standard: 12.0 ±0.4 Ω (20 °C (68 °F))
1FS RM.book 11 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-11

[Point 2]
Intake manifold
Insulator Installation:
Attach the insulators to the intake manifold.

[Point 3]
Installation:
Coat the O-ring with gasoline and insert the injector into the
delivery pipe until it is fully seated.
Note:
• Turn the injector to both sides to insert it securely into the
delivery pipe.
• Make all the four injector connectors face upward.
O-ring • After installation, check that the injector turns smoothly.

[Point 4]
FR Installation:
Install the pressure regulator to the delivery pipe in the direction
shown in the figure.
Note:
Install the pressure regulator by hand, correct the direction
and then fix it by tightening the nut.

30°
1FS RM.book 12 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-12

FUEL PRESSURE REGULATOR

INSPECTION
Fuel filter WARNING:
• Use a cloth or the like to prevent splashing of fuel.
• Keep the working area away from fire.
1. Remove the battery negative terminal.
SST Delivery pipe 2. Remove the fuel pressure. (See page 2-5)
3. Install a fuel pressure gauge between the fuel filter and
delivery pipe through SST.
SST 09268-76007-71
(09268-41047)
4. Turn the ignition key switch ON and activate the fuel pump to
measure the fuel pressure.
Standard: 284 ±3 kPa
Note:
The standard value is provided for the case that the vacuum
port of the pressure regulator is released to the atmosphere.
1FS RM.book 13 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-13

LPG ADAPTER
INSPECTION
Inspect the air-fuel ratio control motor (FCM).
1. Start up the engine.
2. Place a sound scope on FCM.
3. Check the FCM operating sound.
Standard: Ticking sound is produced for a few seconds.
4. Remove FCM.
Note:
Do not disconnect the connector.
5. Cover the surface that contacts the adapter with masking tape
to prevent air leakage.
A 6. Measure the length of A while the engine is stopped or idling.
Standard:
Engine stop: 3.3 to 4.3 mm (0.13 to 0.17 in.)
Engine idle: 5.9 to 6.9 mm (0.23 to 0.27 in.)
(pneumatic model)
5.7 to 6.7 mm (0.22 to 0.26 in.)
(cushion model)
Caution:
Do not apply an excessive force to the needle valve.
7. Disconnect the connector from FCM.
8. Measure resistance between FCM connector terminals.
Standard:
Measurement terminals Resistance
3 2 1 15 to 25 Ω (when cool)
2 to 1, 2 to 3
20 to 30 Ω (when warm)
6 5 4 15 to 25 Ω (when cool)
5 to 4, 5 to 6
20 to 30 Ω (when warm)

Note:
When cool:
FCM surface temperature: -10 to 50 °C (14 to 122 °F)
When warm:
FCM surface temperature: 50 to 100 °C (122 to 212 °F)
9. Inspect the FCM operation.
(1) Apply a battery positive voltage to the terminal 2 and a
negative voltage to the terminals 1, 3, 4 and 6 in this
order.
(2) Check the needle valve behavior.
Standard: The needle valve gradually moves to the
close side.
(3) Apply a battery positive voltage to the terminal 5 and a
negative voltage to the terminals 1, 3, 4 and 6 in this
order.
Close (4) Check the movement of the needle valve.
Standard: The needle valve gradually moves to the
close side.
Caution:
Do not apply an excessive force to the needle valve.

Open
1FS RM.book 14 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-14

LPG INJECTOR
INSPECTION
1. Place a sound scope on the LPG injector.
2. Check the injector operating sound while the engine cranks.
Standard: The injector produces operating sound.
<Reference>
The fuel is injected twice per engine rotation during cranking.
3. Start up the engine.
4. Hold the injector hose gently with your fingertips to check the
pulsation.
Standard: Pulsation occurs continuously.
5. Check the idling status of the engine when the injector
connector is disconnected.
Standard: The idle speed decreases when the connector
is disconnected.
6. Inspect the air tightness of LPG injector.
(1) Disconnect the LPG injector connector and then remove
the injector with the hose attached.
Note:
Do not disconnect the injector hose.
(2) Turn the ignition key switch ON and OFF to check for LPG
leakage.
Standard: No LPG leak occurs.

7. Measure the resistance of LPG injector.

Standard: 3.5 to 4.5 Ω (at 20 °C (68 °F))

2 1

LPG INJECTOR CLEANING

1. Wipe off carbon fouling around the nozzle with a clean cloth.
2. Prepare a wire with a diameter of 1.2 mm (0.0472 in.) or less.
Insert and pull out the wire from the injector while applying
compressed air of 343 to 490 kPa (3.5 to 5.0 kgf/cm2) from the
intake port
Caution:
Insert and pull out the wire within the 20 mm (0.7874 in.) range.
1FS RM.book 15 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-15

LPG REGULATOR
GENERAL
1FS RM.book 16 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-16

COMPONENTS

2314

01

CO
01K=(INCL. )
30L 30M
AF

BA AH
AZ
30 AT BE
AX BF
EA
DF

AV BA

30M
BL
AC BK
BB
AP

BL
BK
45
22

CO
DZ

DL 49A
24

49

30M AP

AY

21

AL

2314-068
1FS RM.book 17 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-17

REMOVAL, INSPECTION AND INSTALLATION

Caution:
• Clean the regulator surface thoroughly and keep the work table clean.
• Check the filter for clogging and perform pre-disassembly checks (See page 3-18) first. Only when a
defect is found during these checks, disassemble the regulator.
• Disassembly of the regulator must be performed with care not to cause a poor contact of diaphragm or
valve.

Handling of Adjustment Prevention Ring

Adjustment of VF voltage is not necessary, but when the regulator
Idling speed is overhauled or the regulator is replacced adjustment must be
adjusting done.
screw
When a VF voltage adjustment is completed on the vehicle
(See page 3-26), attach a new adjustment prevention ring(21673-
13370-71)securely.
1FS RM.book 18 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-18

Inspection of regulator before disassembly

Inspection 1
SST(3) 1. Remove the idling speed adjusting screw and then
install the SSTs.
SST(2) SST 80339-76026-71...(1)
SST 09817-23600-71...(2)
SST(1)
SST 09820-23600-71...(3)
Union tightening torque:
T = 0.2 to 0.3 N·m [0.14 to 0.19 ft·lbf]
2. Apply compressed air at 400 kPa [57 psi] through
the IN port and maintain the air pressure.
Compressed air
Caution:
Don't apply compressed air more than 780 kPa [110
psi].
3. Check that the gauge indicates 0.

0 NG More than 0
OK

Slow solenoid valve defect

Inspection 2
1. Apply 12 V to the slow solenoid valve.
2. Check that the gauge points a value within the
range of 24.5 to 34.3 kPa [3.6 to 5.0 psi].

Compressed air

12V

OK 24.5 to 34.3 kPa NG1 0 NG2 Other than

[3.6 to 5.0 psi] 24.5 to 34.3 kPa
[3.6 to 5.0 psi]
1FS RM.book 19 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-19

From From
NG1 NG2

OK Slow solenoid • Problem in primary chamber control pressure

valve defect • Primary valve defect
• Secondary valve defect
• Primary diaphragm defect
• Problem in primary chamber air tightness

Inspection 3
1. While keeping the condition for the inspection 2,
stop supplying compressed air.
2. Read the gauge value.

12V

The condition for inspection NG The pressure decreases

OK 2 maintained. gradually toward 0.

Go to Inspection 5

Inspection 4
1. While keeping the condition for the inspection 2,
stop supplying compressed air.
2. Exhale into the inner vent port and read the gauge
value.

Air

Inner vent port

OK The pressure decreases NG The condition for inspection 2

gradually toward 0. maintained

Normal • Secondary diaphragm defect

• Secondary valve defect
1FS RM.book 20 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-20

From inspection 3

NG

Inspection 5
C Apply soapy water to the A - F areas and then check for
gas leakage while keeping the condition for the
inspection 2.
Compressed air E
D 12V
A

Air leaks from B or F. Air leaks from A, C, D or F.

Result Result
1 2

Air leaks from B: Retighten each part and check again. (Re-install the union A
Idling speed adjusting screw O-ring defect at the intake port since liquid packing is applied to it.)
Air leaks from F:
Regulator body defect OK No air leakage. NG Air leaks from D.

Go to • Secondary valve defect

Inspection 3 • Loose secondary valve fixing screw
1FS RM.book 21 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-21

T = N·m

T = 3.5 to 4.4

6
2
T = 3.5 to 4.4

T = 3.5 to 4.4
T = 3.5 to 4.4

3 T = 3.5 to 4.4
5

Disassembly procedure
1 Remove the secondary regulator cover and secondary diaphragm. [Point 1]
2 Remove the secondary valve ASSY. [Point 2]
3 Remove the primary regulator cover, primary diaphragm, and spring. [Point 3]
4 Remove the primary valve ASSY. [Point 4]
5 Remove the slow solenoid valve.
6 Remove the idling speed adjusting screw and O-ring. [Point 5]

Reassembly procedure
The installation procedure is the reverse of the removal procedure.
1FS RM.book 22 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-22

Point operation
4 [Point 1]
2 Reassembly:
Install the diaphragm.
1. Align the pin of the diaphragm with the dent on the secondary
valve lever.
1 2. Tighten the screws in the order shown in the figure.
3 Tightening torque:
T = 3.5 to 4.4 N·m

Pin Dent

[Point 2]
Dent on lever
Reassembly:
Install the spring while supporting the lever by hand to prevent it
from moving off the dent on the lever. Be careful not to push the
Spring valve seat against the housing during work.

Seat

Reassembly:
Spring washer
Follow the procedure below to replace the secondary valve with
Snap ring new one.
1. Insert the seat.
2. Install the spring washer.
3. Install the snap ring.
4. Check the valve for air tightness. (See page 3-25)
5. Apply adhesive (Castle Super Cement) to the snap ring and
spring washer. Be careful not to apply adhesive to the valve
seat.
Seat

Inspection:
B
SST Check the secondary valve lever height.
1. Check that SST touches the lever when the A side of SST is
A passed on the lever.
2. Check that SST does not touch the lever when the B side of
SST is passed on the lever.
SST 09819-23600-71

If the above is not satisfied, adjust the lever height by bending it

SST(1) using SST.
SST 09814-22000-71............................................................. (1)
SST 09815-22000-71............................................................. (2)
Lever height for reference:
SST(2) 0 to 2 mm (0 to 0.0787 in.) from surface in contact with regulator
Be careful not to push the valve seat against the port in adjusting
the lever height
1FS RM.book 23 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-23

[Point 3]
7
1 Disassembly:
Since each part is subjected to the reaction force of the spring,
3 remove the bolts slowly by loosening them evenly in several steps.
5
Tightening torque:
T = 3.5 to 4.4 N·m
Reassembly:
4 Tighten the bolts evenly in several steps to prevent the spring from
6 coming off. As a last step, tighten them in the order shown in the
2 left figure.

Diaphragm hook Disassembly:

The diaphragm hook is hung on the primary valve lever. Pull out the
diaphragm as shown in the left figure with an arrow to remove it.
Reassembly:
Hang the diaphragm hook on the primary valve lever.

Primary valve lever

[Point 4]
Disassembly:
Disassemble the primary valve ASSY.
1. Remove the primary valve ASSY.
2. Disassemble the primary valve.

Reassembly:
Reassemble the primary valve ASSY.
1. Reassemble the primary valve ASSY.
Note:
Replace the O-ring with a new one.
2. Install the primary valve ASSY.
Tightening torque:
T = 3.5 to 4.4 N·m
O-ring

3. Check the primary valve for air tightness.

SST (1) Install SST between the end of the lever and regulator
body.
SST 23627-22000-71
1FS RM.book 24 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-24

(2) Install SST (gauge) to the fuel intake port.

SST
SST 09820-23600-71
(3) Check that no leakage occurs until the air pressure
reaches the range of 49.0 to 58.8 kPa.
If a leakage occurs, replace the primary valve.

4. Check and adjust the primary lever height.

SST (1) Push the primary valve lever ASSY at the primary valve
side and check the height at the other side
T
SST 09813-26600-71
Standard: S side touches the valve lever but T
S
side does not.
Lever height for reference:
13.2 to 13.7 mm (0.52 to 0.54 in.) from surface in contact
with regulator.

5. If the above is not satisfied, adjust the lever height by bending

it using SST.
SST 09814-22000-71............................................ (1)
SST 09815-22000-71............................................ (2)
Note:
• Do not stress the valve seat to prevent it from being
SST(2) damaged.
• Attach the notch of SST to the valve lever.

SST(1)

6. Hang the diaphragm hook on the end of the primary valve

lever and install it to the regulator body.
7. Install the regulator primary cover to the body while holding the
diaphragm spring by hand.
Tightening torque:
T = 3.5 to 4.4 N·m

[Point 5]
Reassembly:
Idling speed
adjusting Install the idling speed adjusting screw.
screw 1. Install the idling speed adjusting screw temporarily at the
following height.
Temporary installation height: 6.2 mm (0.2441 in.)
(0.25 in)
6.2 mm

2. When a VF voltage adjustment is completed on the vehicle

(See page 3-26), attach a new adjustment prevention ring
(21673-13370-71) securely
1FS RM.book 25 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-25

SST(2) Secondary Valve Air Tightness Check

1. Assemble the secondary valve ASSY temporarily.
SST(1)
2. Remove the idling speed adjusting screw and then install the
SST(3) SSTs.
SST 09817-23600-71............................................ (1)
SST 09820-23600-71............................................ (2)
Union tightening torque:
T = 0.2 to 0.3 N·m
3. Install SST to the injector port.
SST 80339-76026-71............................................ (3)
4. Apply 12 V to the slow solenoid valve.

5. Apply compressed air using SST and adjust the valve as

shown in the left figure to prevent air leakage.
1FS RM.book 26 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-26

VF voltage O2 Sensor Output

1. Increase the engine speed slightly and keep it for about two
minutes to warm the hot wire O2 sensor.
2. Check that the OX value indicates 0 and 1 alternately using
the plug-in analyzer or deluxe multifunction display.
Standard: The value changes at least four times in 20
seconds.
Note:
• Keep the engine speed at 1800 rpm during the check.
• Adjust the VF voltage if the value is out of the stan
OX value

VF Voltage Check
1. If the VF voltage does not fall within the standard range, adjust
Idling speed it by slowly turning the idling speed adjusting screw.
adjusting Standard: 2.5 ± 1.25 V
screw Reference:
VF
Condition Measures
voltage
Turn the screw
0V Air fuel ratio: RICH
CLOCKWISE
Turn the screw
5V Air fuel ratio: LEAN
COUNTERCLOCKWISE
2. After racing the engine several times, check that the VF
voltage is within the specified range.
Note:
If the VF voltage dose not falll within the standard range,
disconnect the for mone than 60 second and then
connect it again/
1FS RM.book 27 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-27

LPG main solenoid

Main solenoid

INSPECTION
1. Check that the operating sound is heard when applying 12 V to
the main solenoid.
Standard: Operating sound is heard
2. Measure resistance of the main solenoid
Standard: 8.0 to 9.0 Ω (at 20 °C (68 °F))

12V

LPG PROPERTY
Name LPG
Normal Gasoline
Item Propane Propylene Isobutane
butane
Molecular formula C 3 H8 C 3 H6 C4H10 C4H10 C8H18
-42.07 -47.70 -0.50 -11.73 128
Boiling point °C(°F)
(-43.73) (-53.86) (31.10) (10.87) (262)
Steam kPa (kgf/cm2) 784 961 196 289
-
pressure 20 °C (68 °F) (8.0) (9.8) (2.0) (2.95)
15 °C
Water = 1 0.508 0.522 0.584 0.563 0.66 to 0.75
Specific (59 °F)
gravity 15 °C
Air = 1 1.548 1.453 2.071 2.067 -
(59 °F)
481 458 441 544 210 to 300
Ignition temperature °C(°F)
(898) (856) (826) (1011) (410 to 572)
Heat generation kcal / kg 12.034 11.692 11.832 11.797 11.200
Flammable range % in air 2.37 to 9.50 2.00 to 11.10 1.86 to 8.41 1.80 to 8.44 1.5 to 4.7
Maximum flaming speed 0.81 1.01 0.825 1.825 0.83
m/sec, within a pipe
Air required for
kg / kg 15.71 14.80 15.49 15.49 14.70
complete combustion
Evaporative latent heat kcal / kg 101.8 104.6 92.09 87.56
1FS RM.book 28 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

3-28

REQUIRED CONDITIONS FOR LPG FUEL

1. Having a moderate steam pressure: 98 to 981 kPa (1 to 10 kgf/cm2).
2. Good antiknock properties
3. Low olefinic hydrocarbon
4. Low content of tarry constituents
A moderate steam pressure is required because the engine cannot be started in the cold season if the steam
pressure is too low (propane has lower pressure). The engine can be started comfortably when the constant steam
pressure (pressure in the container) is 98 kPa (1 kgf/cm2) or higher. On the other hand, an excessively high steam
pressure may cause problems in instruments.
The composition of LPG needs to be examined to satisfy the required conditions. The following figure shows a
general relation between the temperature and pressure of mixed gas.

C3H8 • C4H10
100% • 0%
90% • 10%
80% • 20%
70% • 30%
60% • 40%
50% • 50%
40% • 60%
30% • 70%
Pressure 20% • 80%
(kgf/cm2) 10% • 90%
0% • 100%

Temperature (°C)