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OPERATION DESCRIPTION
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OUTLINE OF LPG DEVICE....................................1-2
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FUEL FILTER FOR LPG ........................................1-4
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SOLENOID VALVE .................................................1-4
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ADAPTER...............................................................1-5
REGULATOR..........................................................1-6
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SPECIFICATIONS ....................................................1-6 4
REGULATORS SYSTEM COMPONENTS .................1-12 5
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OUTLINE OF LPG DEVICE

The explanation in this section is based on the newly adopted 4Y-E engine. For the 4Y-M engine, refer to the LPG
DEVICE repair manual (Pub. No. CE610-4).
Compared to the 4Y-E engine, the 4Y-M engine has the following different points:
• No LPG injector
• No slow path
• Equipped with an outer vent circuit instead of an inner vent circuit (released to the atmosphere)

LPG (in liquid form supplied from the cylinder) passes through the LPG filter in the engine room to remove foreign
matter and reaches to the regulator through the main solenoid valve. LPG is reduced and gasified in the regulator,
and supplied to engine with its pressure kept at a certain rate.
Engine coolant is led to the regulator for use as the heat source for LPG gasification.

4Y-E (Electronic Controlled)

Ignition Regulator set

Battery switch
Fuse
Injector path
Slow solenoid valve

Regulator Main path

Coolant path
Main
LPG solenoid
filter valve
Adapter
Injector

Cylinder
Valve

LPG

Engine
 1-3

4Y-M (Mechanical Controlled Except for Russia)

Ignition
Battery switch
Fuse
Regulator
0
LPG
switch 1
Main path
2
Main
Coolant path
3
LPG solenoid
filter valve
Carburetor
4
5
Cylinder 6
Valve
7
LPG

8
Engine 9
10
4Y-M (Mechanical Controlled for Russia)
11
LPG low pressure pipe
Main solenoid 12
valve
Ignition
Carburetor
Slow solenoid Regulator switch 13
valve
14
Fuse
Battery 15
16
Engine
Cylinder 17
LPG 18

Coolant path
LPG 19
Engine high pressure
speed
detection
pipe 20
switch
21
Relief valve
E
1-4

FUEL FILTER FOR LPG

The filter is mounted between the LPG cylinder and the right before
the solenoid valve to remove various kinds of foreign materials in
From To
LPG. It consists of a filter element and permanent magnet, and the
LPG Main
cylinder solenoid
filter element is detachable for easy cleaning and has sufficiently
valve strong construction to withstand LPG vapor pressure.
When low-grade LPG is used, vary small impurity particles flow into
Filter the regulator causing start difficulty due to clogging of the slow
element path. The filtering performance has been improved to be able to
remove foreign matters of 2 µm* or more in size.
Filtering Performance 2 µm*
*: Vehicles for Russia: 10 µm

To SOLENOID VALVE
Solenoid coil Regulator
The solenoid valve is mounted between the LPG filter and the
regulator, and controls gas flow according to the engine condition.
From For example, when the engine is running, the solenoid valve is ON
LPG filter and supplies fuel. Once the engine stops running, it turns OFF and
cuts off the gas flow.
When the current flows through the solenoid valve, which consists
IN OUT
of a slide valve, back spring, and solenoid coil, magnetic force is
generated. The slide valve overcomes the spring force by such
Back spring
magnetic force to move forward the IN side, and fuel flows.
When the current stop flowing through the solenoid valve, the slide
valve is forced to back to the OUT side by the LPG pressure and
spring force to shut off the flow.
 1-5

ADAPTER
The adapter is installed on the right upper position of the electric
governor, and mixes air with gaseous LPG decompressed in the
Seat regulator. The air-mixed fuel is led to the engine. The adapter has a

Ventury
diameter FCM (Fuel/air Control Motor) at the ventury part and the FCM 0
controls the amount of fuel based on the engine ECU signal. The
diameter motor has a taper-shaped needle valve that moves right or left
based on the engine ECU signal. This sliding of the valve changes
1
Seat
the opening space of the fuel path.
Ventury angle
2
3
Needle
FCM
valve
4
Electronic
governor 5
6
7
Specifications 8
Ventury diameter mm (in) 24 (0.9) 9
Needle valve seat diameter mm (in) 11 (0.4)
Needle valve seat angle ° 60 10
FCM specifications 11
Magnetized way 1-2 magnetized type
Stroke mm (in) 5 (0.2) 12
[0.05 (0.002) / step]
Pulse generation rate pulse / second 140 13
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REGULATOR
The regulator supplies vaporized LPG after pressure reduction to the engine while maintaining the pressure at a fixed
level.

SPECIFICATIONS
First chamber pressure kPa (psi) 24.5 to 34.3 (3.6 to 5.0)
First seat inner diameter mm (in) 3.2 (0.1)
Secondary seat inner diameter mm (in) 6.0 (0.2)
Slow system flow shut off method Solenoid valve
Drain cock Optionally available
 1-7

Regulator Function
The LPG is gasified by depriving the engine coolant, led into the regulator, of heat. The regulator consists of chamber
A where LPG vaporization starts, chamber B (first reducing chamber) where the gasified LPG pressure is reduced,
chamber C (second reducing chamber) for reducing the pressure down to almost atmospheric level to supply fuel
using the adopter venturi vacuum, and chamber D for forced fuel supply during engine start and idling.

LPG flowing into chamber A of the regulator pushes elastic face valve 1 open by vapor pressure allowing it to enter
first reducing chamber B where it is vaporized by pressure reduction. When the pressure in chamber B becomes in
the range of 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) (3.6 to 5.0 psi), first diaphragm pushes first regulator spring, so
first diaphragm hook acuates first valve lever to close elastic face valve 1. When LPG flows out to second reducing
chamber C, the first pressure drops and first valve lever is operated by first regulator spring to open elastic face valve
1 to cause fuel to flow into first reducing chamber B again. Opening and closing of elastic face valve is repeated to
maintain the first pressure at a fixed level. The pressure of the fuel entering from chamber B into chamber C through
elastic face valve 2 is reduced to atmospheric level. Chamber C is connected to the adapter.
The vacuum of the ventury nozzle at the adapter operates second diaphragm to open elastic face valve 2 via second
valve lever. The valve is closed by the force of second regulator spring to maintain a constant pressure (atmospheric
pressure).

Injector path
(to injector) Slow path

Chamber D
Slow solenoid valve
Main path (to adaptor)

Elastic face valve 2

Chamber B
Chamber C

Secondary diaphragm
First diaphragm hook Second valve lever

First regulator spring

First diaphragm

First valve lever

Elastic face valve 1

Chamber A
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1. When starting the engine

When the ignition switch and LPG switch are both turned to ON, the LPG led from the IN port flows into chamber
A. Upon entering chamber A, the LPG pushes open the elastic face valve 1 by its own vapor pressure, and
enters the primary pressure reduction chamber B for pressure reduction and vaporization. When the pressure in
chamber B reaches in the range of 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) (3.6 to 5.0 psi), first diaphragm
pushes first regulator spring to operate first valve lever by means of first diaphragm hook. As a result elastic face
valve is closed and the pressure in the primary pressure reduction chamber B remains at a constant level. When
the starting motor runs, the current flowing in the coil of the slow solenoid operates the valve to connect
chambers B and D. Since the pressure in chamber B at 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) (3.6 to 5.0 psi) is
higher than the atmospheric pressure, LPG flows into chamber D. The LPG entering chamber D flows through
the slow path, and main path into the adapter, and is then supplied to the engine from the venturi nozzle to start
initial explosion. When the throttle valve at the electric governor is opened slightly then, vacuum is generated in
the venturi of the adapter. The vacuum in the adapter acts on the secondary pressure reduction chamber C via
the main path. At this time, secondary diaphragm is operated to open elastic face valve 2 via second valve lever
to cause LPG to flow from the primary pressure reduction chamber B to the secondary pressure reduction
chamber C.
As a result, a large amount of LPG enters the adapter for consecutive combustion.

Injector path
(to injector) Slow path

Chamber D
Slow solenoid valve
Main path (to adaptor)

Elastic face valve 2

Chamber B
Chamber C

Secondary diaphragm
First diaphragm hook Second valve lever

First regulator spring

First diaphragm IN port

First valve lever

Elastic face valve 1

Chamber A
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2. During idling
When the engine is idling, current flows to the slow solenoid valve coil to operate the valve, resulting in opening
of the closed path to connect chambers B with D. Since the pressure in chamber B is high enough, the
depressurized LPG flows chamber D. Though most of the fuel flown to chamber D is led to the adapter through
the slow path, main path, and venturi nozzle of the adapter, and then supplied to the engine, fuel is also
delivered to the engine by the LPG injector to compensate the air-fuel ratio. The idle adjusting screw controls
main flow rate of fuel. Since vacuum at the adapter is very low during idling, elastic face valve 2 is not opened
and the fuel is supplied not from the chamber C, but from the slow path.

Idle adjusting screw

Injector Slow path

path
Main path

Chamber D

Slow
Elastic
solenoid
face
valve Ventury nozzle
valve 2
Chamber B

Adapter

LPG injector

Chamber C
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3. During normal operation

When the throttle valve is opened, vacuum arises at the adapter venturi nozzle, which is applied to chamber C
through the main path. This vacuum pulls second diaphragm to open elastic face valve 2. As a result, LPG flows
from chamber B to chamber C, and enters the adapter venturi nozzle through the main path.
As a current also flows in the slow solenoid valve, LPG also flows from chamber B to chamber D, and through
the slow path to the venturi nozzle, and is also supplied to the engine by the LPG injector through the injector
path.
While the engine is running in medium load range, LPG fuel is mostly supplied through the main path, and LPG
injector injects the shortage amount of fuel to the ideal air-fuel ratio.
While the engine is in high load range, the FCM at adapter changes the amount of fuel flow to adjust the overall
fuel amount, on the other hand, the injector supplies a fixed amount of fuel with engine.

Injector Slow path

path
Main path

Chamber D

Slow
Elastic
solenoid Ventury nozzle
face
valve
valve 2
Chamber B Adapter
Second FCM
diaphragm

LPG injector
Throttle
valve

Chamber C
 1-11

4. When stopping the engine

When the engine stopped, the current to the slow solenoid valve is cut off to close the path between chambers B
and D, resulting in suspension of LPG supply through the slow path. Since the vacuum at the adapter venturi
does not exist, LPG supply through the slow path also stops.

Slow path

Chamber D

Slow
solenoid
valve
Chamber B

Adapter

LPG injector
1-12

REGULATORS SYSTEM COMPONENTS

LPG Cutoff Device
The solenoid valve for slow path control is integrated with the regulator. The solenoid valve is opened and closed
according to the engine speed, starter signal etc. detected by means of engine ECU. When the ignition switch is ON,
with the engine not running, the valve is closed not to flow LPG to the adapter.

Ignition
switch ST

ON LPG-
AM Gasoline Starter
switch relay
Gasoline LPG

Starter
EFI LPG motor
main Solenoid
relay relay
Igniter

Slow Main
solenoid solenoid

Engine ECU

Battery