Engine Fuel
Engine Fuel
Engine Fuel
SECTION EF
CONTENTS
EMISSION CONTROL SYSTEM ........................ EF-2 DISASSEMBLY AND ASSEMBLY OF FUEL
ENGINE OUTSIDE DRAWINGS ......................... EF-3 SYSTEM .............................................................EF-16
SYSTEM DIAGRAM ............................................ EF-4 Vaporizer Mechanism and Operation ............EF-16
K-Engine System Diagram (Gasoline) ........... EF-4 LPG Fuel Injector ..........................................EF-18
K-Engine System Diagram (LPG) .................. EF-5 LPG Assist Fuel Injector ................................EF-19
K-Engine System Diagram (Combined Use) ... EF-6 Relief Valve (2 Relief Valves) ........................EF-19
UNIT LAYOUT .................................................... EF-7 DISASSEMBLY AND ASSEMBLY OF
SERVICE DATA AND SPECIFICATIONS VAPORIZER ......................................................EF-20
(SDS) ................................................................... EF-8 Tar drain, Removal, Installation,
Electric Control System Specifications ........... EF-8 Disassembly and Inspection of Vaporizer .....EF-20
LPG FUEL SYSTEM TROUBLE DIAGNOSIS ... EF-9
DISASSEMBLY AND ASSEMBLY OF
FUEL SYSTEM ................................................. EF-10
Electric Control Throttle Assembly ............... EF-10
Gasoline Fuel Injector (Electric Controlled Gasoline
and Combined Use) ..................................... EF-11
LPG Device (Specifications for LPG and EF
Combined Use) ............................................ EF-13
EMISSION CONTROL SYSTEM
EF-2
ENGINE OUTSIDE DRAWINGS
EF-3
SYSTEM DIAGRAM
SYSTEM DIAGRAM K-Engine System Diagram (Gasoline)
EF-4
SYSTEM DIAGRAM
K-Engine System Diagram (LPG)
EF-5
SYSTEM DIAGRAM
K-Engine System Diagram (Combined Use)
EF-6
UNIT LAYOUT
EF-7
SERVICE DATA AND SPECIFICATIONS (SDS)
EF-8
LPG FUEL SYSTEM TROUBLE DIAGNOSIS
BLE DIAGNOSIS
EF-9
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
EF-10
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
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.
CAUTION:
Fuel remaining in the tube leaks during operation. This
operation should be done in a place free from fire.
• Remove fuel tube bolt.
• Remove fuel tube. Remove fuel injector and fuel tube as a set.
• Remove clips (4) using long-nose pliers. Disconnect fuel injec-
tor and fuel tube.
EFM0098
CAUTION:
Do not reuse clips.
EF-11
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
CAUTION:
Precautions for installation of fuel injector
• Make sure that there is no contamination and damage in O-
ring contact area caused by dirt. Do not clean O-ring with
solvent.
• Do not reuse removed O-ring.
• Handle O-ring with bare hands.
• Apply engine oil into O-ring and holder for assembly. (Do
not apply engine oil into fuel passages of fuel injector.)
• Do not use damaged O-ring.
• Do not apply excessive force to damage O-ring.
• Press clips into fuel injector when assembling. Securely fit
clips to fuel injector locating grooves (a) and (b). (Do not
reuse clips.)
• Always replace O-ring when clips contact with O-ring.
• Assemble fuel injector to fuel tube after installing clips to
fuel injector.
• 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.]
EFM0101 • 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.
• 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
EF-13
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
EF-14
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
EF-15
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
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 (0.29 bar, 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 (0.29 bar, 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 (0.29 bar, 0.3 kg/cm2, 4 psi).
Variation of pressurization can be suppressed by balance
diaphragm (8) even if pressure in LPG tank changes.
EF-16
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
EFM0123
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 (0.30 - 0.33 bar, 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.
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
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
CAUTION:
• 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 (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 sig-
nal wave of related harnesses. When a non-standard sig-
nal 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 nega-
tively affects rubber parts of inside.
EF-18
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
EF-19
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
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.
CAUTION:
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.
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.
CAUTION:
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.
EF-20
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
CAUTION:
Be careful not to lose primary pressurization spring that is on
back of cover when removing.
• Remove the primary diaphragm. Primary diaphragm is removed
while doing slide to direction of outside from center.
CAUTION:
Check primary diaphragm for breakage or damage. Replace if
necessary.
• Remove lever mounting screws (2), then remove primary side
valve lever.
CAUTION:
Do not lose the primary side valve lever because it is fixed with
only the pin.
• The figure shows the condition that primary side valve lever,
valve seat and pin are removed.
EF-21
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
INSPECTION OF DIAPHRAGM
• Check for cracks, damage and hardening.
• Replace each diaphragm if necessary.
CAUTION:
Replace O-ring with a new one.
• Tighten mounting bolts (6) evenly.
• High-pressure side cover tightening torque N·m (kg-m, ft-lb):
6.3 - 8.3 (0.64 - 0.85, 5 - 6)
• PTC heater tightening torque N·m (kg-m, in-lb):
1.0 - 2.9 (0.1 - 0.3, 9 - 26)
EF-22
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
CAUTION:
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 primary side valve lever.
CAUTION:
Be careful not to damage valve.
EF-23
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
EF-24