99789-85100 K21 Service Manual

Service Manual
K15, K21, K25 Gasoline Engine

K15 000001-up
K21 000001-up
K25 004868X-up
For use with GP15N-GP35N, GPE15N-GPE35N

Chassis Service Manual. 99789-85100
Cat Lift Trucks Service Manual K15, K21, K25 Gasoline Engine 99789-85100
Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043
Copyright © 2003 by MCFA. All Right Reserved.

99789-85100 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. Printed in the U.S.A.
FOREWORD
This service manual covers K15, K21 and K25 Gasoline Engine of CatTM Lift Trucks and gives
detailed maintenance and repair information. The instructions are grouped by systems to serve
the convenience of your ready reference.
Long productive life of your lift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on before
attempting any work.
All descriptions, illustration, specifications, and serial numbers in this manual are effective as of
the date printing of this manual. Cat lift truck reserves the right to change specifications or design
without notice and without incurring obligation.
Pub. No. 99789-85100

GROUP INDEX
GROUP INDEX Items
GI GENERAL INFORMATION HOW TO USE THIS MANUAL, PRECAUTIONS FOR SAFETY AND
QUALITY, PRECAUTIONS, TIGHTENING TORUQE.
SPECIAL SERVICE TOOLS, ENGINE OUTSIDE DRAWINGS, MAIN GI
SPECIFICATIONS, STANDARD ANDREPAIR LIMIT, STAMPED LOCA-
TION OF ENGINE NO, TROUBLE DIAGNOSIS
MA MAINTENANCE ENGINE MAINTENANCE

MA
ET ENGINE TUNE-UP SPECIFICATIONS, TIGHTENING TORQUE, TROUBLE DIAGNO-

SIS, ENGINE INSPECTION AND ADJUSTMENT, SPECIAL SER- ET
VICE TOOLS FOR CARBURETOR MODEL
EM ENGINE MECHANICAL PRECAUTIONS, ENGINE OUTSIDE DRAWINGS, MAIN SPECI-

FICATIONS, ADJUSTMENT VALUE, TIGHTENING TORQUE,
TROUBLE DIAGNOSIS, SPECIAL SERVICE TOOLS, REMOVAL EM
AND INSTALLATION OF ENGINE, ENGINE SERVICE
EC ENGINE CONTROL PRECAUTIONS, PREPARATION, DESCRIPTION, BASIC

INSPECTION, TROUBLE DIAGNOSIS, POWER SUPPLY AND
GROUND SYSTEM, CRANKSHAFT POSITION SENSOR (POS)
SYSTEM, CAMSHAFT POSITION SENSOR (PHASE) SYSTEM,
MASS AIR FLOW SENSOR SYSTEM, ENGINE COOLANT TEM-
PERATURE SENSOR SYSTEM, HEATED OXYGEN SENSOR
SYSTEM, THROTTLE POSITION SENSOR SYSTEM, ACCEL-
ERATOR PEDAL POSITION SENSOR SYSTEM, INTAKE AIR EC
TEMPERATURE SENSOR, PNP SWITCH SYSTEM, STOP LAMP
SWITH SYSTEM, ELECTRIC LOAD SWITCH SYSTEM, CAN
COMMUNICATION SYSTEM, IGNITION SYSTEM, FUEL INJEC-
TOR SYSTEM, FUEL PUMP SYSTEM, THROTTLE CONTROL
MOTOR SYSTEM, HEATED OXYGEN SENSOR HEATER SYS-
TEM, PCV GAS PECIRCULATION DEVICE, FUEL CUT FUNC-
TION, REMOVAL AND INSTALLATION OF ECM
COMPONENTS, SERVICE DATA AND SPECIFICATIONS (SDS)
LC ENGINE LUBRICATION LUBRICATION SYSTEM, ENGINE COOLANT SYSTEM

LC
& COOLING SYSTEM
EF ENGINE FUEL EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC

CONTROLLED TYPE), UNIT LAYOUT, SERVICE DATA AND
SPECIFICATIONS (SDS), LPG FUEL SYSTEM TROUBLE DIAG- EF
NOSIS, DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM,
VAPORIZER MECHANISM AND OPERATION
EE ENGINE ELECTRICAL ADJUSTMENT VALUE, TROUBLE DIAGNOSIS, DISTRIBUTOR

EE
(CARBURETOR TYPE), STARTER MOTOR, ALTERNATOR
GENERAL INFORMATION
SECTION GI GI
CONTENTS
HOW TO USE THIS MANUAL ............................. GI-2 Precautions for Assembly and Installation ...... GI-5
Description ...................................................... GI-2 Parts Requiring Angle Tightening .................... GI-6
Definition of Terms .......................................... GI-2 Caution for Use of Power Tools ...................... GI-6
Definition of Units ............................................ GI-2 Precautions for Liquid Ggasket Application ..... GI-6
Description ...................................................... GI-2 TIGHTENING TORQUE ....................................... GI-7
PRECAUTIONS FOR SAFETY AND QUALITY .. GI-3 Standard Bolt Tightening Torque .................... GI-7
Safe Operation ................................................ GI-3 Engine Part Tightening Torque ....................... GI-8
Correct Operation ............................................ GI-4 SPECIAL SERVICE TOOLS .............................. GI-10
Precautions for Radio Equipment Installation . GI-4 ENGINE OUTSIDE DRAWINGS ........................ GI-11
PRECAUTIONS ................................................... GI-5 MAIN SPECIFICATIONS ................................... GI-12
Precautions in Draining Engine Coolant .......... GI-5 STANDARD AND REPAIR LIMIT ..................... GI-16
Precautions for Disconnecting Fuel Piping ...... GI-5 STAMPED LOCATION OF ENGINE NO. .......... GI-19
Precautions for Removing and Disassembling GI-5 TROUBLE DIAGNOSIS ..................................... GI-20
Precautions for Inspection, Correction, and Engine Adjustment ........................................ GI-21
Replacement ................................................... GI-5 Engine LPG Fuel System .............................. GI-26
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL Description

This manual explains how to use "removal, installation, disassembly,
assembly, inspection and adjustment" and "diagnosis".
Definition of Terms
WARNING: Instructions and precautions that may lead to fatal
hazards and/or serious injuries if not observed properly.
CAUTION: Instructions and precautions that require special
attention and may lead to problems and/or accidents as
well as damages to the vehicle and/or components.
NOTE: Provides additional information that facilitates
operation.
Standard: Indicates tolerances for inspection and adjustment.
Repair limit: Indicates maximum or minimum values allowed for
inspection and adjustment.
Definition of Units
The units and numerical values in this Standard are SI units, and
those given in ( ) in this Standard are based on the conventional unit
system and are appended for informative reference.
Example: Tightening torque 59 - 78 N·m (6.0 - 8.0 kgf-m)
SI (Metric system)
Main unit changes

Measure SI Conventional unit Conversion factor to SI
Acceleration m/s2 G 9.80665
Torque, moment N•m kgf-m 9.80665

Force N kgf 9.80665
Pressure MPa kgf/cm 2 0.0980665
kPa mmHg 0.133322

Power efficiency kW PS 0.735499
W kcal/h 1.16279
Volume cm3 cc 1
Spring constant N/mm kgf/mm 9.80665

Fuel consumption *g/kW•h g/PS•h 1.3596
* The conventional unit can be used for SI.
Description
Caution: At the beginning of each section, the precautions
exclusive to the section are described.
Preparation: At the beginning of each section and during the trouble
diagnosis items, the SSTs, gauges, and other tools to
be prepared before operation are described. Some
commercial service tools, assumed to be available in
any workshop, are omitted.
Description: To perform correct operations, operational procedures,
notes, SSTs, and other service information are
described.
CAUTION: Descriptions of visual inspections and cleaning of
removed parts are generally omitted. Please remember
that actual operations require these processes.
GI-2
PRECAUTIONS FOR SAFETY AND QUALITY
PRECAUTIONS FOR SAFETY AND QUALITY • The following precautions must be carefully observed for safe
and appropriate service work.
• Only the qualified and designated personnel must perform
inspections, repairs and adjustments.
• Always keep the workplace clean, and store the tools neatly in
the specified places.
Safe Operation
• Do not run engines inside the workshop without proper
ventilation (ex. no ventilation ducts).
• Keep the workshop well ventilated and free of any flammable
materials. Special care should be taken when flammable or
poisonous materials such as gasoline are handled.
• Discard waste oil after oil changes or parts treatment in
accordance with local laws and regulations.
• Be careful of burns and injury when working on high-
temperature parts, rotating parts, or sliding portions.
• When working in a pit or enclosed area, ensure that adequate
GIM0057 ventilation is provided for discharging any hazardous emissions.
• Do not work underneath a vehicle supported only by a jack.
Always use rectangular lumbers at the prescribed points to
support the vehicle.
• Support it at the prescribed points and lock it in position with
safety devices before lifting the vehicle.
• When removing a heavy component such as the engine and
vehicle side, be careful the vehicle body does not become off-
balance and fall.
• Do not smoke during service work.
• Do not wear any rings and necklaces when working. These
GIM0058
objects may cause electric short.
• Before starting repair work that requires no battery power,
always turn OFF the ignition switch, and disconnect the
negative battery cable.
GIM0059
• Do not touch any metal portions immediately after the engine is

stopped. Otherwise the heated metals may cause burns. Do not
attempt to remove any cooling system parts such as the radiator
cap while the engine is hot.
• To perform repair work safely and efficiently, always use
appropriate commercial service tools and specified SSTs
wherever required.
GIM0060
GI-3
PRECAUTIONS FOR SAFETY AND QUALITY
Correct Operation
• Make sure that you understand the symptoms before starting
trouble diagnosis.
• Check correct installation status prior to removal or
disassembly. Make sure that they do not interfere with the
function of the parts they are applied to if matching marks are
required.
• Once they are removed, always replace parts indicated as "do
not reuse" with new ones. This includes: oil seals, gaskets,
packings, O-rings, lock washers, cotter pins, and self-locking
nuts.
• Replace inner and outer races of tapered or needle roller
bearings as a set.
• Arrange disassembled parts in order and prevent them from
being mixed-up.
• Clean or flush disassembled parts prior to inspection or
assembly.
• Use Genuine NISSAN parts for replacement.
• Use authorized grease and sealer.
• Release the pressure before disconnecting pressurized piping
or hoses.
• Be sure to check for leakage after repairing fuel, oil, coolant,
exhaust, or vacuum systems.
Precautions for Radio Equipment Installation

Check the following when installing a commercial/ham radio or
mobile phone. If mounting position is not chosen carefully, the unit
may interfere with the electronic control system.
• Separate the antenna as far from the Engine Control System as
possible.
• Route an antenna feeder line at least 20 cm apart from the
control unit harness.
• Adjust antenna and feeder line to eliminate radio wave
interference.
GI-4
PRECAUTIONS
PRECAUTIONS Precautions in Draining Engine Coolant

• Drain coolant only after the engine has cooled down.
Precautions for Disconnecting Fuel Piping

• Operation should be done in a place free from fire.
• Release fuel pressure before operation. (Electronic controlled
specifications): Refer to "Release of Fuel Pressure" in EC
section.
• After disconnecting, plug the pipe to prevent fuel from draining.
Precautions for Removing and

Disassembling
• Use correct SSTs in the specified position. Always pay attention
to safety.
• Be careful not to lose surface accuracy of mating or sliding
surfaces.
• To prevent foreign material from entering the engine, close
openings with appropriate tape as necessary.
• Arrange disassembled parts in their normal positions in order to
simplify locating the cause of damage or excessive wear and to
ensure correct reassembly.
• As a rule, nuts and bolts must be tightened in a diagonal
manner starting from an outer one. If a particular tightening
sequence is provided separately, follow the sequence.
Precautions for Inspection, Correction, and

Replacement
• Following the inspection procedure, inspect the parts
adequately and repair or replace as necessary. Perform the
same inspections even for new parts and replace them if
necessary.
Precautions for Assembly and Installation

• Always use a torque wrench when tightening bolts and nuts.
• Unless otherwise specified, tighten nuts and bolts from inside to
outside in a crisscross pattern. Tighten them gradually and
evenly in 2 to 3 steps.
• Always replace gasket, packing, oil seals, and O-rings with new
ones.
• For each part, perform adequate cleaning/washing and drying
with a dryer. In particular, ensure that the oil and coolant
passages are free from plugging and clogging.
• Remove any dirt and lint on sliding and mating surfaces. Before
assembly, apply ample amount of engine oil to sliding surfaces.
• If coolant was drained, bleed air from the system.
• After assembly, start engine and increase the engine speed,
then check coolant, fuel, oil, grease, and exhaust gas for
leakage.
GI-5
PRECAUTIONS
Parts Requiring Angle Tightening

• When tightening the following parts, use an angle wrench
(SST).
• Cylinder head bolt
Before assembly, verify that no grease/oil and dust are present
on the cylinder head, cylinder block mounting face, and head
gasket. Then apply antirust oil or engine oil to the threads and
head bottoms of the head bolts.
Caution for Use of Power Tools

• The use of power tools such as an air runner is only allowed for
disassembly. Do not use them for assembly.
Precautions for Liquid Ggasket Application

REMOVING PARTS ATTACHED WITH LIQUID GASKET
• Remove mounting nuts and bolts. Remove liquid gasket using a
seal cutter (SST).
CAUTION:
Be careful not to damage the mating surfaces.
• In positions where a seal cutter is difficult to use, lightly tap with
a plastic hammer, and remove.
CAUTION:
Be careful not to scratch the mating surfaces when using a
GIM0061
screwdriver.
LIQUID GASKET APPLICATION INSTRUCTION

1. Remove any old liquid gasket remaining on the gasket
application surface and its mating surface using a scraper.
• Remove any old liquid gasket remaining in the gasket
application groove and on the threads of bolts and bolt
holes.
2. Wipe the gasket application surface and its mating surface
using Isozole or any equivalent thinner to remove any moisture,
oil, and foreign material.
3. Set genuine liquid gasket to tube presser (commercial service
tool).
GIM0062
4. Apply a continuous bead of liquid gasket to the specified

position at the specified diameter.
• Apply liquid gasket in the application groove.
• Apply liquid gasket inside bolt holes as a rule. Make sure to
carefully read the relevant instructions.
• Attaching should be done within 5 minutes after gasket
application.
• Immediately wipe off any protruding liquid gasket.
• Do not retighten nuts and bolts after installation.
• After finishing work, wait at least 30 minutes before refilling
GIM0063 engine oil and coolant.
CAUTION:
Follow any directions specified in the text on the following
pages.
GI-6
TIGHTENING TORQUE
TIGHTENING TORQUE Standard Bolt Tightening Torque

Upper: Lubricated (Antirust oil is applied to abrasive faces of
threads and seating faces)
Lower: No lubrication (Threads and seating faces are
completely degreased)
Thread size
Unit 4T (Bolt) 7T (Bolt) 9T (Bolt)
Diameter Pitch
N·m 3.82 - 4.41 6.37 - 7.45 9.22 - 10.8

(kgf-m) (0.39 - 0.45) (0.65 - 0.76) (0.94 - 1.1)
M6 1
N·m 5.00 - 6.47 8.43 - 10.8 11.8 - 15.7
(kgf-m) (0.51 - 0.66) (0.86 - 1.1) (1.2 - 1.6)
N·m 9.32 - 10.8 15.7 - 17.7 22.6 - 25.5
Hexagon head bolt and nut

(kgf-m) (0.95 - 1.1) (1.6 - 1.8) (2.3 - 2.6)
M8 1.25
N·m 12.7 - 15.7 20.6 - 26.5 29.4 - 37.3
(kgf-m) (1.3 - 1.6) (2.1 - 2.7) (3.0 - 3.8)
N·m 19.6 - 22.6 32.4 - 38.2 47.1 - 53.9
(kgf-m) (2.0 - 2.3) (3.3 - 3.9) (4.8 - 5.5)
1.25
N·m 25.5 - 33.3 43.1 - 54.9 61.8 - 78.5
(kgf-m) (2.6 - 3.4) (4.4 - 5.6) (6.3 - 8.0)
M10
N·m 18.6 - 21.6 30.4 - 36.3 44.1 - 52
(kgf-m) (1.9 - 2.2) (3.1 - 3.7) (4.5 - 5.3)
1.5
N·m 24.5 - 31.4 41.2 - 52 58.8 - 74.5
(kgf-m) (2.5 - 3.2) (4.2 - 5.3) (6.0 - 7.6)
N·m 4.9 - 5.69 8.14 - 9.51 11.8 - 13.7
(kgf-m) (0.5 - 0.58) (0.83 - 0.97) (1.2 - 1.4)
M6 1
N·m 5.98 - 7.65 9.81 - 12.7 14.7 - 18.6
(kgf-m) (0.61 - 0.78) (1.0 - 1.3) (1.5 - 1.9)
N·m 11.8 - 13.7 19.6 - 23.5 28.4 - 33.3
(kgf-m) (1.2 - 1.4) (2.0 - 2.4) (2.9 - 3.4)
M8 1.25
N·m 14.7 - 18.6 24.5 - 31.4 35.3 - 45.1
Flanged bolt
(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)

N·m 24.5 - 29.4 41.2 - 48.1 59.8 - 69.6
(kgf-m) (2.5 - 3.0) (4.2 - 4.9) (6.1 - 7.1)
1.25
N·m 30.4 - 39.2 51.0 - 64.7 73.6 - 93.2
(kgf-m) (3.1 - 4.0) (5.2 - 6.6) (7.5 - 9.5)
M10
N·m 23.5 - 27.5 39.2 - 46.1 56.9 - 65.7
(kgf-m) (2.4 - 2.8) (4.0 - 4.7) (5.8 - 6.7)
1.5
N·m 29.4 - 37.3 49.0 - 61.8 69.6 - 89.2
(kgf-m) (3.0 - 3.8) (5.0 - 6.3) (7.1 - 9.1)
CAUTION:
• Except special nuts and bolts.
• The bolts applicable to this table have one of the following
marks embossed on their heads.
4T......4
7T......7
9T......9
GI-7
TIGHTENING TORQUE
Standard Bolt Tightening Torque (Cont’d)

TAPER SCREW TIGHTENING TORQUE
Allowable materials Aluminum Cast iron
for tightening
Unit Max. Max.
Standard Standard
Normal size value value
N·m 7.8 11.8 15.7 21.6

R1/8
(kgf-m) 0.796 1.2 1.6 2.2
N·m 19.6 29.4 34.3 44.1
R1/4
(kgf-m) 2.0 3.0 3.5 4.5
N·m 39.2 54.9 53.9 73.5
R3/8
(kgf-m) 4.0 5.6 5.5 7.5
Engine Part Tightening Torque

TIGHTENING TORQUE AT VARIOUS POINTS OF ENGINE
Tightening point Unit Standard Max. value
Cylinder head (lubricated) Separately given
Main bearing cap (lubricated) Separately given
N·m 220.5 240.1

Crankshaft pulley bolt (lubricated)
(kgf-m) 22.5 24.5
N·m 132 142
Flywheel bolt (lubricated)
(kgf-m) 13.47 14.49
N·m 31.4 37.3
Connecting rod nut (lubricated)
(kgf-m) 3.2 3.81
N·m 44.1 58.8
Rear plate bolt
(kgf-m) 4.5 6.0
N·m 39.2 49
Camshaft sprocket bolt
(kgf-m) 4.0 5.0
N·m 29.4 39.2
Oil filter stud
(kgf-m) 3.0 4.0
N·m 14.7 20.6
Oil filter element
(kgf-m) 1.5 2.1
N·m 19.6 29.4
Spark plug
(kgf-m) 2.0 3.0
N·m 22.6 25.5
Engine slinger bolt
(kgf-m) 2.31 2.6
N·m 13.7 15.7
Rocker cover nut
(kgf-m) 1.4 1.6
N·m 15.7 19.6
Water temperature gauge
(kgf-m) 1.6 2.0
N·m 15.7 21.6
Oil pressure switch
(kgf-m) 1.6 2.2
N·m 41.2 48.1
Exhaust manifold nut
(kgf-m) 4.2 4.91
N·m 44.1 58.9
Straight screw plug (For head top face)
(kgf-m) 4.5 5.5
N·m 29.4 39.2
Oil pan drain plug
(kgf-m) 3.0 4.0
GI-8
TIGHTENING TORQUE
Engine Part Tightening Torque (Cont’d)

N·m 1.27 1.67

Mass air flow sensor mounting screw
(kgf-m) 0.13 0.17
N·m 16.0 23.0
Fuel tube flare nut
(kgf-m) 1.63 2.35
N·m 6.37 7.45
Crankshaft position sensor plug bolt
(kgf-m) 0.65 0.76
N·m 6.37 7.45
Thermo-housing relief plug
(kgf-m) 0.65 0.76
CYLINDER HEAD
Tightening torque for general service is 68.6 N·m (7.0 kgf-m) in the
place of the tightening torque (5) as shown in the figure.
MAM0142
MAIN BEARING CAP

: 83.4 - 93.2 N•m (8.51 - 9.51 kgf-m)
• Apply antirust oil or engine oil to the bolt threads and head
bottom.
• Do not use any power tools such as an air runner for assembly.
GIM0064
GI-9
SPECIAL SERVICE TOOLS

Tool number Tool name
KV11103000 Pulley puller Removing crankshaft pulley
GIM0065
ST05240001 Engine attachment
GIM0066
ST0501S000 Engine stand assembly

(1) ST05011000 Engine stand
(2) ST05012000 Stand
GIM0067
KV101041S0 Crankshaft main bearing cap puller

(1) KV10104110 Crankshaft main bearing puller
(2) ST16512001 Adapter
GIM0068
ST12070000 Valve lifter
GIM0069
ST1102S000 Valve guide reamer set

Valve guide reamer 7.00 mm
GIM0070
ST1524S000 Front oil seal drift

KV10105500 Rear oil seal drift
ST15243000 Drift rod
GIM0071
KV10113700 Heated oxygen sensor wrench Removing and installing heated

oxygen sensor
GIM0072
GI-10
ENGINE OUTSIDE DRAWINGS
ENGINE OUTSIDE DRAWINGS CARBURETOR SPECIFICATIONS
GIM0074
ELECTRONIC CONTROLLED SPECIFICATIONS
GIM0075
GI-11
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS MAIN SPECIFICATIONS OF IGNITION SYSTEM
Engine type K15
Engine control system Electronic controlled specifications Carburetor specifications

Fuel specification Gasoline LPG Combined Gasoline Combined
Total displacement (cc) 1,486
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke (mm) 75.5 x 83
Compression ratio 9.0
Compression pressure [MPa (kg/cm )/rpm]2 1.3(13.0)/250
Engine speed control system Engine Control System, electronically controlled throttle Pneumatic governor
Fuel in use (Note 1) Unleaded regular At 20P See the left Unleaded regular At 20P
gasoline column gasoline
Maximum output [kW (PS)/rpm] 27.2 (37)/2,600 26.2 (35.6)/2,600 See the left 24.9 (33.8)/2,600 22.9 (31.2)/2,600
column
Maximum torque [N·m (kgf-m)/rpm] 104.9 (10.7)/ 101.0 (10.3)/ See the left 100.0 (10.2)/ 95.1 (9.7)/1,600
1,600 1,600 column 1,600
Valve opening/ Intake open (BTDC) 14
closing timing Intake close (ABDC) 30
(degree)
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
Valve clearance (mm) Intake (when engine 0.38
is hot)
Exhaust (when 0.38
engine is hot)
Firing order 1-3-4-2
Ignition timing (idling) (BTDC deg.) 0
On board idle speed ATM 700 700
(rpm)
MTM 700 700
On board high-idle ATM 2,800 2,900
speed (rpm) MTM 2,800 2,900
Allowable maximum Instantaneous, no 3,600
engine speed (rpm) load
Continuous load 3,000
PTO system Silent chain-driven/side PTO
Engine oil (originally Specification 10W-30 (Class SL)
fitted)
Amount (L) 3.8
Engine dimensions (length x width x height) 732.7 x 562.9 x 743 732.7 x 588.6 x 743
(Note 2) (mm)
Engine weight (w/o coolant, w/ oil) (Note 2) 138
(kg)
Note 1: Fuel
Gasoline: Use unleaded regular gasoline with an octane
rating of 91 or more.
LPG: Use a fuel of 30P or more in cold seasons. In ambient
temperature of -5°C or less, use a 100P fuel.
Note 2: The engine dimensions and weight differs with the
customer specifications. The above data should be
deemed as reference.
GI-12
MAIN SPECIFICATIONS
FUEL SYSTEM AND ENGINE SPEED CONTROL SYSTEM

Engine type K21

Valve mechanism OHV
Bore x stroke (mm) 89 x 83
Compression ratio 8.7 9.3 8.7 8.7
Compression pressure [MPa (kg/cm 2)/rpm] 1.2 (12.5)/250 1.3 (13.0)/250 1.2 (12.5)/250 1.2 (12.5)/250
Maximum output [kW (PS)/rpm] 38.2 (51.9)/2,600 39.5 (53.7)/2,600 See the left 34.2 (46.5)/2,600 33.1 (45.0)/2,600
column
Maximum torque [N·m (kgf-m)/rpm] 151.0 (15.4)/ 157.9 (16.1)/ See the left 142.2 (14.5)/ 139.3 (14.2)/
1,600 1,600 column 1,600 1,600
closing timing
Intake close (ABDC) 30
(degree)
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
is hot)
Exhaust (when 0.38
engine is hot)
Ignition timing (idling) (BTDC deg.) 0 2
(rpm)
MTM 700 700
speed (rpm)
MTM 2,700 (Only for 2750 MHI vehicles)
Continuous load 3000
fitted)
Amount (L) 3.8
(Note 2) (mm)
(kg)
Note 1: Fuel
GI-13
MAIN SPECIFICATIONS
EXHAUST GAS CLEANUP DEVICE LIST

Engine type K25

Valve mechanism OHV
Compression pressure [MPa (kg/cm 2)/rpm] 1.2 (12.5)/250 1.3 (13.0)/250 1.2 (12.5)/250 1.2( 12.5)/250
Maximum output [kW (PS)/rpm] 41.4 (56.3)/2,400 44.0 (59.9)/2,400 See the left 38.5 (52.3)/2,400 36.2 (49.3)/2,400
column
1,600 1,600 column 1,600 1,600
closing timing
Intake close (ABDC) 30
(degree)
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
is hot)
Exhaust (when 0.38
engine is hot)
Ignition timing (idling) (BTDC deg.) 0 2
(rpm)
MTM 700 700
speed (rpm)
MTM 2,700 (Only for 2,750 MHI vehicles)
fitted)
Amount (L) 3.8
(Note 2) (mm)
(kg)
Note 1: Fuel
GI-14
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS OF IGNITION SYSTEM

Engine type K15 K21 K25
Engine control Carburetor Carburetor Carburetor

Electronic controls Electronic controls Electronic controls
system type type type
Fuel specification Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined
Non-contact type Non-contact Non-contact type Non-contact Non-contact type Non-contact

Ignition device (Engine Control type (Full (Engine Control type (Full (Engine Control type (Full
System) transistor) System) transistor) System) transistor)
Ignition coil Hanshin
(with power Electric AIC-4002G AIC-4002G AIC-4002G
transistor) type
Crankshaft
Crankshaft position sensor
position Hall IC type Hitachi

sensor
HJ type - -
Unisia Automotive
(POS)
Camshaft
position Hall IC type Hitachi
sensor
HJ type - -
Unisia Automotive
(PHASE)
Mitsubishi
Distributor (with
ignition coil)
Electric T6T87777 T6T87778 T6T87779
type
NGK type FR2A-D FR2A-D FR2A-D

Spark plug
Gap (mm) 0.9 0.9 0.9

Engine control Electronic controls Carburetor type Electronic controls Carburetor type Electronic controls Carburetor type
system
Fuel Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined
specification
Fuel device Electronic controlled Electronic controlled Electronic controlled
standard type fuel injection device fuel injection device fuel injection device
(Engine Control (Engine Control (Engine Control
System) System) System)
Fuel device Gasoline LPG Gasoline Carburetor Carburetor Gasoline LPG Gasoline Carburetor Carburetor Gasoline LPG Gasoline Carburetor Carburetor
injector injector & LPG + LPG injector injector & LPG + LPG injector injector & LPG + LPG
adapter adapter adapter
Air-fuel ratio Air-fuel ratio feedback Air-fuel ratio feedback Air-fuel ratio feedback
control device control control control
Starting Electric throttle control Hot water type Electric throttle control Hot water type Electric throttle control Hot water type
auxiliary device actuator auto choke actuator auto choke actuator auto choke
Idle load control Electric throttle control FICD Electric throttle control FICD Electric throttle control FICD
type actuator actuator actuator
Engine speed Electric throttle control Pneumatic Electric throttle control Pneumatic Electric throttle control Pneumatic
control type actuator governor actuator governor actuator governor

Engine control system Electronic controls Carburetor Electronic controls Carburetor Electronic controls Carburetor
type type type
Fuel specification Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined Gasoline LPG Combined Gasoline Combined
Catalytic Type Three-way catalyst Three-way catalyst Three-way catalyst

device (Monolith) (Monolith) (Monolith)
(Reducing Location In counter weight with In counter weight with In counter weight with
HC, CO, Nox)
muffler separated muffler separated muffler separated
Capacity 0.45L 0.45L 0.45L
PCV gas recirculation Closed type Closed type Closed type Closed type Closed type Closed type
device
GI-15
STANDARD AND REPAIR LIMIT
STANDARD AND REPAIR LIMIT INSPECTION AND ADJUSTMENT

• Oil capacity H line (L)
3.7
• Oil capacityL line (L)
2.7
• (Oil filter capacity) (L)
0.3
• Fan belt deflection (When pressed by a force of approximately
10 kgf) (mm)
Standard 11 - 13
• Compression [MPa (kgf/cm2)/rpm]
Standard 1.27 (13.0)/250 (K15)
1.23 (12.5)/250 (K21)
1.27 (13.0)/250 (K25)
• Difference between each cylinder (kgf/cm2/rpm)
Repair limit 1.0/300
• Spark plug gap (mm)
Standard 0.8 - 0.9
• Distributor (Full transistor type) air gap (mm)
Standard 0.35 - 0.45
• Valve clearance (Hot) (mm)
Standard Intake: 0.38
Exhaust: 0.38
• Thermostat valve opening temperature (STD) (°C)
Standard 76.5
• Idle speed and ignition timing (BTDC°/rpm)
Standard 0/700±50 (K15)
0/700±50 (K21)
0/700±50 (K25)
2/700±50 (K21, carburetor specification)
0/700±50 (other than above)
CYLINDER HEAD
• Cylinder head (mm)
Material Aluminum alloy
Distortion limit 0.1
CYLINDER BLOCK
• Block upper surface (mm)
• Bore diameter dimension (mm)
Standard 75.50 - 75.55 (K15)
89.00 - 89.05 (K21, K25)
• Bore diameter wear (mm)
Repair limit 0.2
• Bore diameter out-of-round (mm)
Standard 0.02 or less
• Bore diameter taper (mm)
• Bore diameter out-of-round and taper (mm)
Repair limit 0.1
GI-16
PISTON
• Piston (mm)
Type Thermal flow type
Outer diameter Standard 75.465 - 75.515 (K15)
88.965 - 89.015 (K21) (K25)
• Clearance between piston and cylinder (mm)
Standard 0.025 - 0.045 (Selective fit service parts)
• Piston pin outer diameter (mm)
Standard 19.993 - 19.998 (K15, K21, K25)
• Piston pin fitting quality
Standard To a degree allowing movement by hand
• Piston ring end clearance (mm)
Standard Top 0.28 - 0.43
Second 0.45 - 0.60
Oil 0.20 - 0.60
Various limit values 1.00
• Clearance between piston ring and ring groove (mm)
Second 0.030 - 0.070
Oil 0.065 - 0.135
Repair limit Top 0.10
Second 0.10
Oil —
CONNECTING ROD
• Distance between both end hole centers (mm)
Standard 143.970 - 144.030 (K25)
152.470 - 152.530 (K15, K21)
• Large end hole diameter (mm)
Standard 48.0 - 48.013 (K15, K21, K25)
• Small end hole diameter (mm)
Standard 19.965 - 19.978 (K15, K21, K25)
• Bend (per 100 mm) (mm)
Repair limit 0.05
• Torsion (per 100 mm) (mm)
Repair limit 0.05
• Large end thrust clearance
Standard 0.2 - 0.3
Repair limit 0.40
• Large end oil clearance (mm)
Standard 0.030 - 0.066 (K15, K21, K25)
Repair limit 0.10
• Difference of weight (Piston combination) (g)
Standard 4 or less
CRANKSHAFT
• Bend (mm)
Repair limit 0.05
• End play (mm)
Repair limit 0.20
• Journal dimension (mm)
Standard 62.942 - 62.955
• Pin standard dimension (mm)
Standard 44.961 - 44.974 (K15, K21, K25)
• Journal oil clearance (mm)
Standard 0.020 - 0.073
GI-17
Repair limit 0.10

• Pin oil clearance (mm)
Standard 0.032 - 0.066
FLYWHEEL
• Flywheel surface swing (mm)
Repair limit 0.10
• Ring gear surface swing (mm)
Repair limit 0.50
• Flatness (mm)
Repair limit 0.30
CAMSHAFT
• Bend (mm)
Repair limit 0.05
• Camshaft height (mm)
Standard 36.750 - 36.800 (For both intake and exhaust)
Size reduction limit 36.5
Standard Front 45.434 - 45.447
Center 43.897 - 43.910
Rear 41.218 - 41.231
• End play (mm)
Standard 0.025 - 0.255
Repair limit 0.40
Center 0.038 - 0.064
Rear 0.025 - 0.051
Repair limit Front 0.10
Center 0.15
Repair limit Rear 0.10
VALVE
• Head outer diameter (mm)
Standard Intake 38.0 - 38.3
Exhaust 32.0 - 32.3
• Valve stem outer diameter (mm)
Exhaust 6.945 - 6.960
• Valve guide inner diameter (mm)
Exhaust 7.0 - 7.018
• Clearance between valve stem and valve guide (mm)
Exhaust 0.040 - 0.073
Repair limit Intake 0.10
Exhaust 0.10
• Clearance between valve lifter and lifter guide (mm)
Standard 0.016 - 0.052
• Clearance between crankshaft and flywheel (mm)
Standard 0 - 0.038
• Clearance between rocker shaft and rocker arm (mm)
Standard 0.020 - 0.054
Intake 0.38±0.03
Exhaust 0.38±0.03
GI-18
STAMPED LOCATION OF ENGINE NO.
STAMPED LOCATION OF ENGINE NO.
GIM0076
GI-19
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS Refer to each section for details.
Application
Condition Possible causes Action Common Electronic Carburetor
controlled specifications
specifications
Incident in ignition • Malfunction of low-voltage electronic Replace. √

system distribution ignition coil
• Condenser malfunction Replace. √
• Electric leakage from rotor cap and Clean or replace. √
rotor
• Spark plug malfunction Clean, adjust gap or replace. √
• Inappropriate ignition timing Adjust. √
• Ignition coil malfunction Replace. √
• Open circuit in high-tension cable Replace. √
• Loose or open primary wire Repair or replace. √
connection
Incident in fuel • Insufficient fuel Fill. √
system
• Contaminated fuel filter Replace. √
Refer to EF section
for the LPG model. • Plugged or contaminated fuel piping Wash. √
• Plugged or contaminated fuel injector Clean or replace. √
• Fuel pump malfunction Repair or replace. √
• Carburetor choke malfunction Check and adjust. √
• Inappropriate carburetor float level Correct. √
• Inappropriate idling Adjust. √
Lowered • Poor tightening of spark plug or Tighten to correct torque or √
compression inappropriate gasket replace.
pressure
• Inappropriate engine oil grade or Replace with appropriate grade √
deteriorated viscosity of oil.
• Inappropriate valve clearance Adjust. √
• Compression pressure leak from Remove head and perform fine √
valve seat grinding to valve.
• Stuck valve stem Repair or replace cylinder head √
and valve.
• Broken or chip valve spring Replace valve spring. √
• Compression pressure leakage from Replace head gasket. √
head gasket
• Worn or stuck piston ring Replace piston ring. √
• Worn piston ring or cylinder Engine overhaul (Diagnosis
procedure)
a. Put a small amount of
engine oil from the ignition
plug hole and measure the
compression pressure.
b. If the pressure builds up, a
possible cause is in the
cylinder or piston ring.
c. If the pressure remains
unchanged, the leakage can
be attributed to the valve,
cylinder head or head
gasket.
GI-20
TROUBLE DIAGNOSIS
Engine Adjust.
Condition Cause Action
1. Engine noise
Slapping noise of bearing and crankshaft Bearing looseness Replace.
Bearing seizure Replace.
Crankshaft bend Repair or replace.
Uneven wear of journal Correct.
Excessive end play Replace center bearing.
Slapping noise of piston, connecting rod Bearing looseness Replace.
Piston looseness Replace piston pin(s) or bushing(s).
Piston looseness relative to cylinder Reselect.
Piston ring damage Replace.
Poor rod alignment Realign.
Slapping noise of camshaft Bearing looseness Replace.
Excessive axial looseness Replace bearing thrust plate(s).
Rough gear tooth face(s) Correct.
Gear damage Replace.
Timing chain noise Inappropriate tension Adjust.
Damaged or sagged chain Replace.
Worn sprocket Replace.
Damaged or loose tensioner Replace.
Excessive camshaft-to-bearing clearance Replace.
Slapping noise of valve gear Inappropriate valve clearance Adjust.
Loose Adjust. screw(s) Replace.
Worn rocker face(s) Replace.
Worn valve guide(s) Replace guide(s).
Loose valve spring(s) Replace.
Valve seizure Repair or replace.
Slapping noise of water pump Inappropriate end play Replace.
Damaged impeller Replace.
2. Other mechanical damage
Stuck valve Inappropriate clearance Adjust.
Valve stem - insufficient guide-to-guide Clean stem(s), ream guide(s).
clearance
Loose or damaged spring Replace.
Seized or damaged valve stem(s) Replace or clean.
Poor fuel quality Use good fuel.
Burnt valve seat(s) Inappropriate valve clearance Adjust.
Deteriorated valve spring(s) Replace.
Edged valve end(s) Replace bulb.
Too narrow valve seat width Correct valve seat(s).
Engine over temperature (Overheat) Repair or replace.
Overrun Operate in optimum speed range.
Stuck valve guide(s) Correct.
GI-21
TROUBLE DIAGNOSIS
Engine Adjust. (Cont’d)

Excessive wear of cylinder piston(s) Insufficient engine oil Refill or replace oil.
Contaminated engine oil Clean crankcase, replace oil filter.
Poor quality oil Use specified oil.
Wrong combination of piston and Repair or replace.
connecting rod
Inappropriate clearance of piston ring Reselect and adjust.
Damaged air cleaner Wash.
Too rich air-fuel mixture Adjust.
Stuck choke valve Clean and adjust.
Excessive use of choke valve Start engine properly.
Poor functioning of connecting rod(s) Insufficient engine oil Fill oil.
Low oil pressure Repair.
Use of poor quality oil Use specified oil.
Rough crank surface(s) Grind surface(s), replace bearing(s).
Plugged oil passage Clean.
Wear or damage of bearing Replace.
Inappropriate bearing Correct.
Bearing looseness Replace.
Poor connecting rod alignment Repair or replace.
Poor functioning of crankshaft bearing(s) Insufficient engine oil Fill or replace oil.
Low oil pressure Correct.
Uneven wear of crank journal(s) Repair
Plugged oil passage of crankshaft Wash.
Damaged bearing(s) Replace.
GI-22
TROUBLE DIAGNOSIS

Condition Possible causes Action
No or slow cranking • Inappropriate engine oil grade Replace oil with a proper one.
• Battery is discharged Charge battery.
• Battery damage Replace battery.
• Loose fan belt Belt tension Adjust.
• Incident in charge system Check.
• Incident in starter system wiring Repair.
• Starter switch malfunction Repair or replace.
• Starter motor malfunction Repair or replace.
(Starter circuit diagnosis procedure)
If the light turns off or dims when the starter
switch is turned to "ON" with the headlights on:
a: Check the battery.
b: Check the electric connections and wirings.
c: Check the starter motor.
If the light remains bright when the starter switch
is turned to "ON" with the headlights on:
a: Check the wiring between battery and
starter motor.
b: Check the starter switch.
Engine is cranked but not started. Such incidents are attributed to the following
factors, but most likely, the ignition system or the
Refer to EF section for the LPG model. fuel system is the main cause.
• Incident in ignition system (Diagnosis procedure)
• Incident in fuel system Check the spark plug following the steps below.
• Dynamic valve system does not operate Disconnect the high-tension cable from the No.1
normally. plug and keep it 10 mm away from the engine
• Poor compression metal portions. Then crank the engine.
If a good spark is available:
a. Check the ignition plugs.
b. Check the ignition timing.
c. Check the fuel system.
d. Check the compression pressure.
If no spark is available:
a. Check the primary coil current.
b. If the current level is high, check the primary
coil for short circuit.
Inappropriate idling
Incident in fuel system • Plugged or damaged carburetor jet Clean or replace.
• Damaged or plugged fuel injector Clean or replace.
Refer to EF section for the LPG model.
• Inappropriate idle Adjust. Adjust.
• Plugged air cleaner Replace element.
• Damaged manifold gasket or carburetor Replace gasket or insulator.
insulator
• Inappropriate carburetor float level Adjust. Adjust.
Lowered compression pressure Already described.
Engine power does not increase to an Adjust.
appropriate level
Lowered compression pressure Already described.

Incident in ignition system • Inappropriate ignition timing Adjust.
• Spark plug malfunction Clean, adjust or replace.
GI-23
TROUBLE DIAGNOSIS

Incident in fuel system • Malfunction of carburetor choke system Adjust.

• Plugged fuel piping Clean
• Plugged or contaminated fuel filter Replace.
• Fuel pump malfunction Repair or replace
• Plugged carburetor jet or needle valve Disassemble and clean.
• Poor throttle valve opening Adjust.
• Fuel pump malfunction Adjust.
Incident in intake system • Plugged air cleaner Replace element
• Air leakage from electronic throttle insulator Replace insulator.
• Air leakage from manifold gasket or Replace gasket or insulator.
carburetor insulator
Engine over temperature (Overheat) • Insufficient amount of coolant Fill coolant.
• Loose fan belt. Adjust belt tension.
• Worn or loose fan belt Replace.
• Malfunctioning thermostat Replace.
• Water pump malfunction Replace.
• Plugged or leaking radiator Wash, repair, or replace.
• Radiator cap damage Replace.
• Air in cooling system piping Retighten cooling system piping, bleed system.
• Improper engine oil grade Replace with appropriate grade of engine oil.
• Inappropriate ignition timing Adjust.
• Carburetor malfunction (too lean air-fuel Overhaul carburetor.
mixture)
Overcool • Malfunctioning thermostat Replace.
Other • Inappropriate octane rating of fuel Replace with specified octane rating of fuel.
• Insufficient tire air pressure Charge to specified air pressure.
• Brake dragging Adjust.
• Clutch slippage Adjust.
Engine noise
Knocking • Engine overload Operate with light load
• Knocking due to carbon deposits Remove cylinder head and eliminate carbon
deposits.
• Knocking due to inappropriate ignition timing Adjust ignition timing.
• Knocking due to inappropriate octane rating Use specified octane rating of fuel.
of fuel
• Too advance ignition (Inappropriate spark Use specified type of spark plug.
plug selection)
Mechanical slapping
Crankshaft bearing slapping • Strong and heavy noise from engine during A possible cause is in damage/wear of bearing or
acceleration uneven wear of crankshaft.
• To identify the noise generation point, Need to replace bearing and adjust or replace
attempt to cause misfires at each cylinder. crankshaft.
• If misfires at a particular cylinder stop the
noise, that cylinder is the noise source.
Connecting rod bearing slapping • This noise is also generated during engine Take the same action as that for crankshaft
acceleration but at a little more rapid pitch bearing.
than crank slapping.
• To identify the noise generation point,
attempt to cause misfires at each cylinder.
• If misfires at a particular cylinder almost stop
the noises, that cylinder is the noise source.
GI-24
TROUBLE DIAGNOSIS

Piston and cylinder slapping • Mechanical rapping noise that increases This noise is caused by excessive wear of
according the engine speed but decreases cylinders and accompanied by engine power
as the engine is warmed up is attributed to deterioration and excessive oil consumption.
the pistons and cylinders.
• To identify the noise generation point, For a corrective action, engine overhaul is
attempt to cause misfires at each cylinder. needed.
Piston pin slapping • This noise is generated at piston TDC and A possible cause is wear of the piston pin hole or
BDC positions. piston pin.
• To identify the noise generation point, Need to replace piston and piston pin assembly.
attempt to cause misfires at each cylinder.
Water pump noise • This noise is generated from worn or Replace water pump.
damaged bearing(s) due to the uneven
sliding faces.
Excessive oil consumption
Oil leakage • Worn piston ring groove(s) and ring(s) Replace piston(s) and piston ring(s).
• Deteriorated valve oil seal lip(s) Replace valve oil seal(s).
• Worn valve stem(s) Replace valve(s).
Other • Use of inappropriate quality of oil Use specified oil.
• Engine overheat Already described
Inappropriate fuel consumption
Refer to description of engine power • Excessive idling speed Adjust to specified level.
deterioration.
• Insufficient throttle return Adjust.
Other
Refer to EF section for the LPG model. • Fuel leakage Repair fuel piping and additionally tighten
connections.
Incident due to other factors
Low oil pressure • Use of inappropriate quality of oil Replace specified oil.
• Engine over temperature (Overheat) Already described.
• Oil pump regulator valve malfunction Overhaul or replace oil pump.
• Oil pump malfunction Overhaul or replace oil pump.
• Oil filter malfunction Replace with a new one.
• Enlarged clearance of each sliding Disassemble and replace relevant sliding
component component(s).
• Clogged oil strainer Wash.
• Malfunction of oil pressure gauge pressure Replace with a new one.
switch
Excessive wear of sliding part(s) • Low oil pressure Already described.
• Poor quality of oil or foreign objects in oil Replace oil element and oil with appropriate
ones.
• Poor performance of air cleaner Check element.
• Overheat or excessive cooling Already described.
• Inappropriate air-fuel ratio Check fuel system.
Bite of sliding parts • Low oil pressure Already described.
• Insufficient clearance Adjust clearance to specified value.
• Engine over temperature (Overheat) Already described.
• Inappropriate air-fuel ratio Check fuel system.
GI-25
TROUBLE DIAGNOSIS
Engine LPG Fuel System

Fuel leakage
Nasty smell • Looseness of piping connection Tighten.
• Operating malfunction of vaporizer Repair and adjust.
• Poor connection or some foreign object is Clean and rub.
caught in between plunger rubber seat and
valve seat of solenoid valve
• Operating malfunction of lock off mechanism Adjust.
Excessive fuel consumption • Looseness of piping connection Retighten and adjust.
• Primary side room pressure at idle is Clean and adjust.
excessively high.
• Clogged air cleaner Wash.
• Adjusting malfunction of LPG mixer main Adjust.
adjusting screw
Low output • Operating malfunction of vaporizer Repair and adjust.
• Looseness of piping connection or clogged Clean and retighten.
filter
• Adjusting malfunction of vaporizer primary Adjust.
and secondary room pressures
• Adjusting malfunction of LPG mixer main Adjust.
adjusting screw
• Use improper fuel. Use proper fuel.
• Clogged fuel passage Clean.
Inconsistent or rough idle • Improper position of vaporizer idle Adjust. Adjust.
screw or carburetor throttle valve, or
operating malfunction of electric throttle
control actuator
• Operating malfunction of vaporizer Repair and adjust.
• Operating malfunction of vaporizer valve (It is Clean, adjust or replace.
closed improperly.)
Engine hesitation or hunting • Operating malfunction of vaporizer Adjust.
• Adjusting malfunction of idle speed Adjust.
Poor starting engine • 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 Replace.
• Water pump malfunction Repair and adjust
• Adjusting malfunction of idle speed Adjust.
Operating malfunction of vaporizer • Adjusting malfunction of vaporizer primary Adjust.
and secondary room pressures
• Leakage from primary and secondary valve Clean, adjust, or replace.
seats of vaporizer
• Damage of diaphragm Replace.
• Foreign materials enter vaporizer inside Clean and adjust.
• Leakage by looseness of setscrew Tighten.
• Overcool of vaporizer (Fur deposit, damage Check, clean, and adjust.
of hose, poor coolant circulation)
• Tar deposit in valve Remove tar and clean.
GI-26
MAINTENANCE
SECTION MA MA
CONTENTS
ENGINE MAINTENANCE .................................. MA-2 Maintenance Schedule ...................................MA-8
Specifications .................................................MA-2 Oil and Grease, and Capacity ........................MA-9
Tightening Torque ..........................................MA-6 On Board Inspection and Service .................MA-10
ENGINE MAINTENANCE
ENGINE MAINTENANCE Specifications

INSPECTION AND ADJUSTMENT
• Oil capacity H line (L)
3.7
• Oil capacity L line (L)
2.7
• (Oil filter capacity) (L)
0.3
• Fan belt deflection (When pressed by a force of approximately
10 kgf) (mm)
Standard 11 - 13
• Compression [MPa (kgf/cm2)/rpm]
Standard 1.27 (13.0)/250 (K15)
1.23 (12.5)/250 (K21)
1.27 (13.0)/250 (K25)
• Difference between each cylinder (kgf/cm2/rpm)
Repair limit 1.0/300
• Spark plug gap (mm)
Standard 0.8 - 0.9
• Distributor (Full transistor type) air gap (mm)
Standard Intake: 0.38
Exhaust: 0.38
• Thermostat valve opening temperature (STD) (°C)
Standard 76.5
• Idle speed and ignition timing (BTDC°/rpm)
Standard 0/700±50 (K15)
0/700±50 (K21)
0/700±50 (K25)
2/700±50 (K21, carburetor specification)
0/700±50 (other than above)
CYLINDER HEAD
• Cylinder head (mm)
CYLINDER BLOCK
• Block upper surface (mm)
• Bore diameter dimension (mm)
Standard 75.50 - 75.55 (K15)
89.00 - 89.05 (K21, K25)
• Bore diameter wear (mm)
Repair limit 0.2
• Bore diameter out-of-round (mm)
• Bore diameter taper (mm)
• Bore diameter out-of-round and taper (mm)
Repair limit 0.1
MA-2
ENGINE MAINTENANCE
Specifications (Cont’d)
PISTON
• Piston (mm)
Outer diameter Standard 75.465 - 75.515 (K15)
88.965 - 89.015 (K21) (K25)
• Gap between piston and cylinder (mm)
Standard 0.025 - 0.045 (Selective fit service parts)
Standard 19.993 - 19.998 (K15, K21, K25)
• Piston ring end gap (mm)
Second 0.45 - 0.60
Oil 0.20 - 0.60
• Gap between piston ring and ring groove (mm)
Second 0.030 - 0.070
Oil 0.65 - 0.135
Second 0.10
Oil -
CONNECTING ROD
• Distance between both end hole centers (mm)
Standard 143.970 - 144.030 (K25)
152.470 - 152.530 (K15, K21)
Standard 48.0 - 48.013 (K15, K21, K25)
Standard 19.965 - 19.978 (K15, K21, K25)
Repair limit 0.05
• Torsion (per 100 mm) (mm)
Repair limit 0.05
• Large end thrust gap
Standard 0.2 - 0.3
Repair limit 0.40
Standard 0.030 - 0.066 (K15, K21, K25)
Repair limit 0.10
• Difference of weight (Piston combination) (g)
Standard 4 or less
MA-3
ENGINE MAINTENANCE
CRANKSHAFT
• Bend (mm)
Repair limit 0.05
• End play (mm)
Repair limit 0.20
Standard 62.942 - 62.955
Standard 44.961 - 44.974 (K15, K21, K25)
Standard 0.020 - 0.073
Repair limit 0.10
• Pin oil clearance (mm)
Standard 0.032 - 0.066
FLYWHEEL
• Flywheel surface swing (mm)
Repair limit 0.10
• Ring gear surface swing (mm)
Repair limit 0.50
• Flatness (mm)
Repair limit 0.30
CAMSHAFT
• Bend (mm)
Repair limit 0.05
Center 43.897 - 43.910
Rear 41.218 - 41.231
• End play (mm)
Standard 0.025 - 0.255
Repair limit 0.40
Center 0.038 - 0.064
Rear 0.025 - 0.051
Center 0.15
Repair limit Rear 0.10
MA-4
ENGINE MAINTENANCE
VALVE
Exhaust 32.0 - 32.3
Exhaust 6.945 - 6.960
• Valve guide inner diameter (mm)
Exhaust 7.0 - 7.018
• Gap between valve stem and valve guide (mm)
Exhaust 0.040 - 0.073
Exhaust 0.10
• Gap between valve lifter and lifter guide (mm)
Standard 0.016 - 0.052
• Gap between crankshaft and flywheel (mm)
Standard 0 - 0.038
• Gap between rocker shaft and rocker arm (mm)
Standard 0.020 - 0.054
Intake 0.38±0.03
Exhaust 0.38±0.03
MA-5
ENGINE MAINTENANCE
Tightening Torque
Lower: No lubrication (Threads and seating faces are
completely degreased)
Thread size
Diameter Pitch
N·m 3.82 - 4.41 6.37 - 7.45 9.22 - 10.8

(kgf-m) (0.39 - 0.45) (0.65 - 0.76) (0.94 - 1.1)
M6 1
N·m 5.00 - 6.47 8.43 - 10.8 11.8 - 15.7
(kgf-m) (0.51 - 0.66) (0.86 - 1.1) (1.2 - 1.6)
N·m 9.32 - 10.8 15.7 - 17.7 22.6 - 25.5

(kgf-m) (0.95 - 1.1) (1.6 - 1.8) (2.3 - 2.6)
M8 1.25
N·m 12.7 - 15.7 20.6 - 26.5 29.4 - 37.3
(kgf-m) (1.3 - 1.6) (2.1 - 2.7) (3.0 - 3.8)
N·m 19.6 - 22.6 32.4 - 38.2 47.1 - 53.9
(kgf-m) (2.0 - 2.3) (3.3 - 3.9) (4.8 - 5.5)
1.25
N·m 25.5 - 33.3 43.1 - 54.9 61.8 - 78.5
(kgf-m) (2.6 - 3.4) (4.4 - 5.6) (6.3 - 8.0)
M10
N·m 18.6 - 21.6 30.4 - 36.3 44.1 - 52
(kgf-m) (1.9 - 2.2) (3.1 - 3.7) (4.5 - 5.3)
1.5
N·m 24.5 - 31.4 41.2 - 52 58.8 - 74.5
(kgf-m) (2.5 - 3.2) (4.2 - 5.3) (6.0 - 7.6)
N·m 4.9 - 5.69 8.14 - 9.51 11.8 - 13.7
(kgf-m) (0.5 - 0.58) (0.83 - 0.97) (1.2 - 1.4)
M6 1
N·m 5.98 - 7.65 9.81 - 12.7 14.7 - 18.6
(kgf-m) (0.61 - 0.78) (1.0 - 1.3) (1.5 - 1.9)
N·m 11.8 - 13.7 19.6 - 23.5 28.4 - 33.3
(kgf-m) (1.2 - 1.4) (2.0 - 2.4) (2.9 - 3.4)
M8 1.25
N·m 14.7 - 18.6 24.5 - 31.4 35.3 - 45.1
Flanged bolt
(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)

N·m 24.5 - 29.4 41.2 - 48.1 59.8 - 69.6
(kgf-m) (2.5 - 3.0) (4.2 - 4.9) (6.1 - 7.1)
1.25
N·m 30.4 - 39.2 51.0 - 64.7 73.6 - 93.2
(kgf-m) (3.1 - 4.0) (5.2 - 6.6) (7.5 - 9.5)
M10
N·m 23.5 - 27.5 39.2 - 46.1 56.9 - 65.7
(kgf-m) (2.4 - 2.8) (4.0 - 4.7) (5.8 - 6.7)
1.5
N·m 29.4 - 37.3 49.0 - 61.8 69.6 - 89.2
(kgf-m) (3.0 - 3.8) (5.0 - 6.3) (7.1 - 9.1)
CAUTION:
Except special nuts and bolts.
The bolts applicable to this table have one of the following marks
embossed on their heads.
4T......4
7T......7
9T......9
MA-6
ENGINE MAINTENANCE
Tightening Torque (Cont’d)

Cylinder head (lubricated) Refer to MA-10.

Crankshaft pulley bolt (lubricated) N·m 220.5 240.1
(kgf-m) 22.5 24.5
Oil filter element N·m 14.7 20.6
(kgf-m) 1.5 2.1
Spark plug N·m 19.6 29.4
(kgf-m) 2.0 3.0
Engine slinger bolt N·m 22.6 25.5
(kgf-m) 2.31 2.6
Rocker cover nut N·m 13.7 15.7
(kgf-m) 1.4 1.6
Water temperature gauge N·m 15.7 19.6
(kgf-m) 1.6 2.0
Oil pressure switch N·m 15.7 21.6
(kgf-m) 1.6 2.2
Exhaust manifold nut Refer to MA-10.
Oil pan drain plug N·m 29.4 39.2
(kgf-m) 3.0 4.0
Crankshaft position sensor plug bolt N·m 6.37 7.45
(kgf-m) 0.65 0.76
Thermo-housing air relief plug N·m 6.37 7.45
(kgf-m) 0.65 0.76
MA-7
ENGINE MAINTENANCE
Maintenance Schedule
Make sure to perform appropriate maintenance and service work to
maintain the initial performances of the NISSAN forklift.
PERFORM INSPECTION
Make sure to perform the periodical inspections at appropriate
times, according to the month basis or the operating hour basis,
whichever comes first. ...... Inspection period
Refer to the following notes for values in ( )
Engine system inspection (except LPG fuel system)
Applicable Months of use 1 2 3 4 5 6 7 8 9 10 11 12

Inspection items
No. control Operation hours
system 2 4 6 8 10 12 14 16 18 20 22 24
(x 100 hours)
1 Intake/exhaust valve clearance Electronic A A A A A
controls,
carburetor
2 Engine drive belt tension Electronic I I I I I I I I I I I I
controls,
carburetor
3 Cylinder head bolt and manifold nut Electronic T
controls,
carburetor
4 Radiator appearance Electronic
controls,
carburetor
5 Engine oil Electronic (1) R R R R R R
controls,
carburetor
6 Oil filter Electronic (1) R R R R R R
controls,
carburetor
7 Engine coolant Electronic
controls,
carburetor
8 Fuel filter Carburetor (1) C C C C C
9 Air cleaner element Electronic
controls,
carburetor
10 Engine idle speed Carburetor A A A A A A A A A A A A
11 Ignition timing Carburetor A A A A A A A A A A A A
12 Spark plug Electronic I I I I I I I I I I I I
controls,
carburetor
13 Ignition nozzle Electronic I I I I I
controls
14 Distributor (point, cap, and rotor) Carburetor I I I I I I I I I I I I
15 Distributor (inside) Carburetor (1) C
16 PCV valve Electronic (1) I I I I
controls,
carburetor
17 PCV hose Electronic I I I I
controls,
carburetor
18 Specific gravity of battery electrolyte Electronic
controls,
carburetor
MA-8
ENGINE MAINTENANCE
Maintenance Schedule (Cont’d)

Engine system inspection (LPG models)
Applicable Months of use 1 2 3 4 5 6 7 8 9 10 11 12

No. Inspection items control Operation hours
system 2 4 6 8 10 12 14 16 18 20 22 24
(x 100 hours)
1 Damaged or loose LPG tank bracket
2 Gas leakage from piping and piping Electronic (2) I I I I I I I I I I I I
joints controls,
carburetor
3 Damage to piping and piping joints Electronic I I I I I I I I I I I I
controls,
carburetor
4 Tar in vaporizer Electronic D D D D D D D D D D D D
controls,
carburetor
5 Ignition nozzle Electronic I I I I I
controls
6 LPG filter Electronic C C C R
controls,
carburetor
CAUTION:
• (1) The maintenance work should be performed more
frequently if the vehicle is being used in dusty and dirty
environments.
• (2) Apply soap suds to the piping joints to check for any
gas leakage after replacing the LPG tank.
Meanings of symbols:
I = Inspection. Repair or replace if necessary.
R = Replacement
A = Adjustment
C = Cleaning
D = Draining
T = Tightening (Retightening)
Oil and Grease, and Capacity

OIL, LLC
Items Specification Remarks
Engine oil Gasoline *10W-30 (Class SL) Refer to SAE viscosity index. (SE, SH can be used.)
Antifreeze Genuine NISSAN long life coolant
* It is the oil for filling in at factory.
FILLING CAPACITY (GUIDELINE)

Items Capacity (Liter)
Engine oil K15 3.7

K21 3.7
K25 3.7
MA-9
ENGINE MAINTENANCE
On Board Inspection and Service

TIGHTENING OF HEAD BOLT
Tighten head bolts from inside to outside as shown in the figure.
Tighten bolts gradually as shown in the figure.
Tightening torque: 68.6 N·m (7.0 kgf-m) (This tightening torque can
be used in step (5) as shown in the figure for service.)
CAUTION:
Check tightening angle with an angle wrench (SST) or a
protractor. Do not simply estimate tightening angle.
MAM0142
RETIGHTENING OF MANIFOLD NUT AND BOLT
CAUTION:
Do not retighten nut and bolt until manifold components get
cold. It may cause to get burned.
Tightening torque for manifold and nut

Models N·m kgf-m ft-lbs
K15 41.2 - 48.1 4.2 - 4.91 30.37 - 35.59

K21 41.2 - 48.1 4.2 - 4.91 30.37 - 35.59
K25 41.2 - 48.1 4.2 - 4.91 30.37 - 35.59
(Do not use power tools such as air runner to tighten.)
INTAKE/EXHAUST VALVE CLEARANCE ADJUSTMENT

• Adjustment must be made with the vehicle in hot condition.
1. Warm up engine until engine coolant temperature gauge shows
nearly center, and then stop it.
2. Remove rocker cover.
3. Turn the crankshaft.
CAUTION:
Disconnect high-tension cable from ignition coil when rotating
crankshaft with starter motor.
MA-10
ENGINE MAINTENANCE
On Board Inspection and Service (Cont’d)

4. Set the piston for the No. 1 cylinder to the compression TDC
and adjust the valves of (1), (2), (3), and (5) in the figure.
5. Set the piston for the No. 4 cylinder to the compression TDC by
rotating crank again and adjust the valves of (4), (6), (7), and (8)
in the figure.
Intake/exhaust valve clearance (Hot)

Models Intake Exhaust
K15 0.38 0.38

MAM0143 K21 0.38 0.38
K25 0.38 0.38
INSPECTION AND ADJUSTMENT OF ENGINE DRIVE BELT
CAUTION:
Make sure that engine stops. Wash hands.
1. Visually check fan belt for wear, damage, and cracks. Do not
contact the belt with pulley groove bottom.
2. Push the belt between pulleys. Check tension.
Belt deflection: 11 - 13 mm
Force: 98 N (10 kgf)
ETM0046
REPLACEMENT OF OIL AND OIL FILTER

1. Warm engine.
2. Remove oil pan drain plug and oil filler cap, and discharge all oil.
CAUTION:
• Be careful not to get burned when engine or engine oil is
heated.
• It shows the mixing of coolant so that oil looks likes milk.
Repair if necessary.
• It shows the mixing of gasoline so that oil viscosity is too
lean. Repair if necessary.
3. Wipe around drain hole. Install drain plug.
Tightening torque for oil pan drain plug:
29.4 - 39.2 N·m (3.0 - 4.0 kgf-m)
MA-11
ENGINE MAINTENANCE
On Board Inspection and Service (Cont’d)

4. Replace oil filter.
• Remove oil filter using an oil filter wrench (SST).
• Wipe oil filter mounting surface with a clean shop cloth.
MAM0144
• Apply a small amount of engine oil to the lip of the new oil filter.
MAM0145
• Screw in the oil filter by hand until it contacts cylinder block

boss, and then screw in another 2/3 of a turn.
MAM0146
5. Fill the oil according to the specified lubricant amount.
Standard oil amount

Including filter 3.7L
Not including filter 3.4L
6. Start engine, and make sure that there is no leakage around

drain plug and oil filter. Replace drain plug and oil filter if there is
some leakage.
7. Run engine, and stop it after engine coolant temperature gauge
is in nearly center position. Check oil level after waiting for a few
minutes. Refill oil if necessary.
MA-12
ENGINE TUNE-UP
SECTION ET
CONTENTS ET
SPECIFICATIONS .............................................. ET-2 Engine Body Related ......................................ET-9

TIGHTENING TORQUE ...................................... ET-3 Ignition and Fuel Systems .............................ET-13
TROUBLE DIAGNOSIS ...................................... ET-4 SPECIAL SERVICE TOOLS FOR CARBURETOR
ENGINE INSPECTION AND ADJUSTMENT ..... ET-9 MODEL ..............................................................ET-20
SPECIFICATIONS
SPECIFICATIONS
Items Engine type K15 K21 K25
Intake
Valve clearance (Hot) mm (in) 0.38 (0.015)
Exhaust
Fan belt deflection mm (in) 11 - 13 (0.43 - 0.51)
Belt push force N (kg, lb) 98 (10,22)
Engine oil amount L (US qt, lmp qt)
(including oil filter) 3.7 (3-7/8,3 - 1/4)
(not including oil filter) 3.4 (3-3/4,3 - 1/8)
Compression pressure kPa (bar, kgf/cm2)/rpm
Standard 1.27 (13.0/250) 1.23 (12.5/250) 1.27 (13.0/250)
Minimum value
Spark plug type FR2A-D
Plug gap mm (in) 0.9 (0.035)
Distributor gap mm (in) (Carburetor model only) 0.35 - 0.45 (0.0138 - 0.0177)
High-tension cable resistance Ω (Same as above) 30,000 or less
Ignition timing/idle speed BTDC deg./rpm 700±50 700±50
Maximum engine speed without load rpm (instantaneous) 3,600 3,600 3,600
Maximum engine speed with load rpm 3,000 3,000 3,000
ET-2
TIGHTENING TORQUE
TIGHTENING TORQUE Unit : N·m (kgf-m)

Cylinder head bolt See the figure on the left
Manifold nut 41.2 - 48.1 (4.2 - 4.91)
Oil pan drain plug 29.4 - 39.2 (3.0 - 4.0)
Spark plug 19.6 - 29.9 (2.0 - 3.0)
CYLINDER HEAD
location of the tightening torque (5) as shown in the figure.
Apply antirust oil or engine oil to the threads and head bottom of
each head bolt.
MAM0142
ET-3
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
No or slow cranking • Inappropriate engine oil grade Replace oil with a proper one.
• Battery is discharged Charge battery.
• Battery damage Replace battery.
• Loose fan belt Belt tension adjustment
• Incident in charge system Inspection
• Incident in starter system wiring Repair
• Starter switch malfunction Repair or replace
• Starter motor malfunction Repair or replace
If the light turns off or dims when the starter switch
is turned to "ON" with the headlights on:
a: Inspect the battery
b: Inspect the electric connections and wirings
c: Inspect the starter motor
If the light remains bright when the starter switch is
turned to "ON" with the headlights on:
a: Inspect the wiring between battery and
starter motor
b: Inspect the starter switch
c: Inspect the starter motor
Engine is cranked but not started. Such incidents are attributed to the following
factors, but most likely, the ignition system or the
Refer to EF section for the LPG fuel system is the main cause.
model.
• Incident in ignition system (Diagnosis procedure)
• Incident in fuel system Inspect the spark plug following the steps below
• Dynamic valve system does not operate Disconnect the high-tension cable from the No.1
normally. plug and keep it 10 mm away from the engine
metal portions. Then crank the engine.
• Poor compression
a. Inspect the ignition plugs.
b. Inspect the ignition timing
c. Inspect the fuel system
d. Inspect the compression pressure.
a. Inspect the primary coil current
b. If the current level is high, check the primary
coil for short circuit
ET-4
TROUBLE DIAGNOSIS
Application
Condition Possible causes Action Electronic Carburetor
Common controlled specifications
specifications
Incident in ignition system • Malfunction of low-voltage Replace √

electronic distribution ignition
coil
• Condenser malfunction Replace √
• Electric leakage from rotor Clean or replace √
cap and rotor
• Spark plug malfunction Clean, adjust gap or replace √
• Inappropriate ignition timing Adjustment √
• Ignition coil malfunction Replace √
• Open circuit in high-tension Replace √
cable
• Loose or open primary wire Repair or replace √
connection
Incident in fuel system • Insufficient fuel Fill √
Refer to EF section for the
• Contaminated fuel filter Replacement √
LPG model.
• Plugged or contaminated fuel Washing √
piping
• Plugged or contaminated fuel Clean or replace √
injector
• Fuel pump malfunction Repair or replace √
• Carburetor choke malfunction Inspect and adjust √
• Inappropriate carburetor float Correct √
level
• Inappropriate idling Adjustment √
Lowered compression • Poor tightening of spark plug Tighten to correct torque or √
pressure or inappropriate gasket replace
• Inappropriate engine oil grade Replace with appropriate grade of √
or deteriorated viscosity oil
• Inappropriate valve clearance Adjustment √
• Compression pressure Remove head and perform fine √
leakage from valve seat grinding to valve
• Stuck valve stem Repair or replace cylinder head √
and valve.
• Broken or chip valve spring Replace valve spring. √
• Compression pressure Replace head gasket. √
leakage from head gasket
• Worn or stuck piston ring Replace piston ring. √
• Worn piston ring or cylinder Engine overhaul (Diagnosis √
procedure)
a. Put a small amount of engine
oil from the ignition plug hole
and measure the
compression pressure.
b. If the pressure builds up, a
possible cause is in the
cylinder or piston ring.
c. If the pressure remains
unchanged, the leakage can
be attributed to the valve,
cylinder head or head gasket.
ET-5
TROUBLE DIAGNOSIS
Inappropriate idling
Incident in fuel system • Plugged or damaged carburetor jet Clean or replace
• Damaged or plugged fuel injector Clean or replace
• Inappropriate idle adjustment Adjustment
• Plugged air cleaner Replace element
• Damaged manifold gasket or carburetor Replace gasket or insulator.
insulator
• Inappropriate carburetor float level Adjustment
adjustment
Lowered compression pressure Already described
Engine power does not increase to an Adjustment
appropriate level
Lowered compression pressure Already described

Incident in ignition system • Inappropriate ignition timing Adjustment
• Spark plug malfunction Clean, adjust or replace.
Incident in fuel system • Malfunction of carburetor choke system Adjustment
• Plugged fuel piping Clean
Refer to chapter EF section for the LPG model.
• Plugged or contaminated fuel filter Replacement
• Fuel pump malfunction Repair or replace
• Plugged carburetor jet or needle valve Disassemble and clean.
• Poor throttle valve opening Adjustment
• Fuel pump malfunction Adjustment
Incident in intake system • Plugged air cleaner Replace element
• Air leakage from electronic throttle Replace insulator.
insulator
• Air leakage from manifold gasket or Replace gasket or insulator.
carburetor insulator
Engine over temperature (Overheat) • Insufficient amount of coolant Fill coolant.
• Loose fan belt. Belt tension adjustment
• Worn or loose fan belt Replacement
• Malfunctioning thermostat Replacement
• Water pump malfunction Replacement
• Plugged or leaking radiator Wash, repair, or replace
• Radiator cap damage Replacement
• Air in cooling system piping Retighten cooling system piping, bleed
system.
• Improper engine oil grade Replace with appropriate grade of engine oil.
• Inappropriate ignition timing Adjust.
• Carburetor malfunction (too lean air-fuel Overhaul carburetor
mixture)
Overcool Malfunctioning thermostat Replacement
Other • Inappropriate octane rating of fuel Replace with specified octane rating of fuel.
• Insufficient tire air pressure Charge to specified air pressure.
• Brake dragging Adjustment
• Clutch slippage Adjustment
ET-6
TROUBLE DIAGNOSIS
Engine noise
Knocking • Engine overload Operation with light load
• Knocking due to carbon deposits Remove cylinder head and eliminate carbon
deposits
• Knocking due to inappropriate ignition Adjust ignition timing
timing
• Knocking due to inappropriate octane Use specified octane rating of fuel.
rating of fuel
• Too advance ignition (Inappropriate spark Use specified type of spark plug.
plug selection)
Mechanical slapping
Crankshaft bearing slapping • Strong and heavy noise from engine A possible cause is in damage/wear of
during acceleration bearing or uneven wear of crankshaft.
• To identify the noise generation point, Need to replace bearing and adjust or
attempt to cause misfires at each replace crankshaft.
cylinder.
• If misfires at a particular cylinder stop the
noise, that cylinder is the noise source.
Connecting rod bearing slapping • This noise is also generated during Take the same action as that for crankshaft
engine acceleration but at a little more bearing.
rapid pitch than crank slapping.
• To identify the noise generation point,
attempt to cause misfires at each
cylinder.
• If misfires at a particular cylinder almost
stop the noises, that cylinder is the noise
source.
Piston and cylinder slapping • Mechanical rapping noise, which This noise is caused by excessive wear of
increases according the engine speed cylinders and accompanied by engine power
but decreases as the engine is warmed deterioration and excessive oil consumption.
up, is attributed to the pistons and
cylinders.
• To identify the noise generation point, For a corrective action, engine overhaul is
attempt to cause misfires at each needed
cylinder.
Piston pin slapping • This noise is generated at piston TDC A possible cause is wear of the piston pin
and BDC positions. hole or piston pin.
• To identify the noise generation point, Need to replace piston and piston pin
attempt to cause misfires at each assembly.
cylinder.
Water pump noise • This noise is generated from worn or Replace water pump.
damaged bearing(s) due to the uneven
sliding faces.
Excessive oil consumption
Oil leakage • Worn piston ring groove(s) and ring(s) Replace piston(s) and piston ring(s).
• Deteriorated valve oil seal lip(s) Replace valve oil seal(s).
• Worn valve stem(s) Replace valve(s).
Other • Use of inappropriate quality of oil Use specified oil.
• Engine overheat Already described
Inappropriate fuel consumption
Refer to description of engine power • Excessive idling speed Adjust to specified level
deterioration.
• Insufficient throttle return Adjustment
Other
Refer to EF section for the LPG model. • Fuel leakage Repair fuel piping and additionally tighten
connections.
ET-7
TROUBLE DIAGNOSIS
Incident due to other factors

Low oil pressure • Use of inappropriate quality of oil Replace specified oil.
• Engine over temperature (Overheat) Already described
• Oil pump regulator valve malfunction Overhaul or replace oil pump
• Oil pump malfunction Overhaul or replace oil pump
• Oil filter malfunction Replace with a new one.
• Enlarged clearance of each sliding Disassemble and replace relevant sliding
component component(s).
• Clogged oil strainer Washing
• Malfunction of oil pressure gauge Replace with a new one.
pressure switch
Excessive wear of sliding part(s) • Low oil pressure Already described
• Poor quality of oil or foreign objects in oil Replace oil element and oil with appropriate
ones.
• Poor performance of air cleaner Inspect element
• Overheat or excessive cooling Already described
• Inappropriate air-fuel ratio Inspect fuel system
Bite of sliding parts • Low oil pressure Already described
• Insufficient clearance Adjust clearance to specified value.
• Inappropriate air-fuel ratio Inspect fuel system
ET-8
ENGINE INSPECTION AND ADJUSTMENT
ENGINE INSPECTION AND ADJUSTMENT Engine Body Related

RETIGHTEN CYLINDER HEAD BOLTS
Retighten the bolts in the order shown in the figure on the left while
the engine is cold.
Tightening torque for cylinder head bolt:
68.6 N·m (7.0 kgf-m)
RETIGHTEN MANIFOLD NUTS.

To prevent leakage from intake and exhaust lines
Retighten the intake/exhaust manifold nuts.
Tightening torque for manifold nut:
41.2 - 48.1 N·m (4.2 - 4.91 kgf-m)
ETM0050 (1 month or 200 operating hours)
ADJUSTING VALVE CLEARANCE

Perform adjustment while engine is hot and in standstill.
1. Start the engine and fully warm it up. Then stop the engine.
2. Remove the rocker cover.
3. Turn the crankshaft.
(1) Set the piston for the No.1 cylinder to the compression TDC and
adjust the valve clearance for (1)(2)(3)(5) in step (1) of the figure
on the left.
(2) Set the piston for the No.4 cylinder to the compression TDC and
adjust the valve clearance for (4)(6)(7)(8) in step (2) of the figure
on the left.
MAM0143
ADJUST VALVE CLEARANCE WHEN ENGINE IS HOT

Intake and exhaust : 0.38 mm (0.381 mm)
SMA100
ET-9
Engine Body Related (Cont’d)

INSPECT AND ADJUST ACCESSORY BELT
1. Visually check for cracks, wear, and oil smears.
(The belt must not contact with the bottom of the belt pulley.)
2. Check the belt deflection by pressing at the center between the
pulleys.
Fan belt deflection: 11 - 13 mm
Force: 98N (10 kgf)
ETM0046
REPLACE OIL AND OIL FILTER

1. Start the engine and fully warm it up. Then stop the engine.
2. Remove the oil filler cap and the oil pan drain plug, and
discharge all oil.
3. After discharging oil, install the drain plug with the washer.
CAUTION:
• Be careful not to get burned when engine or engine oil is
heated.
• If the oil looks milky, it is contaminated with coolant.
• If the viscosity is lower than specified, the oil is mixed with
gasoline.
Tightening torque for oil pan drain plug:
29.4 - 39.2 N·m (3.0 - 4.0 kgf-m)
4. Remove the oil filter using an oil filter wrench (SST).
5. Clean the oil filter mounting face with a clean shop cloth.
MAM0144
6. Apply a small amount of engine oil to the lip of the new oil filter.
7. Screw in the oil filter by hand until it contacts bracket surface,
and then screw in another 2/3 of a turn.
MAM0145
ET-10

8. Fill the engine with oil of the recommended specifications and
check the oil level with the oil level gauge.
Engine oil amount Unit: liter (US qt, lmp qt)

With oil filter 3.7 (4, 3-3/8)
Without oil filter 3.4 (3-3/4, 3-1/8)
CAUTION:
Verify that the oil pressure warning lamp lights up before the
SMA890 engine starts and turns off after the engine has started.
9. Start the engine and check the area around the drain plug and
oil filter for any leaks. If any leaks are found, the relevant part is
not installed properly.
10. Warm up the engine sufficiently. Stop the engine and wait for a
few minutes. Check the oil level and fill oil as necessary.
CAUTION:
When checking the oil level, ensure that the engine is level.
ETM0051
CHANGING ENGINE COOLANT
WARNING:
Do not drain coolant when engine is still hot. It may be a cause
to get burned.
CAUTION:
Before mixing antifreeze with water, carefully read the
instructions printed on the antifreeze package.
From the cylinder block plug if the engine is dismounted.
CLEAN RADIATOR OUTER FACE

Apply compressed air to the outer face of the radiator.
CHECK COOLANT HOSES AND CONNECTIONS

Check the hose connections for looseness and deterioration and
retighten or replace the hose clamps as necessary.
ET-11

COMPRESSION PRESSURE INSPECTION
1. Warm up the engine sufficiently and then stop it.
Release the fuel pressure. (Electronic controlled specifications)
2. Remove the spark plug.
3. Apply a compression gauge correctly to the cylinder plug hole to
be measured.
4. Set the throttle valve to the fully-open position. Depress the
throttle pedal to the fully-open position.
5. Crank the engine and read the gauge.
(The same operations can be used for both the carburetor and
electronic control models)
• Keep the engine speed at approximately 250 rpm.
• Finish the pressure measurement in as short a time as
possible.
SMA042
Standard compression pressure
K15 1.27 kPa
13.0kgf/cm2
250 rpm
K21 1.23 kPa
12.5 kgf/cm2
250 rpm
K25 1.27 kPa
13.0kgf/cm2
250 rpm
6. The compression pressure differences between cylinders must

not exceed 1 kgf/cm2/250 rpm. If any cylinder shows an
extremely low compression pressure, put a small amount of oil
into the cylinder through the spark plug hole and remeasure the
pressure.
• If the pressure rises after filling oil, the piston ring is worn or
damaged.
• If the pressure remains unchanged even after filling oil, the
valve is stuck or inappropriately seated.
• If low compression pressure is observed in two adjacent
cylinders and the pressure is not restored even after filling
oil, the head gasket is leaking. In this case, oil and water
may enter in the combustion chamber.
• If the engine RPM is not in the specified range: Measure
the battery specific gravity.
ET-12
Ignition and Fuel Systems

CLEANING OR REPLACEMENT OF AIR CLEANER ELEMENT
Dry filter type
It requires periodical cleaning and replacement. If the engine is used
in a heavily contaminated environment, perform maintenance more
frequently.
FET050
FUEL FILTER
Cleaning and replacement (carburetor model only)
Periodically inspect, clean and replace the fuel filter.
Fuel piping inspection
(Hoses, tubes, fittings)
Check the fuel piping for proper installation as well as leakage,
cracks, and loose connections and replace damaged or
malfunctioning parts as necessary.
MAM0180J
CARBURETOR INSPECTION
ETM0052
Inspecting link mechanism and valves

• Remove the air horn and visually inspect the link system and
internal components.
• Check the throttle shaft for wear by attempting to move it by
hand. The throttle shaft must not move.
• Check the throttle valve and choke valve for proper operation.
(Open, close)
ET-13
Ignition and Fuel Systems (Cont’d)

CARBURETOR MAINTENANCE
• If contaminated heavily, disassemble and clean the carburetor.
• If the link mechanism is excessively worn or damaged, replace
it.
• If the throttle valve shaft is excessively worn or bent, replace it.
FICD (fast idle control device) inspection (carburetor model
only)
1. Start and warm up the engine sufficiently.
2. Check that the hot water heater is heated.
3. Check that FICD does not contact with the carburetor throttle
lever.
4. Adjust the idle speed by using the throttle adjusting screw and
idle adjusting screw.
Idle speed: 700 rpm
ETM0053
5. Adjust the ignition timing for idling.

Ignition timing: BTDC
• K15: 0°
• K21: 2°
• K25: 0°
6. Remove the vacuum piping from FICD and plug the pipe
openings to prevent air leakage.
7. In this state, the FICD pushrod is pushing the carburetor throttle
lever.
Adjust the engine speed to 1,200 to 1,500 rpm with the throttle
ETM0054 lever adjusting screw.
8. After adjustment, connect the vacuum piping and verify that an
appropriate engine idle speed is obtained.
SPARK PLUG INSPECTION AND REPLACEMENT

1. Inspection
• Visually check electrode for dirt and damage and insulator for
burning.
• Check if the electrode gap is within the standard using a plug
gap gauge.
Standard (mm): 0.9
• Adjust if outside the standard.
• Replace if necessary.
2. Installation
ETM0055 • Install in the reverse order of removal.
Tightening torque (N·m (kgf-m)): 19.6 - 29.4 (2.0 - 3.0)
ET-14

DISTRIBUTOR INSPECTION (CARBURETOR MODEL ONLY)
Ignition coil inspection
• Measure resistance terminals (1) and (2) of the primary coil and
those of the secondary coil using a circuit tester.
Primary coil resistance: 0.9 - 1.2Ω
Secondary coil resistance: 20 - 29Ω
ETM0056
Pickup coil inspection

• Measure the pickup coil resistance using a circuit tester.
Resistance: 420 - 540Ω
FET068
• Move a screwdriver to and fro near the iron core of the pickup
coil and make sure that the tester needle fluctuates.
FET069
INSPECTION OF DISTRIBUTOR CAP AND CARBON

TERMINALS
• If the hemisphere face of a terminal is worn out, replace the cap.
ROTOR HEAD INSPECTION

• Check for cracks and damages.
SIGNAL CORE ROTOR INSPECTION

• Check for bends or damages.
VACUUM CONTROL SYSTEM INSPECTION

• Apply vacuum to the diaphragm with a vacuum pump and check
that the link is drawn.
ET-15

INSPECTION AFTER REASSEMBLING DISTRIBUTOR
Measure the clearance between the signal core rotor and the pickup
coil.
Standard clearance: 0.35 - 0.45 mm
SEL640B
CLEANING INSIDE DISTRIBUTOR

Blow any dust away from inside the distributor with dry compressed
air.
FET051
ENGINE SPEED MEASUREMENT (CARBURETOR MODEL

ONLY)
The ignition coil-integrating distributor of the K engine provides an
adapter harness for engine speed measurement.
1. Remove the distributor connector from the coupling as shown in
the figure on the left.
ETM057
2. Connect the ignition coil adapter harness (SST: EG11140000)

between the distributor connector and the coupling.
Connect the tachometer power supply terminal (red) to the bat-
tery positive terminal and the black terminal to the battery neg-
ative terminal. Connect the measurement terminal (green) to
the measurement wire in the middle of the adapter harness.
ETM058
ET-16

INSPECTION AND ADJUSTMENT OF IGNITION TIMING, IDLE
SPEED, AIR-FUEL RATIO (CARBURETOR MODEL ONLY)
a. In general, the engine requires no idle speed adjustment
because it is adjusted properly before shipment. If the idle
speed must be adjusted in any means, follow the procedure
below.
b. Do not fully tighten the idle adjusting screw. Doing so damages
the screw end and leads to loss of functionality.
ETM0062
ET-17

INSPECTION AND ADJUSTMENT OF AIR-FUEL RATIO (CARBU-
RETOR MODEL ONLY)
ETM0063
GOVERNOR DEVICE
The governor requires no adjustment because it is adjusted properly
before shipment.
If it must be adjusted by any means, follow the procedure below.
ADJUSTING MAXIMUM RPM WITH NO LOAD

1. Set the forward/reverse shift lever to the neutral position.
2. Start the engine and fully open the throttle. Monitor the engine
speed.
Maximum engine speed with no load (rpm)
K15 3,600
K21 3,600
K25 3,600
3. If the engine speed does not fall in the specified range, adjust by
turning the governor adjusting handle.
ETM0059
ET-18

ADJUSTING MAXIMUM RPM WITH LOAD
1. Set the forward/reverse shift lever to the neutral position.
2. Start the engine and fully tilt the mast rearward with the tilt lever.
3. Fully open the throttle and monitor the engine speed.
Maximum engine speed with load (rpm)
K15 3,000
K21 3,000
K25 3,000
4. If the engine speed does not fall in the specified range, adjust by
turning the governor adjusting handle. In addition, adjust the
maximum engine speed with no load.
FICD (FAST IDLE CONTROL DEVICE) INSPECTION

(CARBURETOR MODEL ONLY)
1. Start and warm up the engine sufficiently.
2. Check that FICD does not contact the carburetor throttle lever.
3. Adjust the idle speed by using the throttle adjusting screw and
idle adjusting screw.
Idle speed: 700±50 rpm
4. Adjust the ignition timing for idling.
Ignition timing: BTDC
K15: 0°
ETM0054 K21: 2°
K25: 0°
5. Remove the vacuum piping from FICD and plug the pipe
openings to prevent air leakage.
6. In this state, the FICD pushrod is pushing the carburetor throttle
lever.
Adjust the engine speed to 1,200 to 1,500 rpm with the throttle
lever adjusting screw.
7. After adjustment, connect the vacuum piping and verify that an
appropriate engine idle speed is obtained.
ET-19
SPECIAL SERVICE TOOLS FOR CARBURETOR MODEL
SPECIAL SERVICE TOOLS FOR CARBURETOR MODEL

EG11140000 Ignition coil For checking engine speed

Adapter harness
ETM0060
ET-20
ENGINE MECHANICAL
SECTION EM
CONTENTS
PRECAUTIONS ..................................................EM-2 TIGHTENING TORQUE ....................................EM-11
Precautions for Draining Engine Coolant .......EM-2 Standard Bolt Tightening Torque .................EM-11
EM
Precautions for Disconnecting Fuel Piping .....EM-2 Engine Part Tightening Torque ....................EM-12
Precautions for Removing and TROUBLE DIAGNOSIS ....................................EM-14
Disassembling ................................................EM-2 SPECIAL SERVICE TOOLS .............................EM-16
Precautions for Inspection, Correction, and REMOVAL AND INSTALLATION OF ENGINE EM-17
Replacement ..................................................EM-2 Removal .......................................................EM-17
Precautions for Assembly and Installation .....EM-2 Installation ....................................................EM-18
Parts Requiring Angle Tightening ...................EM-3 Inspection .....................................................EM-18
Caution for Use of Power Tools .....................EM-3 ENGINE SERVICE ............................................EM-19
Precautions for Liquid Gasket Application ......EM-3 Engine Disassembly .....................................EM-19
ENGINE OUTSIDE DRAWINGS .........................EM-4 Inspection and Correction ............................EM-26
MAIN SPECIFICATIONS ....................................EM-5 Engine Assembly ..........................................EM-39
ADJUSTMENT VALUE .......................................EM-8
PRECAUTIONS
PRECAUTIONS Precautions for Draining Engine Coolant

• Drain coolant only after the engine has cooled down.
Precautions for Disconnecting Fuel Piping

• Operation should be done in a place free from fire.
• Release fuel pressure before operation. (Electronic controlled
specifications): Refer to "Release of Fuel Pressure" in EC
section.
• After disconnecting, plug the pipe to prevent fuel from draining.
Precautions for Removing and

Disassembling
• Use correct SSTs in the specified position. Always pay attention
to safety.
• Be careful not to lose surface accuracy of mating or sliding
surfaces.
• To prevent foreign material from entering the engine, close
openings with appropriate tape as necessary.
• Arrange disassembled parts in their normal positions in order to
simplify locating the cause of damage or excessive wear and to
ensure correct reassembly.
• As a rule, nuts and bolts must be tightened in a diagonal
manner starting from an outer one. If a particular tightening
sequence is provided separately, follow the sequence.
Precautions for Inspection, Correction, and

Replacement
• Following the inspection procedure, inspect the parts
adequately and repair or replace as necessary. Perform the
same inspections even for new parts and replace them if
necessary.
Precautions for Assembly and Installation

• Always use a torque wrench when tightening nuts and bolts.
• Unless otherwise specified, tighten bolts and nuts from inside to
outside in a crisscross pattern. Tighten them gradually and
evenly in 2 to 3 steps.
• Always replace gasket, packing, oil seals, and O-rings with new
ones.
• For each part, perform adequate cleaning/washing and drying
with a dryer. In particular, ensure that the oil and coolant
passages are free from plugging and clogging.
• Remove any dirt and lint on sliding and mating surfaces. Before
assembly, apply ample amount of engine oil to sliding surfaces.
• If coolant was drained, bleed air from the system.
• After assembly, start engine and increase the engine speed,
then check coolant, fuel, oil, grease, and exhaust gas for
leakage.
EM-2
PRECAUTIONS
Parts Requiring Angle Tightening

• When tightening the following parts, use an angle wrench
(SST).
• Cylinder head bolt
Before assembly, verify that no grease/oil and dust are present
on the cylinder head, cylinder block mounting face, and head
gasket. Then apply antirust oil or engine oil to the threads and
head bottoms of the head bolts.
Caution for Use of Power Tools

• The use of power tools such as an air runner are only allowed
for disassembly. Do not use them for assembly.
Precautions for Liquid Gasket Application

REMOVING PARTS ATTACHED WITH LIQUID GASKET
• Remove mounting nuts and bolts. Remove liquid gasket using a
seal cutter (SST).
CAUTION:
• Be careful not to damage the mating surfaces.
• In positions where a seal cutter is difficult to use, lightly tap
with a plastic hammer, and remove.
• Be careful not to scratch the mating surfaces when using a
screwdriver.
GIM0061
LIQUID GASKET APPLICATION INSTRUCTION

1. Remove any old liquid gasket remaining on the gasket
application surface and its mating surface using a scraper.
• Remove any old liquid gasket remaining in the gasket
application groove and on the threads of bolts and bolt
holes.
2. Wipe the gasket application surface and its mating surface
using Isozole or any equivalent thinner to remove any moisture,
oil, and foreign material.
3. Set genuine liquid gasket to tube presser (commercial service
GIM0062 tool).
4. Apply a continuous bead of liquid gasket to the specified
position at the specified diameter.
• Apply liquid gasket in the application groove.
• Apply liquid gasket inside bolt holes as a rule. Make sure to
carefully read the relevant instructions.
• Attaching should be done within 5 minutes after gasket
application.
• Immediately wipe off any protruding liquid gasket.
• Do not retighten nuts and bolts after installation.
• After finishing work, wait at least 30 minutes before refilling
GIM0063 engine oil and coolant.
CAUTION:
Follow any directions specified in the text on the following
pages.
EM-3
GIM0075
EM-4
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS
Engine type K15

Valve mechanism OHV
Bore x stroke (mm) 75.5 x 83
Compression ratio 9.0
Compression pressure [MPa (kgf/cm 2)/rpm] 1.3 (13.0)/250
Engine speed control system Engine Control System, Pneumatic governor

electronically controlled throttle
Fuel in use (Note 1) Unleaded At 20P See the left Unleaded At 20P
regular gasoline column regular gasoline
Maximum output [kW (PS)/rpm] 27.2 (37)/2600 26.2 (35.6)/2600 See the left 24.9 (33.8)/2600 22.9 (31.2)/2600
column
Maximum torque [N·m (kgf-m)/rpm] 104.9 (10.7)/ 101.0 (10.3)/ See the left 100.0 (10.2)/ 95.1 (9.7)/1600
1600 1600 column 1600
Valve opening/closing Intake open (BTDC) 14
timing (degree) Intake close (ABDC) 30
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
is hot)
Exhaust (when 0.38
engine is hot)
Ignition timing (idling) (BTDC°) 0
(rpm)
MTM 700 700
speed (rpm) MTM 2,800 2,900
Engine oil Specification 10W-30 (Class SL)
(When shipped)
Amount (L) 3.8
(Note 2) (mm)
Engine weight (w/o coolant, w/ oil) (Note 2) (kg) 138
Note 1: Fuel
Note 2: The engine dimensions and weight differ with the customer
specifications. The above data should be deemed as
reference.
EM-5
MAIN SPECIFICATIONS
Engine type K21

Valve mechanism OHV
Compression pressure [MPa (kgf/cm 2)/rpm] 1.2 (12.5)/250 1.3 (13.0)/250 1.2 (12.5)/250 1.2 (12.5)/250

Maximum output [kW (PS)/rpm] 38.2 (51.9)/ 39.5 (53.7)/ See the left 34.2 (46.5)/ 33.1 (45.0)/
2,600 2,600 column 2,600 2,600
1,600 1,600 column 1,600 1,600
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
is hot)
Exhaust (when 0.38
engine is hot)
Ignition timing (idling) (BTDC°) 0 2
(rpm)
MTM 700 700
speed (rpm) MTM 2,700 (Only for 2,750 MHI vehicles)
(When shipped)
Amount (L) 3.8
(Note 2) (mm)
Note 1: Fuel
reference.
EM-6
MAIN SPECIFICATIONS
Engine type K25

Valve mechanism OHV
Compression pressure [MPa (kgf/cm 2)/rpm] 1.2 (12.5)/250 1.3 (13.0)/250 1.2 (12.5)/250 1.2 (12.5)/250

Maximum output [kW (PS)/rpm] 41.4 (56.3)/ 44.0 (59.9)/ See the left 38.5 (52.3)/ 36.2 (49.3)/
2,400 2,400 column 2,400 2,400
1,600 1,600 column 1,600 1,600
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
is hot)
Exhaust (when 0.38
engine is hot)
Ignition timing (idling) (BTDC°) 0 2
(rpm)
MTM 700 700
speed (rpm) MTM 2,700 (Only for 2,750 MHI vehicles)
(When shipped)
Amount (L) 3.8
(Note 2) (mm)
Note 1: Fuel
reference.
EM-7
ADJUSTMENT VALUE
ADJUSTMENT VALUE VALVE MECHANISM

Standard Intake 0.38
Exhaust 0.38
VALVE
Exhaust 32.0 - 32.3
• Valve total length
Intake mm (in) 98.85 - 99.45
(3.892 - 3.915)
Exhaust mm (in) 98.95 - 99.55
(3.896 - 3.919)
Exhaust 6.945 - 6.960
• Valve spring free length
Intake and exhaust mm (in) 45.9 (1.807)
Valve-opening compressed length
Intake and exhaust mm/N (mm/kgf, in/lb) 25.0/347.0 - 391.2
(25.0/35.4 - 39.9, 0.984/78.1 - 88.0)
Valve spring installation length (when closed)
Intake and exhaust mm/N (mm/kgf, in/lb) 33.8/177.9 to 200.7
(33.8/18.1 - 20.5, 1.331/40.0 - 45.1)
Valve spring slant
Intake and exhaust mm (in) 1.5 (0.059)
• Clearance between valve stem and valve guide (mm)
Exhaust 0.040 - 0.073
Exhaust 0.10
Valve seat width
Intake mm (in) 1.3 - 1.5 (0.051 - 0.059)
Exhaust mm (in) 1.6 - 1.8 (0.063 - 0.071)
Valve seat angle
Intake and exhaust. 45°
Valve face angle
Intake and exhaust. 45°30'
CAMSHAFT
• Bend (mm)
Repair limit 0.05
• End play (mm)
Repair limit 0.40
• Journal dimensions (mm)
Center 43.897 - 43.910
Rear 41.218 - 41.231
• Oil clearance at journal (mm)
Center 0.038 - 0.064
Rear 0.025 - 0.051
Center 0.15
Rear 0.10
EM-8
ADJUSTMENT VALUE

CRANKSHAFT
• Bend (mm)
Repair limit 0.05
• End play (mm)
Repair limit 0.20
• Journal dimensions (mm)
Standard 62.942 - 62.955
Standard 44.961 - 44.974 (K15, K21, K25)
• Oil clearance at journal (mm)
Standard 0.020 - 0.062
Repair limit 0.10
FLATNESS OF FLYWHEEL AND DRIVE PLATE

• Flatness of flywheel (mm)
Repair limit 0.10
• Runout of drive plate (mm)
Repair limit 0.20
• Flatness of ring gear (mm)
Repair limit 0.50
• Flatness (mm)
Repair limit 0.30
CONNECTING ROD
• Center distance between both end holes (mm)
Standard 143.970 - 144.030 (K25) 152.47 - 152.53 (K15, K21)
Standard 48.0 - 48.013 (K15, K21, K25)
Standard 19.965 - 19.978 (K15, K21, K25)
Repair limit 0.05
• Twist (per 100 mm) (mm)
Repair limit 0.05
• Large end thrust clearance
Standard 0.2 - 0.3
Repair limit 0.40
Standard 0.030 - 0.066 (K15, K21, K25)
Repair limit 0.10
• Weight difference (piston combination) (g)
Standard 5 or less
PISTON
• Piston (mm)
Outer diameter
Standard 75.465 - 75.515 (K15)
88.965 - 89.015 (K21, K25)
• Clearance to cylinder (mm)
Standard 0.025 - 0.045
EM-9
ADJUSTMENT VALUE

Standard 19.993 - 19.998 (K15, K21, K25)
• Piston ring closed gap (mm)
Second 0.45 - 0.60
Oil 0.20 - 0.60
• Clearance between piston ring and ring groove (mm)
Second 0.03 - 0.07
Oil 0.65 - 0.135
Second 0.10
Oil —
Pin outer diameter (mm)
19.993 - 19.998 (K15, K21, K25)
CYLINDER HEAD
Valve guide (mm)
Standard 7.000 - 7.018 (for both intake and exhaust)
Valve stem-to-valve guide clearance (mm)
Repair limit 0.10 (for both intake and exhaust)
CYLINDER BLOCK
Cylinder bore inner diameter mm (in)
Standard 75.5 - 75.55 (2.9724 - 2.9744) (K15)
89.00 - 89.05 (3.5089 - 3.5059) (K21, K25)
Wear limit 0.2 (0.0079)
Cylinder bore taper and out-of-round mm (in)
0.2 (0.0008)
Top face distortion limit mm (in)
0.05 (0.0020)
Distortion limit (mm)
Intake manifold 0.1
Exhaust manifold 0.3
Cylinder head 0.1
Cylinder block 0.1
EM-10
TIGHTENING TORQUE
TIGHTENING TORQUE Standard Bolt Tightening Torque

Lower: No lubrication (Threads and seating faces are completely
degreased)
Thread size
Diameter Pitch
N•m - 4.41
3.82 6.37 - 7.45 9.22 - 10.8
(kgf-m) (0.39 - 0.45) (0.65 - 0.76) (0.94 - 1.1)
M6 1
N•m 5.00 - 6.47 8.43 - 10.8 11.8 - 15.7
(kgf-m) (0.51 - 0.66) (0.86 - 1.1) (1.2 - 1.6)
N•m 9.32 - 10.8 15.7 - 17.7 22.6 - 25.5

(kgf-m) (0.95 - 1.1) (1.6 - 1.8) (2.3 - 2.6)
M8 1.25
N•m 12.7 - 15.7 20.6 - 26.5 29.4 - 37.3
(kgf-m) (1.3 - 1.6) (2.1 - 2.7) (3.0 - 3.8)
N•m 19.6 - 22.6 32.4 - 38.2 47.1 - 53.9
(kgf-m) (2.0 - 2.3) (3.3 - 3.9) (4.8 - 5.5)
1.25
N•m 25.5 - 33.3 43.1 - 54.9 61.8 - 78.5
(kgf-m) (2.6 - 3.4) (4.4 - 5.6) (6.3 - 8.0)
M10
N•m 18.6 - 21.6 30.4 - 36.3 44.1 - 52
(kgf-m) (1.9 - 2.2) (3.1 - 3.7) (4.5 - 5.3)
1.5
N•m 24.5 - 31.4 41.2 - 52 58.8 - 74.5
(kgf-m) (2.5 - 3.2) (4.2 - 5.3) (6.0 - 7.6)
N•m 4.9 - 5.69 8.14 - 9.51 11.8 - 13.7
(kgf-m) (0.5 - 0.58) (0.83 - 0.97) (1.2 - 1.4)
M6 1
N•m 5.98 - 7.65 9.81 - 12.7 14.7 - 18.6
(kgf-m) (0.61 - 0.78) (1.0 - 1.3) (1.5 - 1.9)
N•m 11.8 - 13.7 19.6 - 23.5 28.4 - 33.3
(kgf-m) (1.2 - 1.4) (2.0 - 2.4) (2.9 - 3.4)
M8 1.25
N•m 14.7 - 18.6 24.5 - 31.4 35.3 - 45.1
Flanged bolt
(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)

N•m 24.5 - 29.4 41.2 - 48.1 59.8 - 69.6
(kgf-m) (2.5 - 3.0) (4.2 - 4.9) (6.1 - 7.1)
1.25
N•m 30.4 - 39.2 51.0 - 64.7 73.6 - 93.2
(kgf-m) (3.1 - 4.0) (5.2 - 6.6) (7.5 - 9.5)
M10
N•m 23.5 - 27.5 39.2 - 46.1 56.9 - 65.7
(kgf-m) (2.4 - 2.8) (4.0 - 4.7) (5.8 - 6.7)
1.5
N•m 29.4 - 37.3 49.0 - 61.8 69.6 - 89.2
(kgf-m) (3.0 - 3.8) (5.0 - 6.3) (7.1 - 9.1)
CAUTION:
• Except special nuts and bolts.
• The bolts applicable to this table have one of the following
marks embossed on their heads.
4T......4
7T......7
9T......9
TAPER SCREW TIGHTENING TORQUE

Allowable materials
for tightening
Aluminum Cast iron
Unit
Normal size Standard Max. value Standard Max. value
R1/8 N•m 7.8 11.8 15.7 21.6
(kgf-m) 0.796 1.2 1.6 2.2
R1/4 N•m 19.6 29.4 34.3 44.1
(kgf-m) 2.0 3.0 3.5 4.5
R3/8 N•m 39.2 54.9 53.9 73.5
(kgf-m) 4.0 5.6 5.5 7.5
EM-11
TIGHTENING TORQUE
Engine Part Tightening Torque

TIGHTENING TORQUE AT VARIOUS POINTS OF ENGINE
Cylinder head (lubricated) Separately given

Main bearing cap (lubricated) Separately given
N•m 220.5 240.1
Crankshaft pulley bolt (lubricated)
(kgf-m) 22.5 24.5
N•m 132 142
Flywheel bolt (lubricated)
(kgf-m) 13.47 14.49
N•m 31.4 37.3
Connecting rod nut (lubricated)
(kgf-m) 3.2 3.81
N•m 44.1 58.8
Rear plate bolt
(kgf-m) 4.5 6.0
N•m 39.2 49
Camshaft sprocket bolt
(kgf-m) 4.0 5.0
N•m 29.4 39.2
Oil filter stud
(kgf-m) 3.0 4.0
N•m 14.7 20.6
Oil filter element
(kgf-m) 1.5 2.1
N•m 19.6 29.4
Spark plug
(kgf-m) 2.0 3.0
N•m 22.6 25.5
Engine slinger bolt
(kgf-m) 2.31 2.6
N•m 13.7 15.7
Rocker cover nut
(kgf-m) 1.4 1.6
N•m 15.7 19.6
Water temperature gauge
(kgf-m) 1.6 2.0
N•m 15.7 21.6
Oil pressure switch
(kgf-m) 1.6 2.2
N•m 41.2 48.1
Exhaust manifold nut
(kgf-m) 4.2 4.91
N•m 44.1 58.9
Straight screw plug (For head top face)
(kgf-m) 4.5 5.5
N•m 29.4 39.2
Oil pan drain plug
(kgf-m) 3.0 4.0
N•m 1.27 1.67
Mass air flow sensor mounting screw
(kgf-m) 0.13 0.17
N•m 16.0 23.0
Fuel tube flare nut
(kgf-m) 1.63 2.35
N•m 6.37 7.45
Crankshaft position sensor plug bolt
(kgf-m) 0.65 0.76
N•m 6.37 7.45
Thermo-housing relief plug
(kgf-m) 0.65 0.76
EM-12
TIGHTENING TORQUE
CYLINDER HEAD
place of the tightening torque (5) as shown in the figure.
MAM0142
MAIN BEARING CAP

: 83.4 - 93.2 N•m (8.51 - 9.51kgf-m)
• Apply antirust oil or engine oil to the bolt threads and head
bottom.
• Do not use any power tools such as an air runner for assembly.
GIM0064
EM-13
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
1. Engine noise
Slapping noise of bearing and crankshaft Bearing looseness Replace.
Crankshaft bend Repair or replace.
Uneven wear of journal Correct.
Excessive end play Replace center bearing.
Slapping noise of piston, connecting rod Bearing looseness Replace.
Piston looseness Replace piston pin(s) or bushing(s).
Piston looseness relative to cylinder Reselect.
Poor rod alignment Realign.
Slapping noise of camshaft Bearing looseness Replace.
Excessive axial looseness Replace bearing thrust plate(s).
Rough gear tooth face(s) Correct.
Gear damage Replace.
Timing chain noise Inappropriate tension Adjust.
Damaged or sagged chain Replace.
Worn sprocket Replace.
Damaged or loose tensioner Replace.
Excessive camshaft-to-bearing clearance Replace.
Slapping noise of valve gear Inappropriate valve clearance Adjust.
Loose adjustment screw(s) Replace.
Worn rocker face(s) Replace.
Worn valve guide(s) Replace guide(s).
Loose valve spring(s) Replace.
Valve seizure Repair or replace.
Slapping noise of water pump Inappropriate end play Replace.
Damaged impeller Replace.
2. Other mechanical damage
Stuck valve Inappropriate clearance Adjust.
Valve stem - insufficient guide-to-guide clearance Clean stem(s), ream guide(s).
Loose or damaged spring Replace.
Seized or damaged valve stem(s) Replace or clean.
Poor fuel quality Use good fuel.
Burnt valve seat(s) Inappropriate valve clearance Adjust.
Deteriorated valve spring(s) Replace.
Edged valve end(s) Replace Bulb.
Too narrow valve seat width Correct valve seat(s).
Stuck valve guide(s) Correct.
EM-14
TROUBLE DIAGNOSIS
Excessive wear of cylinder piston(s) Insufficient engine oil Refill or replace oil.
Contaminated engine oil Clean crankcase, replace oil filter.
Poor quality oil Use specified oil.
Wrong combination of piston and connecting rod Repair or replace.
Inappropriate clearance of piston ring Reselect and adjust.
Damaged air cleaner Wash.
Too rich air-fuel mixture Adjust.
Stuck choke valve Clean and adjust.
Excessive use of choke valve Start engine properly.
Poor functioning of connecting rod(s) Insufficient engine oil Fill oil.
Low oil pressure Repair.
Rough crankshaft surface(s) Grind surface(s), replace bearing(s).
Plugged oil passage Clean.
Bearing looseness Replace.
Poor connecting rod alignment Repair or replace.
Poor functioning of crankshaft bearing(s) Insufficient engine oil Fill or replace oil.
Low oil pressure Correct.
Uneven wear of crankshaft journal(s) Repair
Plugged oil passage of crankshaft Wash.
Damaged bearing(s) Replace.
EM-15

ST05240001 Engine attachment
GIM0066
ST0501S000 Engine stand assembly

(1) ST05011000 Engine stand
(2) ST05012000 Stand
GIM0067
KV101041S0 Crankshaft main bearing

(1) KV10104110 Crankshaft main bearing cap puller
(2) ST16512001 Ring puller
Adapter
GIM0068
ST12070000 Valve lifter
GIM0069
ST1102S000 Valve guide reamer set

Valve guide reamer 7.00 mm
GIM0070
ST1524S000 Front oil seal drift

KV10105500 Rear oil seal drift
ST15243000 Drift rod
GIM0071
EM-16
REMOVAL AND INSTALLATION OF ENGINE
REMOVAL AND INSTALLATION OF ENGINE CAUTION:

• Always pay attention to safety.
• Do not remove engine until exhaust system and engine
coolant have completely cooled off.
• Support the vehicle at the specified lift points.
• For operation procedure for components other than
engine, refer to appropriate sections.
Removal
[OPERATION DESCRIPTION]
• Remove engine by pulling up after removing transmission.
[PREPARATION WORK]
1. Release the fuel pressure. Refer to "Release of Fuel Pressure"
in EC section.
2. Remove radiator drain plug and drain engine coolant.
3. Remove the following parts.
• Undercover of battery
• Radiator, shroud, and radiator hose
• Engine drive belt and cooling fan
4. Disconnect accelerator cable from throttle drum and move it out
of position.
[LEFT SIDE OF ENGINE ROOM]

5. Remove air duct and air cleaner case.
6. Disconnect heated oxygen sensor harness connector and
ground (between exhaust manifold cover and body).
[RIGHT SIDE OF ENGINE ROOM]

7. Disconnect vacuum hose (for brake booster and for differential
lock) on engine side.
8. Remove fuel hose.
CAUTION:
After disconnecting hoses, plug them immediately to prevent
fuel from draining.
9. Disconnect all harness connectors on engine side, and then
move harnesses to body side.
10. Remove starter motor.
11. Remove transmission.
[REMOVAL]
12. Engage chain block hook in front/rear engine slingers and
support.
CAUTION:
Be careful not to contact hook and chain with body and piping
when engaging hook in slingers
13. Remove engine mount insulator LH/RH nuts.
14. Pull up and remove engine by adjusting the position diligently.
CAUTION:
• Make sure that all wires and piping were disconnected
while removing.
• Be careful not to contact with body side parts.
EM-17
REMOVAL AND INSTALLATION OF ENGINE
Installation
Note the following, and install in the reverse order of removal.
• Do not allow oil to get on the engine mount insulator. Be careful
not to damage the engine mount insulator.
• Securely insert positioning stopper pin into mating side hole.
• Make sure all mount insulators are seated properly, then tighten
mount nuts and bolts.
Inspection
• Before starting engine, check amount of engine coolant, oil and
grease. Refill as necessary.
• Start engine and check for any unusual noise and vibration.
• Warm up engine, and then check engine coolant, oil and
grease, fuel, and exhaust gas for leakage.
EM-18
ENGINE SERVICE
ENGINE SERVICE Engine Disassembly

Always use appropriate tools and ensure that no parts are damaged.
The following tasks can be performed more easily by using the
relevant engine attachment (SST) and engine stand (SST).
1. Preparation for engine disassembly
• Drain coolant and engine oil.
2. Installation of engine attachment
Remove the following parts from the cylinder block and install
the engine attachment (SST).
• Oil filter
• Engine mount bracket (RH)
• Fuel tube (and fuel pump for carburetor model)
• Oil pressure switch
• Release the alternator adjusting lever and remove the
alternator.
• Using some of the existing holes on the engine attachment
EMM0312 (SST), retain the attachment with the mounting bracket
bolts at four points at least.
EMM0313
3. Removal of exterior and electrical parts
Set the engine to the engine stand (SST) and remove the fol-
lowing parts.
• Ignition system wiring (or high-tension cords for carburetor
model)
• Ignition coil unit (or distributor for carburetor model)
• Spark plug
• Oil level gauge
• Cooling fan and pulley
• Starter motor
• Clutch and flywheel
• Rear plate
• Rocker cover
• Crankshaft pulley
• Remove the injector unit (for LPG, gasoline)
• Remove the electric throttle control unit (or carburetor for
carburetor model)
• Remove the oil pump and drive shaft (for carburetor type,
also remove the distributor).
EM-19
ENGINE SERVICE
Engine Disassembly (Cont’d)

4. Removal of manifold
• Remove the manifold and head retaining bolts.
• Remove the intake and exhaust manifold assembly.
FEM002
EMM0314
DISASSEMBLY OF INTAKE MANIFOLD
The figure below illustrates Step 3 and Step 4 in the previous page.
Remove in the order of (1), (2), (3), (4) and (5).
Assemble in the reverse order of disassembly. (Always use new
gaskets.)
Electronic control system component view
EMM0315
EM-20
ENGINE SERVICE

5. Removal of rocker cover and gasket
• Remove the rocker cover retaining nuts.
• Remove rocker cover.
EMM0316
6. Removal of rocker shaft assembly

• Loosen the eight valve rocker adjusting nuts and screws to
remove the valve rocker shaft.
• Pull off the push rod.
• Make sure to remove the push rod and other parts by
cylinder and by port (intake or exhaust), and store them in
an organized manner so that the part installation locations
are easily identifiable.
• When removing the valve rocker shaft, compress the coil
spring slightly and tie the spring with a metal wire, as
shown in the figure, before loosening the bolts. This will
facilitate the reassembly work later.
EMM0317
7. Removal of cylinder head assembly

• Pull off the push rod.
• Loosen the cylinder head bolts according to the following
sequence.
• Remove cylinder head.
EMM0318
EM-21
ENGINE SERVICE

8. Remove oil pan.
Remove any sealant.
FEM008
9. Remove oil pump with strainer.
FEM009
10. Disassembly of PTO device
EMM0319
• Remove crankshaft pulley bolt.

• Remove crankshaft pulley.
• Remove the sprocket bushing.
EM-22
ENGINE SERVICE

• Remove the front cover.
• To remove the cover, remove the bolts and lightly tap on it
with a plastic hammer.
Before installing the cover, apply sealant (liquid packing) to
the mounting face.
EMM0320
11. Remove the sprocket and chain as an assembly from the oil
pump side and the crankshaft side.
FEM012
After removing the retaining bolts, remove the signal plate

bushing and remove the hydraulic pump sprocket along with
the bearing by hand.
CAUTION:
Ensure that the chain is not damaged.
EMM0321
12. To separate the oil pressure pumpside sprocket and the

bearing, use the relevant Special Service Tool with a press.
ST3D031000 Bearing puller
ST22360002 Bearing drift
FEM014
EM-23
ENGINE SERVICE

13. Timing chain cover
• Remove front oil seal.
Remove from the front cover using the front oil seal drift (SST).
Special Service Tools (SST): Front oil seal drift ST1524S000
Drift rod ST15243000
FEM015
14. Remove timing chain cover.

15. Remove chain tensioner (1).
16. Loosen the camshaft gear bolts.
17. Remove the camshaft sprocket (3) and crankshaft sprocket (2)
along with the chain (4).
18. If shim(s) are attached for the crankshaft gear, also remove
them.
19. Removal of camshaft
• Remove locating plate.
• Turn over the cylinder block. Lower and pull off the valve
EMM0322 lifter.
• Pull off the two bolts retaining the camshaft locating plate
and remove the camshaft. Be careful not to damage the
metal faces.
• Pull the piston toward the cylinder block top deck and
tentatively assemble the rod cap to prevent incorrect
assembly.
Place the parts in the order of cylinder arrangement.
20. Removal of piston and connecting rod
• Remove connecting rod cap and push the piston out toward
cylinder head side with handle of a hammer. Be careful not
to drop the pistons.
• Pull the piston toward the cylinder block top deck and
tentatively assemble the rod cap to prevent incorrect
assembly.
Place the parts in the order of cylinder arrangement.
CAUTION:
Store the connecting rod caps and bushings in the order of
FEM017
cylinder arrangement to prevent incorrect assembly.
21. Loosen the flywheel bolts and remove the flywheel.
22. Remove rear plate.
23. Removal of crankshaft
• Remove the rear oil seal retainer.
• Remove the main bearing cap bolts. Remove the main
bearing cap by lightly tapping on it with a wooden hammer.
CAUTION:
Store the bearing bushings in an organized manner so that the
part installation locations are easily identifiable.
EMM0323
EM-24
ENGINE SERVICE

24. Remove the oil seal from the oil seal retainer using the rear oil
seal drift (SST).
SST: KV10105500
EMM0324
25. Remove the crankshaft and bearing.

After removing the bearing, place the corresponding cap at a
correct position on the block side face to prevent incorrect
assembly.
FEM019
26. Disassembly of cylinder head

• Remove valve spring using a valve lifter (SST).
SST: ST12070000
• Before removing the lip seal for valve disassembly, first
remove the garter spring.
This is necessary to prevent the lip seal from being
damaged by sharp edges of the valve stem.
• Store the removed valves, valve collets, valve retainers,
valve springs, and valve seals in an organized manner to
identify which part combination corresponds to which
FEM020 cylinder.
27. Disassembly of piston and connecting rod
• Disassemble the piston and connecting rod.
• Remove piston rings.
The oil ring is a combined type. To remove it, first remove
the upper and lower rails, and then the expander.
CAUTION:
Store the removed pistons, pins, connecting rods and bushings
in an organized manner to identify which part combination
corresponds to which cylinder.
EM102
EM-25
ENGINE SERVICE

28. Pull off the piston pin.
The piston pin is press-fit into the connecting rod.
To remove the piston pin, first remove the snap ring, heat the
piston to 80°C, and then pull off the piston pin by using the pis-
ton pin press stand (SST).
CAUTION:
Store the removed pistons, piston pins, piston rings and
connecting rods in an organized manner to identify which part
combination corresponds to which cylinder.
EM103
Inspection and Correction

1. General precautions
• Inspect each part for damage, distortion, bend or excessive
play and repair/replace the part if the condition is
unallowable.
• Before cleaning the cylinder head and block, check for any
trace of water leakage.
• Completely remove any water scale, sealant, and carbon
from each part.
CAUTION:
Be careful not to damage the sliding faces when using a carbon
scraper or brush.
• After cleaning the oil passage of each part, verify that no
plugging is present by applying compressed air.
• Make sure that any parts requiring correct combination are
identified appropriately.
• For a part that is to be stored for a long time after cleaning,
make sure to apply oil to the high-finished surfaces to
prevent rust creation.
2. Intake manifold water jacket
• Also inspect the water jacket connector. Repair or replace it
if any traces of leakage are found.
• Also inspect the water hoses. If any deterioration or
damages are found, replace them. If any leakage is found
at the connections, retighten the clamps.
3. Cylinder head
REMOVING CARBONS
• Remove any carbons from the combustion chamber and
mounting faces of each cylinder. At that time, also check for
scratches and damages.
• Remove oil, scale, gasket, sealant, and carbon deposits
from surface of cylinder head using a scraper.
CAUTION:
Do not allow gasket fragments to enter oil or engine coolant
passages.
FEM024
EM-26
ENGINE SERVICE
Inspection and Correction (Cont’d)

MEASURING CYLINDER HEAD DISTORTION
• Visually check for any cracks and damages.
• Measure distortion at six points on the head bottom face. If the
measured distortion exceeds the specified limit, correct the
head bottom face with a surface grinder or an equivalent tool, or
replace the head.
Surface flatness 0.1 mm or less
Grinding limit 0.2 mm or less
EMM0325
VALVE SEAT CONTACT

• This inspection must be done after ensuring that the dimensions
of the valve guide and the valve are within the standard.
• Check valve contact by applying DICATOL PL-1 to valve seat
contact surface.
• Make sure that areas around all connect surfaces are
connected.
• If seating condition is not correct, reseat the valve and check
again.
If seating condition cannot be corrected by reseating, replace
valve seat.
EMV0149D
EM-27
ENGINE SERVICE

VALVE SEAT PROCESSING
• Cut the valve seat to the specified dimensions using a valve
seat cutter set and valve seat grinder (commercial service tool).
CAUTION:
Tightly hold the cutter handle with both hands when using a
valve seat cutter, and cut the entire periphery of the contacting
face without a break while pressing the cutter.
Poor pressure onto the cutter or repeated cutting may create
steps in the seat.
• Cut the valve seat to the dimensions specified in the figure.
Standard processing dimensions
D1: 35.9 - 36.1 mm
D2: 37.6 - 37.8 mm
D3: 41.0 mm
D4: 28.6 - 28.8 mm
D5: 31.4 - 31.6 mm
D6: 35.0 mm
EMM0326
4. Cylinder block
Measure distortion of the cylinder block top face in the longitu-
dinal and lateral directions.
Measuring cylinder block distortion.
• Remove any foreign material deposits such as carbon from
the cylinder block.
• (Use a straight ruler and filler gauge for distortion
measurement)
• Visually check for any cracks and damages.
• Measure distortion at six points on the head top face . If the
measured distortion exceeds the specified limit, correct the
EMM0327 head top face with a surface grinder or an equivalent tool,
or replace the head.
EM-28
ENGINE SERVICE

Distortion limit: 0.1mm
Standard Repair limit
Longitudinal 0.05 (0.0020) 0.10 (0.0039)

mm (in)
Cylinder block face
Lateral 0.02 (0.0008) 0.04 (0.0016)
mm (in)
Determine the grade based on the measurement at a point located

65 mm from the top deck in the thrust direction.
5. Measuring cylinder bore

• Take the following measurements for the directions A and B
at three levels using a cylinder bore gauge.
EM124
Max. difference between A and B Roundness

Max. difference among three levels Taper
(mm)
Standard Wear limit
Cylinder bore inner diameter 75.5 - 75.55 (K15) 75.7
89.0 - 89.05 (K21, K25) 89.20
Roundness --- 0.2
Taper --- 0.2
Difference in inner diameter --- 0.2
EMM0328 between respective cylinders
6. Balling and horning

(1) Select an appropriate oversize piston according to the wear of
the cylinder inner surface.
Measure the piston skirt diameter. Bore the cylinder to a diam-
eter 0.02 mm larger than the measurement.
EM126
EM-29
ENGINE SERVICE

• Ensure that the piston-to-cylinder clearance is between
0.025 and 0.045. Make sure to perform measurement in
ordinary temperature. If even one cylinder requires boring,
all cylinders must be bored at once.
FEM035
(2) Calculating cylinder inner diameter

• Measure the skirt diameter (dimension H) of the oversize
piston.
• Based on the dimension H of the piston, determine the
cylinder boring diameter.
Boring diameter: R = H + C – M
Boring margin: M = 0.02 mm
Piston-to-cylinder clearance
: C = 0.025 to 0.045 mm (20°C)
∴R= H + (0.005 to 0.025) mm
• Bore the cylinder to the dimension R.
Piston service part list

Oversize
STD
0.50
1.00
(3) Boring precautions

• Make sure to bore the cylinder step-by-step with the boring
depth of each step limited to 0.05 mm.
• Notice that the cylinder inner diameter is affected by the
cutting heat.
• To prevent deformation due to cutting heat, bore the
cylinders in the order of No. 2, No. 4, No. 1 and No. 3.
• Apply an appropriate mark to each piston so that which
piston is for which cylinder is easily identifiable.
(4) After horning, measure the taper and roundness of the bore.
(5) Measuring piston-to-cylinder clearance
Pull off the piston pin from the piston and put the piston into the
cylinder upside down. Insert a filler gauge of 0.04 mm in the
piston-to-cylinder clearance from the piston sliding side and
pull the filler gauge with a spring scale. If the spring scale reads
0.5 kg to 1.5 kg, the clearance is normal.
EMM0329
EM-30
ENGINE SERVICE

Oversize piston
Diameter mm
Piston size
K21, K25 K15
STD 88.965 - 89.015 75.465 - 75.515

0.50 OS 89.465 - 89.515 75.965 - 76.015
1.00 OS 89.965 - 90.015 76.465 - 76.515
Standard measurements for piston and cylinder

Specified clearance mm (in) 0.025 - 0.045
(0.0010 - 0.0018)
[20°C (68°F)]
Filler gauge N (Kgf, lb) Drawing force 4.9 to 14.7
(0.5 - 1.5,1.1 - 3.3)
Filler gauge in use Thickness mm (in) 0.04(0.0016)
7. Measuring piston wear

• Inspect the piston sliding face. Replace it if significant
sticking damage or wear is observed.
• Measuring piston ring-to-groove clearance
Measure the clearance between the piston ring groove and
the piston ring. If excessive wear is observed, replace the
piston ring along with the piston.
(mm)
Standard Limit
Top 0.045 - 0.080 0.1
Second 0.030 - 0.070 0.1
Oil 0.065 - 0.135 —
EM423
8. Piston ring
• Measuring piston ring closed gap
• Put the piston ring into the cylinder bore and measure the
ring closed gap.
(mm)
Standard Limit
Top 0.28 - 0.43 1.0

Second 0.45 - 0.60 1.0
Combined rail 0.20 - 0.60 1.0
Measure the end gap of the piston ring with a feeler gauge. If
EM542 the gap exceeds 1 mm, replace the piston ring. If the gap is
0.15 mm or less, correct the ring ends with an oil stone or
replace the piston ring.
CAUTION:
Always measure the ring gap near the bottom of the cylinder
where the wear is relatively small when replacing the piston
ring without correcting the cylinder bore.
EM-31
ENGINE SERVICE

9. Piston pin
FITTING PISTON PIN TO PISTON
• In ordinary temperatures, the piston pin should rotate when
turned by hand or the pin should go smoothly when
inserted.
• If the piston pin behavior is unusual, replace the piston and
piston assembly.
Engine type K15, K21, K25
Piston pin outer diameter 19.993 - 19.998
10. Connecting rod

MEASURING BEND, TWIST
• Measure the bend and twist using a connecting rod aligner.
If the measured bend or twist is excessive, replace the
component.
Usable limit: Bend 0.05 mm (per 100 mm)
Twist 0.05 mm (per 100 mm)
CAUTION:
The center distance between both end holes must be
143.97 to 144.03 mm. (K25)
152.47 - 152.53 (K15, K21)
EM133 Standard Repair limit
Bend Twist Parallelism 0.025(0.0010) (B) 0.05 (0.002)

[per 100 mm (3.94in)] mm (in)
for every 100 mm (T) 0.05 (0.002)
11. Connecting rod weight

WEIGHT ADJUSTMENT
• When replacing the connecting rod assembly, ensure that
the maximum difference in the connecting rod assembly
weight between any two cylinders does not exceed 4 g.
MEASURING CONNECTING ROD THRUST CLEARANCE

• Measure the thrust clearance using a feeler gauge.
• Measure the connecting rod side clearance. If the
clearance exceeds the limit, replace the connecting rod.
Standard clearance: 0.2 - 0.3 mm
Max. clearance: 0.4 mm
EM134
EM-32
ENGINE SERVICE

12. Connecting rod and bushings
• Check the bushings for bend, melting, or tearing and
replace them if damaged.
• Measure the oil clearance using a plastigage.
MEASURING OIL CLEARANCE

• The following paragraphs describe how to use a plastigage.
a. Remove any oil and dust from the bearing inner/outer
faces and journal faces. Cut off the plastigage to a
length slightly shorter than the bearing width. Place
the cut plastigage on the journal face so as not to
cover any oil holes.
b. Assemble the bearing cap and tighten it to the
EMM0330
specified torque.
CAUTION:
Do not turn the crankshaft while the plastigage is in the
bearing.
c. Remove the cap and read the plastigage width using
the scale printed on the bag.
d. If the clearance exceeds the limit, use an undersize
bearing. At that time, grind the journal or pin.
Standard
Oil clearance Oil clearance Cap tightening
Items
Standard Limit torque
Main bearing 0.02 - 0.073 0.1 Lubricated

83.4 - 93.2N•m
(8.51 - 9.51Kgf-m)
Connecting rod 0.032 - 0.066 0.1 Lubricated
FEM036 bearing 31.4 - 37.3N•m
(3.2 - 3.81Kgf-m)
• If the oil clearance exceeds the limit, grind the journal or pin
with a surface grinder and use an undersize bearing.
Undersize bearing list

Connecting rod bearing
Main bearing
K15, K21, K25 Pin diameter
STD STD 44.974 - 44.96

0.08 44.894 - 44.8
0.02 0.12 44.854 - 44.89
0.25 0.25 44.724 - 44.71
0.50
0.75
1.00
EM-33
ENGINE SERVICE

13. Crankshaft and bearing
CRANKSHAFT INSPECTION
• Inspect the journal and pin for damage or wear and replace
them as necessary.
FEM037
To determine the diameter, measure the journal or pin at a

total of four points using a micrometer.
Roundness and taper of journal and pin:
Limit 0.03 mm (0.079 in)
CAUTION:
The roundness is represented by the difference between the
dimensions X and Y in the left figure.
The taper is represented by the difference between the
dimensions A and B in the left figure.
EMM0331 Standard Repair limit Limit
Roundness and taper mm (in) 0.01 (0.0004) 0.03 (0.0012)
MEASURING BEND
• Apply the probe of a dial gauge to the center journal and
take a reading while turning the crankshaft. Determine half
of the reading as the bend. If the bend exceeds the
specified limit, replace the crankshaft.
Bend limit: 0.05 mm
Standard mm (in) Usable limit mm (in)
Crankshaft bend 0.02 (0.0008) 0.05 (0.0020)
MEASURING CRANKSHAFT END PLAY

EM137 • Tighten to the specified torque. After that, measure end
play.
• Assemble the crankshaft and measure the end play.
• If the end play exceeds the limit, replace the main bearing
center bushing.
Measuring main bearing end play

Standard Limit
End play mm (in) 0.05 - 0.18 (0.0020 - 0.0071) 0.2 (0.0079)
EM138
EM-34
ENGINE SERVICE

MAIN BEARING CRUSH HEIGHT
• With main bearing installed, tighten bearing cap to the
specified torque. Remove bearing cap and make sure that
the main bearing edges protrude.
Standard: There must be crush height
EMA0558D
CRANKSHAFT MAIN BEARING

• Inspect the main bearing bushing.
• As shown below, the main bearing bushings in use are
classified in two types.
Nos. 1, 2, 4 and 5 are common.
No.3 (center) is provided with a thrust bushing.
Check the bearing for scratch, metal fatigue, peeling or bend
and replace the upper and lower bearings together as neces-
sary.
EMM0332
MAIN BEARING CAP AND BEARING

Measuring oil clearance
(1) Remove the cap and read the plastigage width using the scale
printed on the bag.
(2) If the clearance exceeds the limit, use an undersize bearing. At
that time, grind the journal or pin.
Standard
Oil clearance Oil clearance
Items Cap tightening torque
Standard Limit
Main bearing 0.02 - 0.06 0.1 Lubricated

83.4 - 93.2N•m
(8.51 - 9.51Kgf-m)
Main bearing specifications

Undersize mm (in) Crankshaft journal diameter mm (in)
0.02 (0.000787) 62.922 - 62.935 (2.47724 - 2.47775)

0.25 (0.098) 62.692 - 62.705 (2.4682 - 2.4687)
0.50 (0.0197) 62.422 - 62.455 (2.4576 - 2.4589)
0.75 (0.0295) 62.192 - 62.205 (2.4485 - 2.4490)
1.00 (0.0394) 61.942 - 61.955 (2.4387 - 2.4392)
EM-35
ENGINE SERVICE

14. Camshaft
INSPECTION OF CAMSHAFT BEND
• Apply the probe of a dial gauge to the center journal and
measure the fluctuation while turning the camshaft.
Determine half of the reading as the camshaft bend.
Bend limit: 0.05 mm
Measuring camshaft bend

Standard (Shall not
Usable limit
exceed the value)
Camshaft bend mm (in) 0.02 (0.0008) 0.05 (0.0020)

EM122
CAMSHAFT JOURNAL INSPECTION

• Inspect the camshaft journal and replace it if any damage
or uneven wear is observed.
• If the wear is found to exceed the limit by measurement
with a micrometer, replace the camshaft.
Camshaft journal inspection

Standard (Shall not
Camshaft journal Usable limit
exceed the value)
Taper Out-of-round mm (in) 0.01(0.0004) 0.03 (0.0012)
Journal wear mm (in) 0.05 (0.0020)
FEM039 MEASURING CAMSHAFT HEIGHT

• Measure the camshaft height by applying calipers to the
camshaft nose.
(mm)
Camshaft height
Standard Intake/exhaust 36.750 - 36.800

Usable limit 36.5
• Inspect the oil pump and distributor drive gear. If excessive

wear or damage is observed, replace the camshaft.
FEM040
VALVE TIMING
The figure on the left is applicable to all cylinders.
If any of the valves deviate from the specifications, the camshaft
ridges may be worn out or damaged. The camshaft must be
replaced.
Camshaft bushing inspection
• Check for bend, melting, uneven contact or peeling.
• If any damage is found, replace the camshaft bushing.
Measuring camshaft journal clearance
EMM0333
EM-36
ENGINE SERVICE

• Measure the inner diameter of the camshaft bushing and
the outer diameter of the camshaft journal. If any non-
standard condition is found, replace the camshaft bushing.
(mm)
Journal No. Standard Usable limit
Clearance #1 0.025 - 0.051 0.1

#3
#2 0.038 - 0.064 0.15
Bushing inner diameter #1 45.472 - 45.485
#2 43.948 - 43.961
FEM041 #3 41.256 - 41.269
Journal outer diameter #1 45.434 - 45.447
#2 43.897 - 43.910
#3 41.218 - 41.231
• When installing a new camshaft bushing, always align the

oil holes correctly.
15. Timing sprocket
• Check camshaft gear surface for flatness.
• Place the camshaft with camshaft sprocket on a V block
and measure the sprocket runout. If the deflection exceeds
0.1 mm, repair or replace the camshaft. Also inspect the
gear teeth and bosses. If any excessive wear or damage is
observed, replace the camshaft.
16. Front cover and timing chain housing
• Inspect the housing mounting faces and oil seal. If any
excessive damage is observed, replace the relevant
component(s).
EM148 17. Valve lifter

• Inspect the contact face between the valve lifter body and
camshaft. If excessive wear, damage or melting is
observed, replace the component. Also inspect the
installation status to the cylinder block and replace the
component.
• The valve lifter, if correctly installed and lubricated, should
seat into the hole slowly by its weight.
Measuring valve lifter

Standard (Shall not
FEM042 Repair limit
deviate from the range)
Valve lifter and cylinder block 0.016 - 0.052 0.1(0.0039)

hole (0.0006 - 0.0020)
Clearance mm (in)
EM-37
ENGINE SERVICE

18. Push rod
• Inspect the push rod and replace it if excessive wear, twist
or damage is observed. If a bend of 0.05 mm or more is
present, repair or replace the push rod.
19. Rocker shaft
• Check the rocker shaft for wear, damage or bend and
replace it if wear of 0.05 mm or more is observed.
EMM0334
20. Rocker arm and adjusting bolt

• Inspect the valve stem-to-rocker shaft contact face of the
rocker arm and adjusting bolt. If excessive wear is found or
the rocker shaft clearance exceeds the specified limit,
replace the rocker arm (adjusting bolt).
Standard Repair limit
Rock arm/shaft 0.020 - 0.054 0.1(0.0039)

Clearance mm (in) (0.0008 - 0.0021)
EMM0335 21. Flywheel

• Inspect the flywheel sliding face and the ring gear teeth.
• If excessive damage or wear is observed, repair or replace
the relevant component.
• If the wear of the flywheel ring gear is relatively small,
reuse the ring gear by shifting the installation position by 45
degrees.
To install a new ring gear, heat it to 180°C and use a
compression fitting method.
MEASURING FLATNESS
• Measure the flatness while turning the crankshaft using a
dial gauge.
• The flatness limit A is the maximum allowable flatness
measured vertically to the flywheel clutch sliding face.
Flywheel flatness limit
A: 0.1 mm (0.004 in) or less
EM156
EM-38
ENGINE SERVICE
Engine Assembly
1. General assembly precautions
• Apply an adequate amount of oil to the sliding faces.
• Clean the part completely. In particular, ensure that no oil
passages are plugged.
• As a rule, replace all gaskets, packing and oil seals with
new ones.
• Always replace the lock plates.
• Always follow the instructions about the tightening torque
and tightening order. While tightening, monitor the
clearance at each critical point.
• Always install the nuts, bolts and washers to their original
positions.
• For sealing, use liquid packing as necessary. Make sure to
apply liquid packing if so instructed.
• Always keep the tools and work benches clean from dust,
dirt and oil/greases.
2. Assemble the piston and connecting rod.
• Install the assembled connecting rod and piston to the
relevant cylinder.
• To install the piston pins, press-fit them into the relevant
pistons with a force of 0.5 to 1.5 t by using the piston pin
press stand (SST). When press-fitting, apply a small
amount of oil to the pin and the small end of the rod.
• A round recess on the piston top is the piston's front mark.
EMM0337
• The front of the connecting rod is determined as follows:

When installed to the piston and viewed from the front, the
projection should come to the right.
EMM0338 3. Assembly of piston ring

• Securely assemble the top ring, second ring and oil ring to
their relevant positions.
• Make sure to assemble these parts in the following order:
oil ring, second ring, top ring.
EMM0338
EM-39
ENGINE SERVICE
Engine Assembly (Cont’d)

• The top ring is plated with chrome on its sliding face.
• When installing the compression ring, turn the
manufacturer marking upward.
• The upper and lower combined rings are identical.
EMM0339 4. Assembly of valve and valve spring

• Set the lip seal with the valve oil seal drift (SST) and insert
the valve. Assemble the valve spring and valve spring
retainer in order and insert the collet by compressing the
spring with the valve lifter (SST).
CAUTION:
• Always assemble the valves to their original cylinders.
The wear level of the sliding face differs depending on the
cylinder.
• Verify that the valves are seated securely and no foreign
EMM0340 objects are caught inside.
5. Rocker shaft assembly

• Assemble the bracket and intermediate spring to the rocker
shaft. The shaft has four installation holes.
• The large hole located on the lateral face also serves as
the oil passage.
• Ensure that this comes to the front.
• Following the rocker arms at both ends, assemble the rock
washers and spacers.
6. Assembly of camshaft bushing
• Assembly of center bushing
Turn the cutout toward the distributor driving direction and
drive in the bushing with the jig.
• Assembly of rear bushing
Locate the bushing so that the arrow on the bushing faces
upward. Align the bushing to the oil hole on the cylinder
block and drive in the bushing as shown.
• The bushing has a slightly larger diameter toward its rear
end. This ensures that the bushing is press fit into the
cylinder block.
EMM0341
EM-40
ENGINE SERVICE

7. Assembly of crankshaft
• Assemble the main bearing bushing to the cap.
• As shown below, the main bearing bushings in use are
classified in two types.
Nos. 1, 2, 4 and 5 are common.
No.3 (center) is provided with a thrust bushing.
• Assemble crankshaft.
• Assemble main bearing caps.
• For the front bearing cap, align the cap to the cylinder block
so that they are flush with each other.
EMM0332
• Apply engine oil to the cap bolts and tighten them to the
specified torque from inside to outside as shown in the
figure on the left.
• Make sure that the crankshaft can be turned with a light
force every time one bolt is tightened.
: 83.4 - 93.2N•m (8.5 - 9.5Kgf-m)
NOTE:
Cranking torque 1.5 kgf-m or less
CAUTION:
EMM0342 For assembly, see the front of the part. An (embossed) arrow
and numbers indicating the assembly position can be seen.
8. Assembly of rear oil seal retainer
• Assemble the oil seal to the rear oil seal retainer.
To drive in the oil seal, use the special service tool
(KV10105500).
EMM0343
• Install rear oil seal retainer to cylinder block.

Rear oil seal retainer retaining bolt:
2.1 - 3.7 kgf-m
20.6 - 26.5 N•m
EMM0345
EM-41
ENGINE SERVICE

CAUTION:
• Before installing the rear oil seal retainer, apply liquid
packing to the retainer as shown in the figure.
• Once attaching the retainer and tightening the bolts, do not
make additional tightening or remove the retainer (and
retighten).
• For the mounting face, apply a continuous bead of sealant
along the groove. For the bolt holes, apply sealant so that it
does not run off the inner edges.
• Make sure to finish the assembly within 5 minutes after
sealant application.
EMM0344 • After the assembly, leave the assembled parts as is for 30
minutes or more.
PRECAUTIONS BEFORE APPLICATION:

• The mounting faces (both sides) shall be free from moisture, oil,
grease, waste, dust and other foreign objects.
• Make sure to remove any sealant from the flange/mounting
faces and threads when reassembling the part that has once
been attached and disassembled.
9. Assembly of piston
(1) Assemble the bearing to the connecting rod.
(2) To each cylinder, assemble the corresponding connecting rod
and piston subassembly according to the cylinder number.
(3) When assembling, turn the bottom mark of the piston toward
the front.
(4) Set the crankshaft pin positions to TDC or BDC.
(5) Insert the pistons into the cylinder block using the piston ring
compressor (SST).
CAUTION:
Do not mistake the piston front.
(6) Assemble each connecting rod and connecting rod cap while
aligning their matching marks.
EM164
(7) Tighten connecting rod cap.

Connecting rod cap bolt:
3.2 - 3.8Kgf-m (K15, K21, K25)
EM166
10. Assembly of valve lifter

• Fit the valve lifter in the correct position. Apply a small
amount of oil and press the valve lifter into the hole on the
cylinder block.
EM-42
ENGINE SERVICE

11. Assembly of camshaft
(1) Gently put the camshaft into the camshaft hole so that the bear-
ing bushings are not damaged.
(2) Tighten locating plate bolt to the specified torque.
M6 x 16 (thread length) 7T bolt:
: 8.43 - 10.8 N·m (0.86 - 1.1 kgf-m)
12. Assembly of timing chain/sprocket
(1) Tighten camshaft bolts.
Tightening torque: 39.2 - 49 N·m (4.0 - 5.0Kg-m)
(2) Check the height of the camshaft gear and crankshaft gear end
faces, and adjust the height by adding shims to the crankshaft
side as necessary.
EMM0347
(3) Assemble the sprocket and timing chain simultaneously while

aligning their matching marks.
Height difference of gear end faces Within 0.2 mm
Shim thickness 0.16 mm (per 1 shim)

Shim part number 12299 32200
EM392
13. Installation of timing chain tensioner

• Assemble chain tensioner.
• When installing the chain tensioner, align the oil holes of
the tensioner body to those of the cylinder block to ensure
that the tensioner spindle shoe (synthetic rubber) is held
parallel with the chain.
CAUTION:
Assembling the shoe in the reverse position will prevent
tightening of the tensioner bolt, resulting in tensioner damage.
M6 x 35 (thread length) bolt:
: 8.43 - 10.8 N·m (0.86 - 1.1 kgf-m)
EMM0348
14. Installation of timing chain housing
• Before installing the timing chain housing, apply liquid
packing to the housing as shown in the figure.
EMM0349
EM-43
ENGINE SERVICE

15. Inspection and installation of oil pump sprocket and chain
PTO DEVICE
Inspection
• Sprocket (Oil pump side)
If the gear teeth have significant scratches, excessive wear
or stepped wear at the spline, replace the sprocket.
• Sprocket (Crankshaft side)
If the gear teeth have significant scratches or wear,
replace the sprocket.
Ball bearing
• If the bearing is loose or drags, replace the sprocket.
• Chain
If the link has significant scratches, stretch (unusual
slapping noise is generated when tilt lever is operated) or
wear, replace the sprocket.
Assembly
• Assemble oil seal to front cover.
Drive in the sprocket using the front oil seal drift
(ST1524S000).
CAUTION:
First, apply grease to the lip of the oil seal. When driving in the
sprocket, ensure that the sprocket is not inclined.
• Install the bearing to the oil pump-side sprocket.
The bearings before and after the sprocket are identical.
To install them, use a press as done for disassembly.
EMM0350
• Install the sprocket and chain as an assembly.

Install the chain to the sprocket, and then install the chain
and sprocket assembly to the crankshaft and timing chain
housing.
• Remove any old grease from the oil pump spline and apply
new molybdenum grease.
• Install front cover.
EMM0351
EM-44
ENGINE SERVICE

• Install the bushing crankshaft pulley for the crankshaft
position sensor.
Before installing the front cover, apply liquid packing to the
cover as shown in the figure. (Refer to the rear oil seal
retainer installation procedure.)
M8 x 25 (thread length) 7T bolt:
: 20.6 - 26.5 N·m (2.1 - 2.7 Kgf-m)
EMM0352
16. Installation of crankshaft pulley
EMM0353
(1) Set the crankshaft pulley by aligning the pulley claws to the
groove of the bushing.
(2) Attach the washer, apply engine oil to the crankshaft pulley bolt
and tighten the bolt.
Crankshaft pulley bolt:
: 220.5 - 240.1 N·m (22.5 - 24.5 kgf-m)
17. Installation of cylinder head
(1) Both ends of cylinder block top
Drive in dowels into the head bolt holes (two positions).
(2) Place the head gasket on the block top with the copper side fac-
ing up.
EM-45
ENGINE SERVICE

(3) Set the cylinder head. Apply engine oil to the cylinder bolts and
tighten them to the specified torque in the order shown in the left
figure.
CAUTION:
Check tightening angle with an angle wrench (SST) or a
protractor. Do not simply estimate tightening angle.
For the service purposes, the following substitution torque may
be used: 68.6 N·m (7.0 kgf-m).
(4) Assembly of push rod
18. Installation of rocker shaft assembly
MAM0142
(1) Securely set the push rod onto the holder of the valve lifter.
FEM058
(2) Assemble the rocker shaft assembly.

: 17.64 - 21.56 N·m (1.8 - 2.2 kgf-m)
CAUTION:
Tighten the rocker shaft retaining bolts evenly from inside to
outside.
FEM059
• For the electronic control models, install the spindle

support (left figure) to the distributor installation holes.
EMM0354
EM-46
ENGINE SERVICE

(3) Adjust the valve clearance.
Valve clearance:
Both intake and exhaust
0.38 mm (when engine is hot)
CAUTION:
The valve clearance must be finally adjusted when the engine is
hot. However, preliminary adjustment in cold state will make
the final adjustment easier.
(4) Assemble the rocker cover.
EMM355 : 13.7 - 15.7 N·m (1.4 - 1.6 kgf-m)
19. Installation of engine accessories
• Install the oil pressure switch.
• Installing oil pump (all models) and distributor (carburetor
model)
(1) Set the crankshaft position to the compression TDC for cylinder
No.1.
EMM0356
(2) Locate the distributor so that the center of its flange long hole
aligns to the bolt hole on the cylinder block, and insert the dis-
tributor. (Do not turn the distributor to align the holes)
EMM0357
(3) Align the drive shaft groove of the engine lubricating oil pump.
EMM0358
EM-47
ENGINE SERVICE

(4) Align the distributor gear mark to the short mark on the housing.
CAUTION:
Do not align the gear mark to the gear installation pin or the
long mark.
(5) Tentatively tighten the retaining bolts.
(6) After installing the distributor gear, adjust the ignition timing by
using a timing light. Then, fully tighten the retaining bolts.
Idle speed and ignition timing (BTDC°/rpm) Electronic controlled specifications
0°/700 rpm
EMM0359 Carburetor specifications
K15 0°/700 rpm
K21 2°/700 rpm
K25 0°/700 rpm
(7) Installation of oil pan

• Before installing the oil pan, apply liquid packing to the oil
pan flange as shown in the figure.
EMM0360
• Tighten the oil pan retaining bolts to the specified torque in

the order shown in the left figure.
• Tightening torque for oil pan retaining bolt:
: 8.43 - 10.8 N·m
(0.86 - 1.1 kgf-m)
M6 x 12 (thread length) 7T bolt
(8) Installation of flywheel housing (or rear plate)
• Install flywheel housing.
• Tightening torque for housing retaining bolt
: 44.1 - 58.8 N·m (4.5 - 6.0 kgf-m)
EMM0361 (9) Installation of flywheel
• Install flywheel.
EMM0362
EM-48
ENGINE SERVICE

• Tightening torque for flywheel
(Apply engine oil to the bolt seat face and threads)
: 132 - 142 N·m (13.47 - 14.49 kgf-m)
• Check the flywheel runout with a dial gauge by turning the
crankshaft.
Measurement position Repair limit
Section A 0.1 mm (0.079 in)
EMM0363
20. Other parts

• Install the (fuel pump) and piping. (Carburetor model)
• Install the oil filter. For the installation procedure, refer to
page MA-10.
• Install oil level gauge.
(Carburetor model only)
• Install thermostat.
FEM061
• Install thermal transmitter, engine coolant temperature

sensor, and heater connector.
• Install spark plugs.
: 18 - 24 N·m (1.8 - 2.4Kg-m)
• Installation of distributor vacuum control tube (carburetor
model)
• Installation of high-tension cord (or low-voltage distribution
cord for electronic control model)
• Remove from the engine attachment.
• Install engine mount bracket LH.
EMM0364 • Install engine mount bracket RH.
• Install the alternator and adjusting bar.
• Install the fan belt and fan.
• Adjust the fan belt. Refer to MA section for the adjustment
procedure.
EM-49
ENGINE SERVICE
EM-50
ENGINE CONTROL
SECTION EC
CONTENTS
PRECAUTIONS .................................................. EC-3 Circuit Diagram ............................................. EC-56
General precautions for service operations .... EC-3 Component Parts Inspection ........................ EC-56
PREPARATION .................................................. EC-4 MASS AIR FLOW SENSOR SYSTEM ............. EC-57
Special Service Tools ..................................... EC-4 SST Data Monitor Display ............................ EC-57
DESCRIPTION .................................................... EC-5 ECM Input/Output Signal Specifications ...... EC-57
BASIC INSPECTION ........................................ EC-11 Circuit Diagram ............................................. EC-57
Inspection of Idle Speed, Ignition Timing, and Component Parts Inspection ........................ EC-57
Air-fuel Ratio ................................................. EC-11 ENGINE COOLANT TEMPERATURE SENSOR
Throttle Valve Closed Position Learning and SYSTEM ............................................................ EC-58
Idle Air Volume Learning .............................. EC-13 SST Data Monitor Display ............................ EC-58
Accelerator Pedal Released Position ECM Input/Output Signal Specifications ...... EC-58
Learning ....................................................... EC-14
Fuel pressure inspection .............................. EC-14
Circuit Diagram ............................................. EC-58
Component Parts Inspection ........................ EC-58
EC
TROUBLE DIAGNOSIS .................................... EC-16 HEATED OXYGEN SENSOR SYSTEM ........... EC-59
How to Proceed with Trouble Diagnosis ...... EC-16 SST Data Monitor Display ............................ EC-59
Diagnosis Chart by Symptom ....................... EC-20 ECM Input/Output Signal Specifications ...... EC-59
Component Parts Location ........................... EC-26 Circuit Diagram ............................................. EC-59
ECM Component .......................................... EC-27 THROTTLE POSITION SENSOR SYSTEM ..... EC-60
Circuit Diagram ............................................. EC-30 SST Data Monitor Display ............................ EC-60
ECM Terminal Layout ................................... EC-33 ECM Input/Output Signal Specifications ...... EC-60
ECM Input/Output Signal Specifications ...... EC-36 Circuit Diagram ............................................. EC-60
SST .............................................................. EC-42 Component Parts Inspection ........................ EC-60
Self-Diagnosis Function (Without SST) ........ EC-47 ACCELERATOR PEDAL POSITION SENSOR
SST Reference Value in Data Monitor ......... EC-50 SYSTEM ............................................................ EC-61
Fail-Safe Function ........................................ EC-53 SST Data Monitor Display ............................ EC-61
POWER SUPPLY AND GROUND SYSTEM .... EC-54 ECM Input/Output Signal Specifications ...... EC-61
ECM Input/Output Signal Specifications ...... EC-54 Circuit Diagram ............................................. EC-61
Circuit Diagram ............................................. EC-54 Component Parts Inspection ........................ EC-61
CRANKSHAFT POSITION SENSOR (POS) INTAKE AIR TEMPERATURE SENSOR ......... EC-62
SYSTEM ............................................................ EC-55 SST Data Monitor Display ............................ EC-62
ECM Input/Output Signal Specifications ...... EC-55 ECM Input/Output Signal Specifications ...... EC-62
Circuit Diagram ............................................. EC-55 Circuit Diagram ............................................. EC-62
Component Parts Inspection ........................ EC-55 Component Parts Inspection ........................ EC-62
CAMSHAFT POSITION SENSOR (PHASE) PNP SWITCH SYSTEM .................................... EC-63
SYSTEM ............................................................ EC-56 SST Data Monitor Display ............................ EC-63
ECM Input/Output Signal Specifications ...... EC-56 ECM Input/Output Signal Specifications ...... EC-63
Circuit Diagram ............................................ EC-63 System Diagram .......................................... EC-73
STOP LAMP SWITCH SYSTEM ...................... EC-64 Component Parts Inspection ........................ EC-73
SST Data Monitor Display ............................ EC-64 FUEL CUT FUNCTION ..................................... EC-74
ECM Input/Output Signal Specifications ...... EC-64 Inspection Procedure ................................... EC-74
Circuit Diagram ............................................ EC-64 REMOVAL AND INSTALLATION OF ECM
Component Parts Inspection ........................ EC-64 COMPONENTS ................................................ EC-75
ELECTRIC LOAD SWITCH SYSTEM .............. EC-65 Removal and Installation of ECM ................. EC-75
SST Data Monitor Display ............................ EC-65 Removal and Installation of Crankshaft Position
ECM Input/Output Signal Specifications ...... EC-65 Sensor (POS) ............................................... EC-75
Circuit Diagram ............................................ EC-65 Removal and Installation of Camshaft Position
CAN COMMUNICATION SYSTEM .................. EC-66 Sensor (PHASE) .......................................... EC-75
ECM Input/Output Signal Specifications ...... EC-66 Removal and Installation of Mass Air Flow
Circuit Diagram ............................................ EC-66 Sensor .......................................................... EC-76
IGNITION SYSTEM ........................................... EC-67 Removal and Installation of Engine Coolant
SST Data Monitor Display ............................ EC-67 Temperature Sensor. ................................... EC-76
ECM Input/Output Signal Specifications ...... EC-67 Removal and Installation of Heated Oxygen Sensor
Circuit Diagram ............................................ EC-67 (with Heated Oxygen Sensor Heater) .......... EC-76
Component Parts Inspection ........................ EC-67 Removal and Installation of Throttle Position Sensor
FUEL INJECTOR SYSTEM .............................. EC-69 (Electric Throttle Control Actuator Assembly) .. EC-77
SST Data Monitor Display ............................ EC-69 Removal and Installation of Accelerator Pedal Position
ECM Input/Output Signal Specifications ...... EC-69 Sensor (Accelerator Pedal Assembly) .............. EC-77
Circuit Diagram ............................................ EC-69 Removal and Installation of Intake Air Temperature
Component Parts Inspection ........................ EC-69 Sensor (with Mass Air Flow Sensor) ............ EC-77
FUEL PUMP SYSTEM ...................................... EC-70 Removal and Installation of Neutral Switch (M/T
SST Data Monitor Display ............................ EC-70 Model) .......................................................... EC-77
ECM Input/Output Signal Specifications ...... EC-70 Removal and Installation of Ignition Coil (with Power
Circuit Diagram ............................................ EC-70 Transistor) .................................................... EC-77
Component Parts Inspection ........................ EC-70 Removal and Installation of Fuel Injector ..... EC-77
THROTTLE CONTROL MOTOR SYSTEM ...... EC-71 Removal and Installation of Fuel Pump ....... EC-77
ECM Input/Output Signal Specifications ...... EC-71 Removal and Installation of Throttle Control Motor
Circuit Diagram ............................................ EC-71 (Electric Throttle Control Actuator Assembly) .. EC-77
Component Parts Inspection ........................ EC-71 Removal and Installation of LPG Injector
HEATED OXYGEN SENSOR HEATER Holder .......................................................... EC-77
SYSTEM ............................................................ EC-72 Removal and Installation of LPG Injector Drive
SST Data Monitor Display ............................ EC-72 Unit ............................................................... EC-78
ECM Input/Output Signal Specifications ...... EC-72 SERVICE DATA AND SPECIFICATIONS
Circuit Diagram ............................................ EC-72 (SDS) ................................................................ EC-79
Component Parts Inspection ........................ EC-72 Standard, Repair Limit ................................. EC-79
PCV GAS RECIRCULATION DEVICE ............. EC-73
PRECAUTIONS
PRECAUTIONS General precautions for service operations

• Even when ignition switch is OFF, battery voltage may damage
the control unit. Turn ignition switch OFF and disconnect battery
ground cable before removing and installing control unit
harness.
GIM0059
• Be careful not to damage connector terminals when connecting

and disconnecting.Check the terminals for bend or breakage
before connecting.
ECM0010
• Check the input/output signal of terminal before replacing

control unit. Make sure that it operates normally.
Refer to EC-36, "ECM Input/Output Signal Specifications".
• Ensure the appropriate distance between test probes when

using a circuit tester. A longer distance is recommended,
because if the distance is too short, it may cause contact of test
probes, resulting in a short circuit. A short circuit allows battery
voltage to be applied directly to the control unit, resulting in
damage to its internal power transistors.
ECM0012
EC-3
PREPARATION
PREPARATION Special Service Tools

Description Application
EGI fuel pressure indicator For measuring fuel pressure gauge

ST19590000
ECM0013
Heated oxygen sensor wrench Removing and installing heated oxygen

KV10113700 sensor
ECM0014
SST For system inspection and diagnosis
ECM0015
Check adapter V For control unit input/output signal inspection

EG1755000 (for SMJ 150-pin connector)
ECM0016
Harness adapter
EG17550200
(150-pin to 121-pin conversion adapter)
ECM0017
EC-4
DESCRIPTION
DESCRIPTION • Adopts Electronic Concentrated engine Control System

(ECCS). Fuel injection control, ignition timing control, idle speed
control, and electronically controlled governor control etc. are all
performed by a single control unit.
• Adopts electric throttle control actuator system to control
electronically controlled governor.
• Adopts Hall IC type crankshaft position sensor (POS) and
camshaft position sensor (PHASE).
Items Description
Electric throttle control actuator • Adopts electronic throttle control actuator with integrated throttle control motor to adjust
throttle valve opening optimally according to driving conditions or to improve safety and
operability by electronically controlled governor.
Fuel injection control • With SOFIS control, amounts of injected fuel are optimized to improve exhaust
performance and response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects
the ratio during transitional conditions, such as sudden sharp changes in the ratio, in order
to improve drivability.
Ignition timing control • Uses Hall IC crankshaft position sensor (POS) and camshaft position sensor (PHASE) to
perform controls so that optimum ignition timing is obtained for every operating condition.
Optimum ignition timing setup according to each fuel is also enabled at the time of a
combined use formula.
• Adopts electronic distribution system (NDIS) in which each cylinder is equipped with an
ignition coil incorporating a power transistor for better ignition performance.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount
required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine
speed signal.
Maximum speed regulation control • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs
variable control of maximum speed by changeover switch as an option.
Idling area torque up control • Performs torque up control in idling area by engine speed signal in order to also enable
cargo work at idling.
Engine speed regulation control at lifting up • Reducing engine speed before the maximum lift enables reaching to a full lift by lifting up
switch signal.
Overheat prevention control • Reduces engine heat generation by reducing maximum engine speed and regulating
maximum throttle opening when engine coolant temperature reaches approximately
110°C.
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or
more when engine coolant temperature reaches approximately 135°C.
Slow operation mode control • Changes throttle opening characteristic of throttle position by slow operation mode switch,
and then minute operation of engine speed is enabled.
Fuel pump control (gasoline) • Turns fuel pump relay ON/OFF depending on engine speed signal.
LPG interception valve control • Turns interception valve relay ON/OFF depending on engine speed signal and fuel
pressure sensor signal.
Fail-safe function • Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when
any of the major system components (mass air flow sensor, engine coolant temperature
sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
EC-5
DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM

(GASOLINE)
ECM0018
EC-6
DESCRIPTION

(LPG)
ECM0019
EC-7
DESCRIPTION

(LPG AND GASOLINE)
ECM0020
EC-8
DESCRIPTION
SENSORS AND ACTUATORS CONTROL ITEMS

Main sensors and actuators related to the ECM are listed below.
Combined
Gasoline std std std std — std std std std opt opt std std
Fuel
Fuel changing (Gasoline and LPG) Combined

LPG std std std — std std std std std opt opt std std
Control Item Fuel injection

control
Maximum vehicle speed control

Maximum engine speed control
PTC heater control in cold area
Loading speed control

Ignition timing control
Fuel injection control
A/F feedback control
Slow mode control

Fuel pump control
Idle speed control
Self-diagnosis
Fuel cut off
Fail-safe
⊕: Significant impact to control
♦: Impact to control
Crankshaft position sensor (POS,
⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦
PHASWE)
Mass air flow sensor ⊕ ⊕ ♦ ⊕ ♦ ♦
Intake air temperature sensor ♦ ⊕ ♦
Engine coolant temperature sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦
Heated oxygen sensor ⊕ ♦ ♦
Vehicle speed sensor ♦ ♦ ♦ ♦ ⊕ ♦
Throttle position sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Accelerator pedal position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Sensors
Ignition switch ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
P/N POSI SW ♦ ♦ ♦ ♦ ♦
Stop lamp switch ♦
Headlamp (electrical load) switch ♦
Lifting up switch (opt) ⊕ ♦
Slow mode switch (opt) ⊕
Battery voltage ♦ ♦ ♦ ♦ ♦ ♦
LPG fuel pressure sensor ♦ ⊕ ♦
LPG injector drive unit check signal ♦
Fuel changing switch ⊕ ⊕ ⊕ ⊕ ⊕
EC-9
DESCRIPTION
Combined
Gasoline std std std std — std std std std opt opt std std
Fuel
Fuel changing (Gasoline and LPG) Combined

LPG std std std — std std std std std opt opt std std
Control Item Fuel injection

control
Maximum vehicle speed control

Maximum engine speed control
PTC heater control in cold area
Loading speed control

Ignition timing control
Fuel injection control
A/F feedback control
Slow mode control

Fuel pump control
Idle speed control
Self-diagnosis
Fuel cut off
Fail-safe
⊕: Significant impact to control
♦: Impact to control
Gasoline injector ⊕ ⊕ ⊕
Ignition Power transistor ⊕ ♦

system Ignition coil ⊕
Throttle control motor relay ⊕ ⊕ ♦
Throttle control motor ⊕ ⊕ ♦ ♦
Gasoline fuel pump relay ⊕ ⊕
Gasoline fuel pump ⊕ ♦
Actuators
Ignition relay ⊕
ECM relay ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
LPG injector drive unit ⊕ ⊕ ⊕
LPG injector ⊕ ⊕ ⊕ ♦
LPG assistance injector ⊕ ⊕ ⊕ ♦
LPG interception valve relay ⊕ ⊕ ♦
LPG interception valve ⊕ ♦
LPG PTC heater relay ♦ ⊕
LPG PTC heater ♦ ♦
EC-10
BASIC INSPECTION
BASIC INSPECTION Inspection of Idle Speed, Ignition Timing,

and Air-fuel Ratio
STANDARD AT IDLE
Transaxle M/T A/T
Idle speed (neutral or N position) (rpm) 700±50 700±50

Ignition timing (°BTDC/rpm) 0±2/700 0±2/700
CO density (%) 0.1 or less
HC density (ppm) 50 or less
CAUTION:
Perform "Idle Air Volume Learning" (on page EC-13) when idle
speed or ignition timing is outside the standard.
• Turn ignition switch ON, and then make sure that no malfunction
is detected by self-diagnosis.
• Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever in
the neutral or N position.
• Warm up engine and transaxle to the normal operating
temperature.
IDLE SPEED
With SST
1. Connect SST to VCM connector.
2. Indicate "Eng.rev" in ECM Input/Output monitor and make sure
that idle speed is 700 ±50 rpm.
CAUTION:
speed is outside the standard.
Without SST
1. Connect an induction type (current detection type) tachometer
to the primary wire of the 1 cylinder to check idle speed.
• The primary wire for the 1 cylinder is looped and longer than the
wires for other cylinders. It is used for detecting idle speed and
ignition timing.
2. Make sure that idle speed is 700 ±50 rpm.
CAUTION:
speed is outside the standard.
EC-11
BASIC INSPECTION
Inspection of Idle Speed, Ignition Timing,

and Air-fuel Ratio (Cont’d)
IGNITION TIMING INSPECTION
1. Install a timing light to the primary wire for 1 cylinder.
2. Make sure that ignition timing and idle speed are 0 ±2°BTDC/
700 rpm.
CAUTION:
Perform "Idle Air Volume Learning" (on page EC-13) when
ignition timing is outside the standard.
CO/HC DENSITY INSPECTION

The vehicle uses an air-fuel ratio feedback system with a self-
learning function. Because a wide compensation range is available,
no additional CO/HC density adjustment is necessary.
• Warm up engine to normal operating temperature. Confirm idle
speed and ignition timing are within the standards. Then, check
CO/HC density with a CO/HC measuring device.
• Check condition of air-fuel ratio feedback with the following
steps when measured values are outside the standard:
With SST
1. Indicate "O2 sensor rich" in ECM Input/Output monitor.
2. Keep engine speed at approximately 2,000 rpm, and make sure
that "ON" and "OFF" are alternately displayed.
ECM0024
Without SST
1. Check it with heated oxygen sensor monitor mode. (Refer to
EC-49, "DIAGNOSTIC TEST MODE II - HEATED OXYGEN
SENSOR MONITOR" for operation procedure.)
2. Keep engine speed at approximately 2,000 rpm, and make sure
that MIL blinks at least 5 times within 10 seconds.
NOTE:
• Increase engine speed when inspecting while air-fuel ratio feed-
back control is activated during idle.
EC-12
BASIC INSPECTION
Throttle Valve Closed Position Learning and

Idle Air Volume Learning
DESCRIPTION
When electric throttle control actuator or ECM connector is removed,
it is necessary for ECM to learn throttle valve closed position (throttle
position sensor output with throttle valve fully closed) after
reinstallation. Thus, throttle valve closed position learning is
performed.
When electric throttle control actuator or ECM is replaced, the
minimum required idle air volume needs to be learned. Thus, throttle
valve closed position learning and idle air volume learning are
performed.
Idle air volume learning is necessary even when idle speed or
ignition timing is outside the standard. Note that idle air volume
learning is equivalent to the base idle speed adjustment by
conventional throttle adjusting screw of carburetor or LPG mixer.
OPERATION PROCEDURE FOR THROTTLE VALVE CLOSED

POSITION LEARNING
1. Turn ignition switch ON → OFF. (And hold it for approximately 5
seconds after turning it OFF.)
2. Make sure that throttle valve operates. (Check for operating
sound.)
3. Upon completion of the above, learning is complete.
CAUTION:
Throttle valve closed position learning cannot be performed
with SST.
OPERATION PROCEDURE FOR IDLE AIR VOLUME LEARNING

1. Perform throttle valve closed position learning.
2. Fully warm up engine and transaxle. (Engine coolant
temperature: 70 - 99°C)
3. Set the selector lever to neutral or N position. Make sure that
the engine is free of electrical loads, such as air conditioner, oil
pressure pump, and other electrical components.
4. Execute the following contents while idling using SST.
• Touch "OK" in "Idle Air Volume Learning (Normal)" of ECM

Active Test.
CAUTION:
"IDLE AIR VOL LEARN (PLANT)" is the original setting on the
vehicle. Do not use it.
EC-13
BASIC INSPECTION
Throttle Valve Closed Position Learning and

Idle Air Volume Learning (Cont’d)
• When learning is completed, "CMPLT" is displayed.
CAUTION:
It will take approximately 20 seconds to complete the idle air
volume learning. Do not turn OFF the ignition switch until
completion.
• Confirm whether or not the learning has been completed by
checking the "TAS completion" in ECM Input/Output monitor.
Learning completed: ON
Learning not yet completed: OFF
ECM0027
• Make sure that idle speed and ignition timing are within the
standard.
• Perform "Idle Air Volume Learning" again if values are outside
the standard.
Accelerator Pedal Released Position

Learning
DESCRIPTION
When the accelerator pedal assembly has been replaced or the
accelerator pedal position sensor connector has been disconnected,
the accelerator pedal released position needs to be learned after
being repaired, so learn accelerator pedal in fully-released position.
OPERATION PROCEDURE
1. Turn ignition switch ON and wait at least 2 seconds.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Then turn ignition switch ON again and wait at least 2 seconds
(learning completed).
Fuel pressure inspection

QUICK INSPECTION
With SST
1. Turn ignition switch ON (engine stopped).
2. Press "OK" in "Fuel Pressure Release" of ECM Active Test.
3. Pinch the fuel feed hose with the fingers. Hose should not feel
hard.
Without SST
• When the fuel feed hose is squeezed while fuel pump is
operating (immediately after the ignition switch is turned ON or
while cranking), the hose should be swelling with pressure or
pulsating.
FUEL PRESSURE RELEASE
CAUTION:
Relieve fuel pressure before removing fuel piping to secure
safety.
EC-14
BASIC INSPECTION
Accelerator Pedal Released Position

Learning (Cont’d)
With SST
1. Start engine.
2. Select "Fuel Pressure Release" in ECM Active Test, and then
press "OK".
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn ignition switch OFF.
Without SST
1. Disconnect fuel pump fuse.
2. Start engine.
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn OFF the ignition switch, and install the fuel pump fuse.
FUEL PRESSURE INSPECTION
CAUTION:
• Safely and securely remove and install fuel hose.
• Use the fuel pressure gauge for fuel pressure inspection.
• Do not inspect fuel pressure while other systems are oper-
ating. Malfunctions may occur in fuel pressure value.
1. Release the fuel pressure.
2. Install fuel pressure gauge using fuel hose for fuel pressure
inspection.
3. Remove fuel hose, and then install fuel hose for fuel pressure
inspection.
CAUTION:
Usable period of fuel hose for fuel pressure inspection is 30
times or less. (Fuel hoses that are damaged and allow fuel
leakage are not contained above.)
4. Turn ignition switch ON, and then make sure that there is no fuel
leakage.
5. Start engine, and check for fuel leakage.
6. Make sure that fuel pressure is within the standard.
At idle: 0.35MPa (3.6 kgf/cm2)
• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking: 0.35Mpa (3.6 kgf/cm2)
• Check the following items if a malfunction is detected.
CAUTION:
Also check fuel pressure at increased engine speed.
• Malfunctioning pressure regulator (integrated with fuel pump)
• Clogged fuel piping
• Clogged fuel filter (with fuel pump)
• Poor fuel pump discharge
EC-15
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS How to Proceed with Trouble Diagnosis

1. The most important point in performing trouble diagnosis of
malfunctions is to thoroughly understand the vehicle systems
(both control and mechanical).
An ECM-based engine controls actuators such as injectors and
the ignition coil according to information from sensors. Then
through actuator operation, the engine (mechanical system)
runs. Sensors transmit information on the running condition,
which changes constantly, to ECM. It is important to under-
stand these cycles.
ECM0031
2. It is also important to clarify customer concerns before starting

the inspection.
First of all, reproduce the symptom, and understand it fully.
Ask the customer about his/her concerns carefully. In some
cases, it will be necessary to check the symptoms by driving
the vehicle with the customer.
CAUTION:
Customers are not professionals. Do not assume "maybe the
customer means ..." or "maybe the customer mentioned this
ECM0032 symptom".
3. It is essential to confirm symptoms right from the beginning in

order to ensure all malfunctions are completely repaired.
For an intermittent malfunction, it is important to reproduce the
symptom based on an interview with the customer and past
examples. Do not perform an inspection on an ad hoc basis.
Most intermittent malfunctions are caused by poor contacts. In
this case, it will be effective to shake the suspected harness or
connector by hand. When repairs are performed without any
symptom check, no one can judge if the malfunction has actu-
ally been eliminated.
ECM0033
4. The next important thing is to find which system among the
following is causing the malfunction: ECM control signal system,
or a mechanical system (such as the engine main body and
auxiliary component). It is important to inspect the system using
SST or by checking the ECM input/output signals. When
checking the ECM input/output signals, connect a check
adapter (SST) to ECM in order to prevent misdiagnosis.
Special Service Tools (SST):
Check adapter V (EG17530000) (for SMJ 150-pin con-
nector)
Harness adapter (EG17550200) (150-pin → 121-pin
conversion adapter)
EC-16
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis

(Cont’d)
5. Use the reference value of input/output data (guideline) in this
manual in order to judge the ECM input/output signals. Measure
the data of another vehicle of the same model under the same
conditions when it is difficult to judge, and compare the data. It
is advisable to collect sufficient data of a normally operating
vehicle.
ECM0034
TROUBLE DIAGNOSIS FLOW CHART

There are many different malfunction symptoms. So there is no
perfect trouble diagnosis technique applicable to all malfunctions.
Experience is also important to achieving an accurate trouble
diagnosis.
Nonetheless, an accurate trouble diagnosis can be performed by
applying similar procedures, regardless of the malfunction symptom.
Perform trouble diagnosis following the flow chart shown below.
ECM0035
EC-17
TROUBLE DIAGNOSIS

(Cont’d)
DIAGNOSTIC WORK SHEET
Description
• In order to clarify the malfunction symptom, it is important to ask
the customer and collect information about their concerns.
• Ask the customer about what symptoms are present under what
conditions. Use the information to clarify the symptom.
• Use the trouble diagnosis sheet to be certain not to miss any
vital information.
ECM0036
EC-18
TROUBLE DIAGNOSIS

(Cont’d)
ECM0037
EC-19
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOMS
AND THE SENSOR CIRCUIT
The table below shows the possible symptoms caused by the
malfunction of each sensor circuit.
Poor starting
Impossible
Check that symptoms are detected with self-diagnosis.

to start
Engine
Other
Symptoms Poor idle Poor driving control
Check that symptoms are in fail-safe condition.

stall
During surge and constant speed driving

Engine rpm does not increase smoothly.
Inconsistent idle when engine is cold.
Engine over temperature (Overheat)

Inconsistent idle when warming up
Poor fuel consumption efficiency

During surge and acceleration
When engine is warming up
Description/notable
Fast idle is not effective
No initial combustion
When engine is cold
During a heavy load

During deceleration
characteristics of the
Poor power output

Poor acceleration
Initial combustion
symptom
High idle rpm
Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
⊕: Highly possible
♦: Possible
Crankshaft position sensor OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • An open circuit in either REF or

(POS, PHASE) POS signal makes it impossible
for the vehicle to start.
• Control signals for fuel system
and ignition system are not
output.
Momentarily ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦ • The symptom depends on the

open duration of momentarily open
circuit and the operating
conditions. Slight shocks and
surges may be sensed during
driving, while engine stall may
be caused during idle.
Mass air flow Signal OPEN ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be in fail-safe condition,

sensor and vehicle runs at an engine
speed of 2,400 rpm or less.
High output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The air-fuel ratio becomes rich.

Black smoke may accompany.
Poor connection of grounding
may be a possible cause.
Low output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The air-fuel ratio becomes lean.
Contaminated hot wire or
suction of air may be suspected.
Ground OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • It will be over-rich.
Power OPEN ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be in fail-safe condition,

supply and vehicle runs at an engine
speed of 2,400 rpm or less.
Intake air temperature OPEN/ ♦

sensor SHORT
Engine coolant temperature OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • will be in fail-safe condition, and

sensor SHORT then MIL turns ON. This
malfunction tends to occur when
engine is cold or when the
engine coolant temperature is
high.
Resistance ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The engine coolant temperature

is large. is judged as low. This
malfunction tends to occur after
warming up.
Resistance ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The engine coolant temperature

is small. is judged as high. This
malfunction tends to occur when
engine is cold.
Heated oxygen sensor OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be base air-fuel ratio.

SHORT
Vehicle speed sensor OPEN/ ♦ ♦ ♦ ♦ • Duration of fuel cut becomes

SHORT shorter or fuel may not be cut.
EC-20
TROUBLE DIAGNOSIS
Poor starting
Impossible

to start
Engine
Other
Symptoms Poor idle Poor driving control

stall



Description/notable

When engine is cold
During a heavy load

During deceleration
Poor power output

Poor acceleration
Initial combustion
symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
♦: Possible
Throttle position sensor OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Idle will be base rpm. No

SHORT addition for acceleration.
Output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Possible interruption by

fluctuation unnecessary fuel injection. Poor
ground or control unit
connection may be the cause.
Poor ♦ ♦ • Idling is judged as OFF during

adjustment idle. Turning ignition switch
repeatedly to ON and OFF will
set the system to normal.
Accelerator pedal position OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

sensor SHORT
Output ♦ ♦ ♦ ♦ ♦ ♦ ♦
fluctuation
Ignition switch IGN OPEN ⊕ ⊕ ⊕ ⊕ ⊕ • Impossible to start without

outputs for fuel and ignition
systems.
P/N POSI SW OPEN ♦ ⊕ ♦ ⊕ ♦ ♦ ♦ • PNP switch is judged as OFF,

and the target cold engine
speed in N/P position is
lowered.
SHORT • PNP switch is judged as ON,

and fast idle is effective for cold
engine in positions other than N/
P position, making the creep
larger.
Stop lamp switch OPEN/

SHORT
Headlamp (electrical load) OPEN/ ♦ ♦

switch SHORT
Lifting up switch OPEN
CAN communication line OPEN/

SHORT
Power supply for ECM OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • Impossible to start without

outputs for fuel and ignition
systems.
Sensor ground (coolant OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The same as the open circuit in

temperature sensor, throttle SHORT the applicable sensor.
position sensor)
Control unit and connector Poor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • A slightly raised connector often

connection, results in poor connection. Entry
water entry? of water causes engine stall,
and afterwards it is momentarily
impossible to restart engine. In
some cases, restarting is
possible after a short wait.
LPG fuel pressure sensor OPEN/ ♦

SHORT
LPG injector Check OPEN

drive unit signal
line SHORT
Fuel changing switch OPEN • Fuel changing cannot be done.
EC-21
TROUBLE DIAGNOSIS
RELATIONSHIPS BETWEEN MALFUNCTIONING SYMPTOMS

AND ACTUATOR CIRCUITS
malfunction of each actuator circuit.
Poor starting
Impossible

to start
Engine
Other
Symptoms Poor idle Poor driving

stall



When engine is warming up Description/notable
When engine is cold
During a heavy load

During deceleration
Poor power output

Poor acceleration
Initial combustion
High idle rpm symptom

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
♦: Possible
Gasoline injector Power OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • No fuel injection to cylinder with

supply open circuit, resulting in LEAN
circuit Momentarily ♦ ♦ ♦ ♦ output of heated oxygen
open sensors.
• Starting engine is impossible
Coil OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ when the circuits for all the
cylinders are open.
Momentarily ♦ ♦ ♦ ♦
open
Drive OPEN ♦ ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
circuit
(ECM Momentarily ⊕ ♦
side) open
SHORT ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Continuous fuel injection to

cylinder with short circuit,
resulting in OVER-RICH and
misfiring.
• Starting engine is impossible
when the circuits for all the
cylinders are open.
Nozzle Foreign ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The cylinder with foreign

hole material material will keep injecting.
intrusion
Clogging ♦ ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The symptom depends on

clogging status. The correction
factor of air-fuel ratio becomes
larger.
Ground OPEN ♦ ♦ ♦ ♦ ♦ • Shocks may be sensed and

circuit engine stall may be occur
(ECM) depending on the duration of the
operation conditions.
Momentarily ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
open
Ignition signal circuit OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Slight shocks and surges may

be sensed depending on the
Momentarily ♦ ♦ ♦ duration of momentarily open
open circuit and the operating
conditions.
Ignition coil Power OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ •

supply
circuit Momentarily ♦ ♦ ♦ • Engine stall may occur if
open duration of momentarily open
circuit is too long.
Coil OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Shocks may be sensed and

engine stall may be occur
depending on the duration of the
operation conditions.
Ground OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Injects fuel toward spark plug on

circuit the cylinder with open circuit.
Momentarily ♦ ♦ ♦
open
ECM relay circuit OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕
EC-22
TROUBLE DIAGNOSIS
Poor starting
Impossible

to start
Engine
Other

stall



Description/notable

When engine is cold
During a heavy load

During deceleration
Poor power output

Poor acceleration
Initial combustion
symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
♦: Possible
Throttle control motor circuit OPEN/ ♦ ♦ ♦ ♦ ♦ ♦

SHORT
Throttle motor relay circuit OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The same malfunction may

occur as power supply open of
throttle control motor and
throttle position sensor.
Heated oxygen sensor OPEN

heater circuit
• Fuel pump relay circuit OPEN ⊕ ⊕ ⊕ ⊕ ⊕ • Impossible to start

• Fuel pump circuit
• Ignition relay circuit Momentarily ♦ ♦ ♦ ♦ ♦ • Impossible to start
open
Fuel pump OPEN/ ♦ ♦ ♦ ♦
Pressure regulator SHORT
LPG injector Ti OPEN

drive unit circuit
SHORT
Tip OPEN
circuit
SHORT
PWM OPEN
circuit
SHORT
Power OPEN
supply
Ground OPEN
LPG injector HI side OPEN

circuit
SHORT
Coil OPEN
LO side OPEN
circuit
SHORT
LPG assistance injector OPEN
Control unit
side short
LPG interception valve relay OPEN
Control unit
side short
LPG interception valve OPEN
LPG PTC heater relay OPEN/

SHORT
Malfunction indicator lamp OPEN
Improper TAS learning OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦
EC-23
TROUBLE DIAGNOSIS
RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOM AND

THE ENGINE MAIN BODY/AUXILIARY COMPONENT
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. (The table lists general symptoms and
some may not be applicable.)
Poor starting
Impossible
to start
Engine
Other
stall



Description/notable
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
characteristics of the symptom

High idle rpm
Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
♦: Possible
∇: Not very possible
Air sucked from oil level gauge ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Air-fuel ratio becomes LEAN.
• High air-fuel correction factor.
Air sucked from oil filler cap ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ * Check the suction using a pressure
(downstream of PCV) gauge.
* Generally applicable to air suction in air
Air sucked from intake manifold and ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ intake system
gasket
PCV kept open ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ • Noise (high hissing tone)
Clogged fuel strainer ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ • Symptom depends on clogging status.

This tends to happen during high-speed
Clogged air cleaner element ♦ ♦ ♦ ♦ ♦ ♦ or high load operation.
Malfunctioning gasoline pressure ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on

regulator combustion pressure.
Fuel mixture
Poor quality gasoline ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Symptom varies depending on oil quality.
Improper LPG fuel (cold area and ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Starting ability in cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom depends on fuel temperature.
circuit This tends to happen during engine stall
and is impossible to restart during engine
warming up.
Clogged LPG interception valve ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ∇ • Symptom depends on clogging status.

filter This tends to happen during high-speed
or high load operation.
Valve deposit ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ • Air-fuel ratio becomes LEAN. High air-

fuel correction factor.
Improper connection of wire ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ • Check that wiring route is proper.

connector
Poor connection of wire connector ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Check that connector is slightly raised.

Poor starting if slightly raised connectors
are in all cylinders.
Sparking
Improper ignition timing adjustment ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ —
Malfunctioning spark plug ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ∇ • Check that the gap is proper. Check

spark plug for electric wear, soil (fuel
injection, smoking), and damaged
insulator.
Leakage from high-pressure parts ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on the level

of leakage.
EC-24
TROUBLE DIAGNOSIS
Poor starting
Impossible
to start
Engine
Other
stall



Description/notable
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
characteristics of the symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
♦: Possible
∇: Not very possible
Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on contact
Compression
condition and the number of cylinders.

pressure
Worn piston ring ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ • Symptom varies depending on degree of

wear and the number of cylinders.
Clogged three-way catalytic ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • In some cases, after engine stall,

converter /exhaust system restarting is possible.
Low idle base speed ∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.
Dragging of brakes ♦ ♦ ♦ ♦ • Tires/wheels are hot.
Belt tension too high (excessive ♦ ♦ ♦ ♦ ♦ —

tension)
High A/C load ♦ ♦ ∇ ∇ ∇ ∇ ∇ ♦ ∇ ♦ ♦ ♦ • Too much refrigerant
∇ ∇ ♦ ∇ ♦
Other
High A/T load • Insufficient ATF amount, improper oil

specification (This symptom may
especially occur in the cold.)
High HYD PUMP load (PS, Cargo) ∇ ∇ ∇ ♦ ♦ ∇ ∇ ∇ ♦ • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Foreign material in fuel tank (such ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • With low fuel, this may easily occur.
as dust)
Damaged fan, malfunctioning water ♦ • Noise
pump
Clogged/restricted radiator/ ♦ —
condenser
Also check the following items other than the above:

• Check harness tension.
• Check each connector connection.
• Check ground wire for looseness.
• Check battery connection for looseness or corrosion.
• Check water and oil condition.
• Check fan belts for looseness.
EC-25
TROUBLE DIAGNOSIS
Component Parts Location
ECM0038
Specifications
Main component part Type Location
Gasoline LPG Combined
Actuators Gasoline injector High resistance Intake manifold √ √

LPG injector Gas injection Integrated in injector √
holder (on intake
manifold)
Fuel pump Electric motor/turbine Integrated in fuel tank √ √
Fuel pressure regulator Diaphragm √ √
Throttle control motor Electric DC motor (DC Integrated in electronic √ √ √
motor) throttle control actuator
Ignition coil Mold (built-in power Cylinder head (On each √ √ √
transistor) spark plug)
EC-26
TROUBLE DIAGNOSIS
Component Parts Location (Cont’d)

Specifications
Main component part Type Location
Gasoline LPG Combined
Sensors Crankshaft Crankshaft Hall IC (element) Front cover √ √ √

position position sensor
sensor (POS)
Camshaft position Chain housing √ √ √
sensor (PHASE)
Mass air flow sensor Hot wire Air horn √ √ √
Accelerator pedal position Variable resistance Integrated in accelerator √ √ √
sensors 1 and 2 work unit (accelerator
pedal assembly)
Throttle position sensors 1 and 2 Integrated in electronic √ √ √
throttle control actuator
Engine coolant temperature Thermistor Water outlet √ √ √
sensor
Intake air temperature sensor With air flow meter √ √ √
Heated oxygen sensor Zirconia (with heater) Front tube √ √ √
Vehicle speed sensor Electromagnetic power Vehicle side √ √ √
generation
ECM 121-pin digital control Vehicle side √ √ √
ECM & IGN coil relay Compact general relay Vehicle side √ √ √
(1M X 2)
ECM Component
Specifications NOTE
Component Location
Gasoline LPG Combined Actuator Sensor Other
Gasoline injector Intake manifold √ √ √

LPG injector Integrated in injector holder (on √ √ √
intake manifold)
Throttle control motor Integrated in electronic throttle √ √ √ √
Throttle position sensors 1 and 2 control actuator √ √ √ √
Ignition coil Cylinder head (on each spark plug) √ √ √ √
Crankshaft position sensor (POS) Front cover √ √ √ √
Camshaft position sensor (PHASE) Front housing √ √ √ √
Mass air flow sensor Air horn √ √ √ √
Intake air temperature sensor With air flow meter √ √ √ √
Engine coolant temperature sensor Water outlet √ √ √ √
Accelerator pedal position sensors Integrated in accelerator work unit √ √ √ √
1 and 2 (accelerator pedal assembly)
Fuel pump Integrated in fuel tank √ √ √
Fuel pressure regulator √ √ √
Heated oxygen sensor (Vehicle side) √ √ √ √
Vehicle speed sensor (Vehicle side) √ √ √ √
ECM (Vehicle side) √ √ √ √
ECM & IGN coil relay (Vehicle side) √ √ √ √
Stop lamp switch (Vehicle side) √ √ √ √
Throttle control motor relay (Vehicle side) √ √ √ √
Fuel pump relay (Vehicle side) √ √
Vaporizer (Vehicle side) √ √ √
LPG interception valve (Vehicle side) √ √ √
EC-27
TROUBLE DIAGNOSIS
ECM Component (Cont’d)
ECM0039
EC-28
TROUBLE DIAGNOSIS
ECM Component (Cont’d)
ECM0040
EC-29
TROUBLE DIAGNOSIS
Circuit Diagram
K-ENGINE ELECTRONIC CONTROLLED ECM CIRCUIT DIA-
GRAM (GASOLINE)
ECM0041
EC-30
TROUBLE DIAGNOSIS
Circuit Diagram (Cont’d)

GRAM (LPG)
ECM0042
EC-31
TROUBLE DIAGNOSIS
Circuit Diagram (Cont’d)

GRAM (COMBINED GASOLINE AND LPG)
ECM0043
EC-32
TROUBLE DIAGNOSIS
ECM Terminal Layout
ECM0044
The symbol in ( ) next to terminal numbers indicates the data link

connector.
Terminal Description
24 Heated oxygen sensor heater

2 —
6 —
7 —
8 LPG injector
9 —
113 Fuel pump relay
11 LPG assistance injector
12 —
15 —
16 —
17 —
18 —
19 —
111 ECM & IGN coil relay
62 Ignition signal No. 1
25 —
27 PTC heater relay
28 —
29 —
30 —
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
94 CAN communication line H
86 CAN communication line L
36 —
37 —
38 —
39 LPG injector drive keeping
101 Stop lamp switch
109 (IGN) Ignition switch
EC-33
TROUBLE DIAGNOSIS
ECM Terminal Layout (Cont’d)

102 PNP switch

100 —
45 —
46 —
47 Sensor power supply (Throttle position sensor)
49 Fuel changing switch power supply
85 (K LINE) K-line (ECM data transmit/receive)
52 —
84 Headlamp switch
54 —
55 —
56 —
57 —
67 Sensor ground
115 (-) ECM ground
116 (-) ECM ground
13 Crankshaft position sensor (POS)
63 —
91 Accelerator pedal position sensor 2 power supply
48 Sensor power supply
121 Power supply for ECM (Backup)
68 —
70 Fuel changing switch 1 (LPG)
14 Camshaft position sensor (PHASE)
51 Mass air flow sensor
50 Throttle position sensor 1
69 Throttle position sensor 2
106 Accelerator pedal position sensor 1
98 Accelerator pedal position sensor 2
77 —
78 Heated oxygen sensor ground
79 —
34 Intake air temperature sensor signal
83 Accelerator pedal position sensor 2 ground
87 —
88 —
89 —
35 Heated oxygen sensor
92 —
73 Engine coolant temperature sensor signal
95 —
23 Injector No. 1
42 Injector No. 2
22 Injector No. 3
41 Injector No. 4
105 —
107 —
EC-34
TROUBLE DIAGNOSIS
ECM Terminal Layout (Cont’d)

108 —
119 Power supply for ECM
110 Lifting up switch No. 1
104 Throttle control motor relay
3 Throttle control motor relay power supply
5 Throttle control motor (Open)
4 Throttle control motor (Close)
1 ECM ground
10 —
20 —
21 —
26 —
33 —
40 —
43 —
44 LPG injector drive intake
53 —
58 —
59 —
60 —
64 —
65 —
66 Sensor ground (Throttle position sensor)
71 —
72 LPG injector check
74 —
75 —
76 —
82 Accelerator pedal position sensor 1 ground
90 Accelerator pedal position sensor 1 power supply
93 —
96 —
97 —
99 Lifting up switch No. 2
103 —
112 LPG interception valve relay
114 —
117 —
118 —
EC-35
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications

REFERENCE VALUE LIST
• Voltage is measured with a circuit tester, and the sample
waveforms obtained with an oscilloscope are shown below for
each ECM terminal. Measurement data varies depending on
variation in parts as well as many other factors. Such factors
include vehicle history, driving conditions, environmental
conditions, maintenance status, measuring instrument/method,
etc. Data shown below are reference values.
ECM0044
Terminal
Signal name Measurement condition Measured value
signal
24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V

113 Fuel pump relay For approximately 1 second after ignition Approx. 1V
switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
111 ECM & IGN coil relay For approximately 10 seconds with Approx. 1V
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Battery voltage
EC-36
TROUBLE DIAGNOSIS

(Cont’d)
Terminal
signal
61 Ignition signal (power transistor drive At cranking Approx. 0.2V

62 signal)
80
81
ECM0047
At idle after warming up Approx. 0.1V
ECM0048
At approx. 2,000 rpm Approx. 0.1V
ECM0049
94 CAN communication line H Always Approx. 2.4V (Varies depending on

communication status.)
ECM0050
86 CAN communication line L Always Approx. 2.2V (Varies depending on

communication status.)
ECM0051
101 Stop lamp switch Brake pedal released Approx. 0V

Brake pedal depressed Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
102 PNP switch Neutral, or N position Approx. 0V
Other than above Battery voltage (A/T models)
Approx. 4.8V (M/T models)
EC-37
TROUBLE DIAGNOSIS

(Cont’d)
Terminal
signal
85 (K LINE) K-line (ECM data transmit/receive) When connected to SST Approx. 6.6 - Battery voltage
When not connected to SST Approx. 6V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
67 Sensor ground Always Approx. 0V
115 ECM ground Always Approx. 0V
116
1
13 Crankshaft position sensor (POS) At cranking Approx. 2.6V
ECM0052
At idle after warming up Approx. 3V
ECM0053
At approx. 2,000 rpm Approx. 3V
ECM0054
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 2.5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
121 Power supply for ECM (Backup) Always Battery voltage
47 Electric throttle control actuator power Ignition switch ON, engine running Approx. 5V
supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
99 Lifting up switch 2 Lifting up switch OFF Approx. 12V
Lifting up switch ON Approx. 0V
110 Lifting up switch 1 Lifting up switch OFF Approx. 5V
Lifting up switch ON Approx. 0V
EC-38
TROUBLE DIAGNOSIS

(Cont’d)
Terminal
signal
14 Camshaft position sensor (PHASE) At cranking Approx. 0.15V
ECM0055
At idle after warming up Fluctuates between approx. 1.5 - 2V.
ECM0056
At approx. 2,000 rpm Approx. 2V
ECM0057
51 Mass air flow sensor Ignition switch ON Approx. 1V

At cranking Approx. 1.5V
At idle after warming up Approx. 1.3V
50 Throttle position sensor 1 At idle after warming up Approx. 0.6V
Ignition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is fully depressed
Accelerator pedal is released
69 Throttle position sensor 2 At idle after warming up Approx. 4.5V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.6V
EC-39
TROUBLE DIAGNOSIS

(Cont’d)
Terminal
signal
98 Accelerator pedal position sensor 2 At Idle Approx. 0.3V

Ignition switch ON with engine stopped Approx. 2V
34 Intake air temperature sensor signal Intake air temperature is approx. 20°C. Approx. 3.5V
Intake air temperature is approx. 80°C. Approx. 1.2V
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 -
0.4V⇔;approx. 0.6 - 0.9V
ECM0058
At approx. 2,000 rpm Changes between approx. 1 -

0.4V⇔;approx. 0.6 - 0.9V
ECM0059
73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 3.5V
signal 20°C.
Engine coolant temperature is approx. Approx. 1.2V
80°C.
EC-40
TROUBLE DIAGNOSIS

(Cont’d)
Terminal
signal
22 Injector drive signal At cranking Approx. 10.5V

23
41
42
ECM0060
At idle after warming up Battery voltage
ECM0061
At approx. 2,000 rpm Relatively lower than battery voltage
ECM0062
119 Power supply for ECM Ignition switch ON, engine running Battery voltage
120
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power supply Always Battery voltage
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 - 0.15V
At approx. 2,000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
11 LPG assistance injector Other than above (Ignition switch ON, Battery voltage
engine running)
27 PTC heater relay Other than above (Ignition switch ON, Battery voltage
engine running)
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch ON (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay For approximately 10 seconds with Battery voltage
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Approx. 0V
Numerical values are obtained using an analog circuit tester.
EC-41
TROUBLE DIAGNOSIS
SST
DESCRIPTION
SST executes the following functions using the combination of ECM
data reception, instructions, and transmission from the VCM via the
communication line.
Diagnosis test mode Description
WORK SUPPORT • Reduces the preparation work necessary for inspecting.

• Displays input/output signal data related to the work.
• Allows setting control target values of idle speed or ignition timing.
• Allows performing "Idle Air Volume Learning".
SELF-DIAGNOSTIC RESULTS • Displays names of suspect circuits stored in ECM.
• Erases DTCs recorded in memory.
DATA MONITOR • Provides useful data along with self-diagnosis results to determine the main cause.
• Displays input/output data of ECM in real time.
• Records and stores data.
• Detects malfunctions in real-time.
ACTIVE TEST • Can be used to determine and identify the primary sources of malfunctions based on self-
diagnosis results and data from DATA MONITOR.
• Each actuator is activated after receiving a drive signal.
OPERATION PROCEDURE
1. Turn ignition switch OFF.
2. Connect SST to VCM connector.
3. Turn ignition switch ON.
4. Touch "START".
5. Touch "ENGINE".
6. Perform the necessary trouble diagnosis mode.
Refer to "SST Operation Manual" for further information.
WORK SUPPORT
SST assists with idle adjustment work. With SST, it sends an
operation command to ECM, and adjustment control is performed
accordingly. However, inspector performs actual adjustment work.
Display Item List

Work support item Description
FUEL PRESSURE RELEASE Shuts down the fuel pump and stops the engine. (While cranking, pressure in the fuel piping can be
released.)
IDLE AIR VOL LEARN Learns the minimum idle air flow amount required for idle speed control when predetermined conditions
are specified following replacement of electric throttle control actuator and ECM.
SELF-LEARNING CONT Clears air-fuel ratio feedback control correction coefficient.
TARGET IDLE TIM ADJ (*) Allows control target value for initial ignition timing (-10 to 0°).
Note: Inspectors must use timing light to make sure that ignition timing and actual timing are the same.
TARGET IGN RPM ADJ (*) Sets a control target value for the idle speed (0 to 250 rpm).
*: This function is not necessary in the usual service procedure.
EC-42
TROUBLE DIAGNOSIS
SST (Cont’d)
SELF-DIAGNOSTIC RESULTS
When a malfunction occurs in ECM input/output signal circuit, the
malfunctioning circuit is recorded and displayed. Also, the
malfunction item that is occurred is displayed.
Display sample [Example: When there is a malfunction in mass air

flow sensor]
Display DTC and the malfunction item in the alarm monitor screen.
ECM0077
Display Item List

ENGINE
Diagnosis item Malfunction Return Condition Display Warning Trip
lamp
NO DTC • No malfunction is detected in any of the circuits. — — —?

Mass air flow sensor (MAFS) • When engine is stopped (ignition switch ON) and mass air Air flow meter fault — —
flow sensor output voltage has been 4.9V or more for [E21]
predetermined period.
• When engine is running and mass air flow sensor output
voltage has been 0.5V or less for predetermined period.
• When air flow meter output voltage remains approximately
1V for a predetermined time while engine is running.
Engine coolant temperature • Engine coolant temperature sensor output voltage has Water temp sensor — 2
sensor (ECTS) (CIRCUIT) been approximately 4.8V or more (open) or less than fault [E22]
0.06V (short) for predetermined period
Throttle position sensor signal • Sensor power supply voltage has a malfunction. Throttle sensor fault ON* 1
circuit • Throttle position sensor signal circuit is open or shorted. [E23]
• A malfunction occurs in relation between throttle position
sensors 1 and 2.
• When the fully-closed position learning value was
unusually small or was not learning.
Acceleration sensor signal circuit • Accelerator pedal position sensor signal circuit is open or Accel sensor fault — 1
shorted. [E24]
• A malfunction occurs in relation between accelerator
pedal position sensors 1 and 2.
Heated oxygen sensor (circuit) • Heated oxygen sensor signal circuit is open. O2 sensor fault — 2
[E25]
Heated oxygen sensor (high • Heated oxygen sensor output voltage is higher than O2 sensor fault — 2
voltage) normal (2V or more). [E25]
EC-43
TROUBLE DIAGNOSIS
SST (Cont’d)
ENGINE
Diagnosis item Malfunction Return Condition Display Warning Trip
lamp
Crankshaft position sensor • The crankshaft position sensor (POS) signal is not POS sensor fault ON 2
(POS) signal circuit detected for a predetermined time at the engine start or [E27]
during engine running (during camshaft position sensor
(PHASE) signal input).
• A crankshaft position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (during camshaft position sensor (PHASE)
signal input).
Camshaft position sensor • At start-up, no camshaft position sensor (PHASE) signal Phase sensor fault ON 2
(PHASE) signal circuit has been detected for more than a predetermined period. [E28]
• The camshaft position sensor (PHASE) signal is not
detected for a predetermined time during engine running
(during crankshaft position sensor (POS) signal input).
• A camshaft position sensor (PHASE) signal irregular
waveform is detected for a predetermined time during
engine running (during crankshaft position sensor (POS)
signal input).
Engine control module • CPU system or circuits in ECM have a malfunction. CCS C/U system ON* 1 or 2
fault [E30] (Note)
ECM power supply circuit • Power is not supplied to ECM for some time. ECM BACKUP/ ON 2
CIRC [P1065]
Electric throttle control actuator • Because of mechanical malfunction of electric throttle Throttle control fault — 1
control actuator, electric throttle control actuator does not [E31]
operate normally.
Electric throttle control function • When a malfunction occurred due to the correlation Throttle control fault — 1
between the target throttle position and the actual throttle [E31]
position.
• Over current flows into throttle motor control circuit.
Throttle control motor relay • When throttle control motor relay has been locked ON or Throttle control fault — Locked
circuit OFF. [E31] ON: 1
Locked
OFF: 2
Overheat (STEP1) • Coolant temperature sensor output voltage has been Overheat (STEP1) — 1
approximately 0.35V or lower for a predetermined period [E32]
of time. (With the coolant temperature sensor normal)
Ignition signal • Ignition signal has not been continuously generated while Ignition system fault — 1
the engine is running. [E34]
Brake switch • Brake switch signal circuit is open or shorted. Stop lamp SW fault — 2
[E41]
CAN communication system • Malfunction occurs in CAN communication transmit/ Communication — 1
receive data or in ECM, and data transmission/reception fault ECM [E04]
cannot be confirmed.
• CAN communication data is transmitted/received for
predetermined period.
LPG injector control signal circuit • LPG injector control signal circuit is open or shorted. F/INJ disconn [E35] — 1
LPG vaporizer fuel pressure • LPG fuel pressure in vaporizer is excessively high. LPG result signal — 1
fault [E38]
Lifting up switch signal circuit • When lifting up switch has been locked ON or OFF. Mast height SW — 2
fault [E39]
Note: Number of trips varies depending on diagnosis content.
CAUTION:
Some DTC specified above may detect a malfunction related in
vehicle side self-diagnosis when the DTC detects some
malfunction. Check self-diagnosis except engine at this time.
EC-44
TROUBLE DIAGNOSIS
SST (Cont’d)
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as "trip"), MIL is lit. The corresponding DTC is
recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), MIL is lit and the corresponding final DTC is recorded.
SST self-diagnostic results timing

• For items of trip 1, timing "0" is displayed immediately after
detection of a malfunction.
• For items of trip 2, when a malfunction is detected for the first
time (trip 1), timing "1t" is displayed. When a malfunction is
detected again in the next trip (trip 2), it is displayed as "0".
Accumulative counting is performed at the end of warming-up
operation,
Conditions to turn off MIL

• The MIL, marked with *, is turned off when ignition switch is
turned ON (engine starts) again after normal state is resumed.
• For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.
DATA MONITOR
• Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
• Displays ECM input/output signal data in real time.
• Records the data before and after engine stalls, falters or
refuses to start intentionally.
EC-45
TROUBLE DIAGNOSIS
SST (Cont’d)
Display Item List
Monitor item Unit Description
Eng.rev rpm Engine speed computed from crankshaft angle sensor signal
Air flow meter mV Mass air flow sensor output voltage
Cly air ratio GAS % Average of cycles for air-fuel ratio feedback correction coefficient
Cly air ratio LPG
Eng.temp °C Value converted into temperature from the output voltage of the engine coolant temperature
sensor.
O2 sensor volt mV Output voltage of heated oxygen sensor
O2 sensor rich ON/OFF Air-fuel ratio is given as heated oxygen sensor output signal during air-fuel ratio feedback control.
ON: Heated oxygen sensor output is high. Controlling to lower the value for leaner ratio.
OFF: Heated oxygen sensor output is low. Controlling to raise the value for richer ratio.
Battery voltage mV ECM battery voltage
Accelerator % Value converted from the output voltage of accelerator pedal position sensor into accelerator
position
Throttle % Value converted from the output voltage of throttle position sensor into throttle position
Air temp sensor °C Value converted from the output power supply of intake air temperature sensor into intake air
temperature
Stater SW ON/OFF ON/OFF status as judged by each input signal
Idle SW
Air conditioner SW
Neutral SW
Mast high SW 1,2
Electric load SW
Chg fuel SW 1,2
Inching SW
Foot brake SW
Fuel jet pls GAS µs Value calculated by ECM
Fuel jet pls LPG
Spark timing deg
Fuel pump relay ON/OFF Status of each control as calculated by ECM.
Throttle relay
LPG relay
O2 sensor heater
TAS completion ON/OFF State of "Idle Air Volume Learning".
Ratio date clr comp ON/OFF Status of each control as calculated by ECM.
TAS factory run
TAS general run
Spark correct run
Ratio correct run
Power balance run
Pressure clr run
Self chk clr comp
All shut update exp
Connect CONSULT-II
Cly air ratio GAS % Value converted from the output voltage of mass air flow sensor into filling efficiency.
Cly air ratio LPG
Fuel control GASOLINE/ Fuel changing switch connecting condition
LPG/NEUTRAL
LPG pres sensor kg/cm2 Value converted into pressure from the output voltage of LPG fuel pressure sensor.
EC-46
TROUBLE DIAGNOSIS
SST (Cont’d)
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction,
based on self-diagnosis test results and data obtained from DATA
MONITOR mode. SST, instead of the ECM on the vehicle, sends a
drive signal to actuators to check their operation.
Display Item List

Active test item Description
FUEL INJECTION • Can increase or decrease the amount of fuel injection ( ±25%).
• Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor acceleration,
poor racing, etc.) and can help solve these malfunctions by pinpointing the causes.
IGNITION TIMING • Allows setting a correction coefficient for retarding (-10 - 0°)
POWER BALANCE • Stops operation of specified injector. Also, displays the condition at that time.
• Mainly used to inspect for misfiring cylinders.
FUEL PUMP RELAY • Reproduces the malfunctioning conditions (e.g. hesitation, engine stall, etc.) possibly related to fuel pump
malfunction by switching ON or OFF at user option.
Self-Diagnosis Function (Without SST)

DESCRIPTION
• In self-diagnosis, when any of the critical sensors or actuator
and exhaust gas control systems necessary for ECM control
return a malfunction and self-diagnosis detection conditions are
satisfied, a DTC corresponding to the suspect system is stored
in ECM for easier trouble diagnosis. Self-diagnostic results can
be displayed with either SST or MIL in the (combination) meter.
MIL indication is explained here.
• The trouble diagnosis mode has two types: mode 1 and mode
2. Mode 1 is normal mode and mode 2 is self-diagnosis or
heated oxygen sensor monitor function.
OPERATION PROCEDURE
• Refer to the following for how to activate self-diagnosis mode or
erase heated oxygen sensor monitor and self-diagnostic results.
CAUTION:
When a malfunction occurs in accelerator pedal position
sensors, self-diagnosis (without SST) cannot be activated.
Thus, use SST to perform self-diagnosis, and repair
malfunctioning part.
EC-47
TROUBLE DIAGNOSIS

(Cont’d)
ECM0078
DIAGNOSTIC TEST MODE 1 - BULB CHECK

• MIL should turn on when the ignition switch is turned ON
(engine stopped), and turn off after the engine starts.
DIAGNOSTIC TEST MODE 1 - MALFUNCTION WARNING

• When a malfunction is detected by self-diagnosis, the system
goes into the malfunction warning mode and warns the driver by
blinking the MIL in the (combination) meter.
• There are two types of warning indications: items for which
warning is given by MIL indication for the first trip and those for
which warning is given by MIL indication for the second trip. For
the latter, the MIL will not light up for the first trip.
DIAGNOSTIC TEST MODE II - SELF-DIAGNOSTIC RESULTS

• In this mode, the MIL blinks (indicating the DTC) to identify the
system that returned a malfunction.
• If no malfunction is detected, the code "0000" is displayed.
EC-48
TROUBLE DIAGNOSIS

(Cont’d)
Display Item List
DTC ENGINE
(code Diagnosis item Malfunction Return Condition Warning Trip
number) lamp
0000 NO DTC • No malfunction is detected in any of the circuits. — —

E23 Throttle position sensor • Sensor power supply voltage has a malfunction. ON* —
signal circuit • Throttle position sensor signal circuit is open or shorted.
• A malfunction occurs in relation between throttle position sensors 1
and 2.
• When the fully-closed position learning value was unusually small or
was not learning.
E27 Crankshaft position sensor • The crankshaft position sensor (POS) signal is not detected for a ON 2
(POS) signal circuit predetermined time at the engine start or during engine running
(during camshaft position sensor (PHASE) signal input).
• A crankshaft position sensor (POS) signal irregular waveform is
detected for a predetermined time during engine running (during
camshaft position sensor (PHASE) signal input).
E28 Camshaft position sensor • At start-up, no camshaft position sensor (PHASE) signal has been ON 2
(PHASE) signal circuit detected for more than a predetermined period.
• The camshaft position sensor (PHASE) signal is not detected for a
predetermined time during engine running (during crankshaft
position sensor (POS) signal input).
• A camshaft position sensor (PHASE) signal irregular waveform is
detected for a predetermined time during engine running (during
crankshaft position sensor (POS) signal input).
0500 Vehicle speed sensor • Vehicle sensor signal has not been input under some condition for a ON 2
predetermined time during driving after warming up.
E30 Engine control module • CPU system or circuits in ECM have a malfunction. ON* 1 or 2 (Note)
E33 Engine over temperature • Coolant temperature sensor output voltage has been approximately ON 1
(Overheat) 0.35V or lower for a predetermined period of time. (With the coolant
temperature sensor normal)
Note: Number of trips varies depending on diagnosis content.
CAUTION:
Some DTC specified above may detect a malfunction related in
vehicle side self-diagnosis when the DTC detects some
malfunction. Check self-diagnosis except engine at this time.
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as "trip"), MIL is lit. The corresponding DTC is
recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), MIL is lit and the corresponding final DTC is recorded.
Even when 1st trip DTC is being memorized, the appropriate
malfunction code is displayed as self-diagnostic results by MIL.
EC-49
TROUBLE DIAGNOSIS
Self-diagnosis function (without SST)

(Cont’d)
Conditions to turn off MIL
• The MIL, marked with *, is turned off when ignition switch is
turned ON (engine starts) again after normal state is resumed.
• For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.
DIAGNOSTIC TEST MODE II - HEATED OXYGEN SENSOR

MONITOR
• In this mode, status of air-fuel ratio is displayed by blinking of MIL.
• Make sure that MIL blinks at least 5 times within 10 seconds
after warming up engine and keeping engine speed at
approximately 2,000 rpm.
NOTE:
• Although air-fuel ratio feedback control is active at idle, increase
engine speed and check.
• During air-fuel ratio feedback control
Heated oxygen sensor output is large (rich).: OFF
ECM0080 Heated oxygen sensor output is small (lean).: ON
• Air-fuel ratio feedback control is stopped: OFF
• Air-fuel ratio feedback control is clamped: State immediately
before clamping is maintained.
SST Reference Value in Data Monitor

• Values in the table are reference values.
• Values in the table are values detected in ECM or input/output
values sent from ECM. Thus, they may differ from actual part
values. [Example: ignition timing checked using timing light and
display on "IGN TIMING" screen in "DATA MONITOR" mode
could be different. This happens because values on "IGN
TIMING" screen is calculated by ECM using input signal from
various sensors. They are crankshaft position sensor (POS)
and other ignition timing related sensors.]
Monitor item Measurement condition Reference value
Eng. Rev • Tachometer: Connected Almost in accordance

• Start engine, and compare with the value displayed by tachometer.
Air flow meter • After engine warming up At Idle Approx. 1.3V
• A/C SW: OFF
• Selector lever: neutral or N
• No load
Cly air ratio GAS • After engine warming up At Idle Approx. 90 - 110%
Cly air ratio LPG
Eng. temp • After engine warming up Approx. 80°C or more
O2 sensor volt • After engine warming up At Idle Changes between approx.
0.1 - 0.4V⇔0.6 - 0.9V
Maintain at approx. 2,000 rpm Changes between approx.
0.1 - 0.4V⇔0.6 - 0.9V
O2 sensor rich • After engine warming up At Idle Switches slowly between
LEAN⇔RICH.
Maintain at approx. 2,000 rpm Switches between
LEAN⇔RICH at least 5 times
for 10 seconds.
EC-50
TROUBLE DIAGNOSIS

(Cont’d)
Battery voltage • Ignition switch: ON (with engine Approx. 11 - 14V

stopped)
Accelerator • After engine warming up At Idle Approx. 0.6 - 0.65V
Approx. 2,000 rpm Approx. 0.75 - 0.8V
Ignition switch ON with accelerator pedal Approx. 4.1 - 4.3V
depressed (With engine stopped)
Throttle • After engine warming up At Idle Approx. 0.5 - 0.55V
Approx. 2,000 rpm Approx. 0.65 - 0.7V
Ignition switch ON with accelerator pedal Approx. 0.7 - 0.75V
depressed (With engine stopped)
Air temp sensor • After engine warming up Values according to intake air
temperature
Starter SW • Ignition switch: ON → START → ON OFF → ON → OFF
Idle SW • After engine warming up Accelerator pedal is fully depressed ON
• Ignition switch: ON (with engine
Accelerator pedal is released OFF
stopped)
Air conditioner SW • After engine warmed up (at idle) A/C SW: OFF OFF
A/C switch: ON (compressor is ON
operating)
Neutral SW • Ignition switch: ON Neutral, or N ON
Other than above OFF
Electric load SW • Ignition switch: ON Headlamp switch: ON ON
Above switch: OFF OFF
Foot brake SW • Ignition switch: ON Brake pedal depressed ON
Brake pedal released OFF
Fuel jet pls GAS • After engine warming up At Idle Approx. 2 - 4 msec
Fuel jet pls LPG • Selector lever: neutral or N
• No load
Spark timing • After engine warming up At Idle Approx. 15°BTDC
• Selector lever: N At approx. 2,000 rpm Approx. 30 - 40°BTDC
• No load
Fuel pump relay • For 1 second after ignition switch is ON ON
• While engine is running and cranking
• Other than above OFF
Throttle relay • Ignition switch: ON → OFF ON → OFF
O2 sensor heater • After engine warmed up (at idle) ON
TAS completion • After engine warmed up (at idle) Learning completed ON
• All electrical load switches: OFF
Learning not yet completed OFF
• Throttle valve closed position learning
completed
Mast high SW1 • Engine running Fork is approximately 50 cm on this side ON
Mast high SW2 • Lifting up operation of maximum lifting up stroke end.
Fork is down from the above position. OFF
Chg fuel SW1 • Ignition switch: ON Fuel changing switch: LPG ON
Fuel changing switch: Gasoline or OFF
neutral
Chg fuel SW2 • Ignition switch: ON Fuel changing switch: Gasoline ON
Fuel changing switch: LPG or neutral OFF
Inching SW • Ignition switch: ON Inching pedal depressed ON
Inching pedal released OFF
EC-51
TROUBLE DIAGNOSIS

(Cont’d)
LPG relay • While engine is running and cranking ON

• Other than above OFF
Cyl air ratio GAS • After engine warming up At Idle Approx. 30%
At approx. 2,000 rpm Approx. 20%
• While engine is running on gasoline
• While engine is running on LPG. 0%
Cyl air ratio LPG • After engine warming up At Idle Approx. 30%
At approx. 2,000 rpm Approx. 20%
• While engine is running on LPG.
• While engine is running on LPG. 0%
LPG pres sensor • Ignition switch: ON Approx. 0.3 kgf/cm2
Ratio data clr comp • Perform air-fuel ratio learning clear in Complete ON
active test. Not yet complete OFF
TAS factory run • Perform idle air volume learning (plant) Active ON
in active test Inactive OFF
TAS general run Perform idle air volume learning (active) in Active ON
active test
Inactive OFF
Spark correct run • Perform target idle timing adjustment in Active ON
active test
Inactive OFF
Ratio correct run • Perform air-fuel ratio correction in Active ON
active test Inactive OFF
Power balance run • Perform power balance in active test Active ON
Inactive OFF
Pressure clr run • Perform fuel pressure release in active Active ON
test
Inactive OFF
Self chk clr comp • Perform self-diagnostic results clear in Active ON
active test Inactive OFF
All shut update exp • Ignition switch: ON Closed position learning completed ON
Closed position leaning not yet OFF
completed
Tas completion • Perform idle air volume learning in Complete ON
active test Not yet complete OFF
Connect consult2 • Ignition switch: ON When connected to SST ON
When not connected to SST OFF
EC-52
TROUBLE DIAGNOSIS
Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Related sensors Malfunction condition Fail-safe MIL
Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 2,400 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release ON
sensor valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.
Malfunction indicator lamp • Fuel injector will be inhibited at approximately 2,500 rpm to prevent —
MIL malfunction if exhaust performance and driving performance
malfunctions are occurring.
EC-53
POWER SUPPLY AND GROUND SYSTEM
POWER SUPPLY AND ECM Input/Output Signal Specifications

GROUND SYSTEM Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal signal Signal name Measurement condition Measured value
111 ECM & IGN coil relay For approximately 10 seconds with ignition switch Approx. 1V
ON and after ignition switch OFF
Approximately 10 seconds or more after ignition Battery voltage
switch OFF
109 Ignition switch Ignition switch ON
119
121 Power supply for ECM (Backup) Always
115
116
1 Ground Approx. 0V
Circuit Diagram
ECM0081
EC-54
CRANKSHAFT POSITION SENSOR (POS) SYSTEM
CRANKSHAFT POSITION ECM Input/Output Signal Specifications

SENSOR (POS) SYS- Check waveform between terminals shown below and ground using
an oscilloscope.
TEM
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
13 Crankshaft position Approx. 2.6V Approx. 3V Approx. 3V

sensor (POS)
ECM0082 ECM0083 ECM0084
Numerical values (reference values) are obtained using an analog

circuit tester.
Circuit Diagram
ECM0085
Component Parts Inspection

Crankshaft position sensor (POS)
Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-2 : Not 0 Ω nor ∞ Ω
CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the
larger the resistance is.
ECM0086
EC-55
CAMSHAFT POSITION SENSOR (PHASE) SYSTEM
CAMSHAFT POSITION ECM Input/Output Signal Specifications

SENSOR (PHASE) SYS- Check waveform between terminals shown below and ground using
an oscilloscope.
TEM
14 Camshaft position Approx. 0.15V Fluctuates between approx. 1.5 - 2V. Approx. 2V
sensor (PHASE)
ECM0087 ECM0088 ECM0089

circuit tester.
Circuit Diagram
ECM0090

Camshaft position sensor (PHASE)
Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-2 : Not 0 Ω nor ∞ Ω
CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the
ECM0091
larger the resistance is.
EC-56
MASS AIR FLOW SENSOR SYSTEM
MASS AIR FLOW SENSOR SYSTEM SST Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm
Air flow meter Approx. 1.3V Approx. 1.6V

Measure voltage between terminals shown below and ground using
a circuit tester.
51 Mass air flow sensor Approx. 1.5V Approx. 1.3V Approx. 1.5V
67 Mass air flow sensor ground Approx. 0V
Circuit Diagram
ECM0092

Mass air flow sensor
1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing: Approx. 1V
With air blowing: Approx. 1.3V
(The more the air is blown, the higher the voltage is.)
CAUTION:
If air is blown from the air duct side, the voltage becomes lower.
ECM0093
EC-57
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
ENGINE COOLANT TEMPERA- SST Data Monitor Display

TURE SENSOR SYSTEM
Eng. temp After warming up engine: Approx. 80°C or more

a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm
73 Engine coolant Engine coolant temperature at approx.

temperature sensor signal 20°C: Approx. 3.5V
Engine coolant temperature at approx.
80°C: Approx. 1.2V
NOTE:
ECM0094 • If engine coolant temperature sensor has a malfunction, the
value of engine coolant temperature signal is changed along
with start-up time by fail-safe to enable normal operation.
Circuit Diagram
ECM0095

Engine coolant temperature sensor
Check resistance between terminals 1 and 2 on the engine coolant
temperature sensor.
Resistance
Coolant temperature at approx. 20°C: Approx. 2.5 k Ω
Coolant temperature at approx. 80°C: Approx. 0.3 k Ω
ECM0096
EC-58
HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM SST Data Monitor Display

O2 sensor volt Changes between approx. 0.1 - 0.4V⇔ approx. 0.6 - 0.9V
O2 sensor rich ON and OFF alternate slowly. ON and OFF alternate at least 5 times in 10 seconds.

Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At idle after warming up At approx. 2,000 rpm
35 Heated oxygen sensor Changes between approx. 0.1 - 0.4V⇔ approx. ←

0.6 - 0.9V
ECM0097 ECM0098

circuit tester.
Circuit Diagram
ECM0099
EC-59
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM SST Data Monitor Display

Throttle Approx. 0.5 - 0.55V Approx. 0.65 - 0.7V

a circuit tester.
66 Sensor ground (Throttle position sensor) Approx. 0V

47 Sensor power supply (Throttle position sensor) Approx. 5V
50 Throttle position sensor 1 Approx. 0.6V Approx. 0.7V
69 Throttle position sensor 2 Approx. 4.5V Approx. 4.4V
Circuit Diagram
ECM0100

THROTTLE POSITION SENSOR 1, 2 (ELECTRIC THROTTLE
CONTROL ACTUATOR ASSEMBLY)
Check voltage between ECM terminal 50, 69 and ground.
Refer to (EC-36), "ECM Input/Output Signal Specifications" for the
voltage.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor con-
nector. If there are any water drops, completely wipe them
off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if dis-
ECM0101
connecting connector. Perform "Throttle Valve Closed
Position Learning and Idle Air Volume Learning" if replac-
ing electric throttle control actuator. (Refer to (EC-13),
"Throttle Valve Closed Position Learning and Idle Air Vol-
ume Learning".)
• Do not disassemble electric throttle control actuator.
EC-60
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
ACCELERATOR PEDAL POSITION SENSOR SYSTEM SST Data Monitor Display

Accelerator Approx. 0.6 - 0.65V Approx. 0.75 - 0.8V

a circuit tester.
90 Sensor power supply Approx. 5V

106 Accelerator pedal position sensor 1 Approx. 0.6V Approx. 0.65V
82 Sensor ground Approx. 0V
91 Accelerator pedal position sensor 2 power supply Approx. 2.5V
83 Accelerator pedal position sensor 2 ground Approx. 0V
NOTE:
• When the accelerator pedal is depressed slowly from the fully-
closed position, the voltage must increase in proportion to the
opening of the throttle. [Ignition switch ON (engine stopped)]
Ignition switch ON, engine stopped Ignition switch ON, engine stopped
Terminal Signal name
Accelerator pedal is fully depressed Accelerator pedal is fully released
98 Accelerator pedal position sensor 2 Approx. 0.3V Approx. 2V
Circuit Diagram
ECM0102

ACCELERATOR PEDAL POSITION SENSORS 1, 2 (ACCELERA-
TOR WORK UNIT)
Check voltage between ECM terminal 106, 98 and ground.
Refer to (EC-36), "ECM Input/Output Signal Specifications" for the
voltage.
CAUTION:
• Do not apply voltage to accelerator pedal position sensor
terminal.
• Do not disassemble accelerator work unit.
ECM0103
EC-61
INTAKE AIR TEMPERATURE SENSOR
INTAKE AIR TEMPERATURE SENSOR SST Data Monitor Display

Monitor item At Idle At approx. 2,000 rpm
Air temp sensor Values according to intake air temperature

a circuit tester.
34 Intake air temperature sensor signal Intake air temperature at 20°C: approx. 3.5V
Intake air temperature at 80°C: approx. 1.2V
Circuit Diagram
ECM0092

INTAKE AIR TEMPERATURE SENSOR (JOINED WITH MASS
AIR FLOW SENSOR)
Check resistance between intake air temperature sensor (mass air
flow sensor connector) terminals 3 and 5.
Resistance
Intake air temperature at approx. 20°C: Approx. 2.5 kΩ
Intake air temperature at approx. 80°C: Approx. 0.3 kΩ
ECM0105
EC-62
PNP SWITCH SYSTEM
PNP SWITCH SYSTEM SST Data Monitor Display

Monitor item Neutral, or N position Other than the left
Neutral SW ON OFF

a circuit tester.
Terminal Signal name Neutral, or N position Other than the left
102 PNP switch Approx. 0V Battery voltage (A/T models)

Approx. 4.8V (M/T models)
Circuit Diagram
ECM0106
EC-63
STOP LAMP SWITCH SYSTEM
STOP LAMP SWITCH SYSTEM SST Data Monitor Display

Monitor item Brake pedal released Brake pedal depressed
Foot brake SW OFF ON

a circuit tester.
Terminal Signal name Brake pedal released Brake pedal depressed
101 Stop lamp switch Approx. 0V Battery voltage
Circuit Diagram
ECM0107

Stop lamp switch
Check continuity between stop lamp switch terminals 1 and 2.
Brake pedal released: Continuity should not exist.
Brake pedal depressed: Continuity should exist.
ECM0108
EC-64
ELECTRIC LOAD SWITCH SYSTEM
ELECTRIC LOAD SWITCH SYSTEM SST Data Monitor Display

Monitor item Headlamp OFF Headlamp ON
Electric load SW OFF ON

a circuit tester.
Terminal Signal name Headlamp switch OFF Headlamp switch ON
84 Headlamp switch Approx. 0V Battery voltage
Circuit Diagram
ECM0109
EC-65
CAN COMMUNICATION SYSTEM
CAN COMMUNICATION SYSTEM ECM Input/Output Signal Specifications

an oscilloscope.
Terminal Headlamp switch OFF Headlamp switch ON
94 CAN communication line H Approx. 2.4V (Varies depending on communication status.)
ECM0110
86 CAN communication line L Approx. 2.2V (Varies depending on communication status.)
ECM0111

circuit tester.
Circuit Diagram
ECM0112
EC-66
IGNITION SYSTEM
IGNITION SYSTEM SST Data Monitor Display

Spark timing Approx. 0 deg

an oscilloscope.
61 Ignition signal (power Approx. 0.2V Approx. 0.1V Approx. 0.1V

62 transmission drive signal)
80
81
ECM0113 ECM0114 ECM0115

circuit tester.
Circuit Diagram
ECM0116

Spark plug
• Check electrode for dirt, damage, and wear and insulator for
damage.
• Replace spark plug if necessary.
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
Spark plug gap: 0.8 - 0.9 mm
ECM0117
EC-67
IGNITION SYSTEM
Ignition coil
Check the resistance between terminals of the power transistor by
applying and exchanging (+ and -) the inspection rods of an analog
circuit tester.
(+) - (-) Resistance (at room temperature)
1-2 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-1 : Except 0 Ω
1-3 : Except 0 Ω
3-2 : Except 0 Ω
2-3 : Except 0 Ω
ECM0118
CAUTION:
Do not use a digital circuit tester because the standard is
different.
EC-68
FUEL INJECTOR SYSTEM
FUEL INJECTOR SYSTEM SST Data Monitor Display

Fuel jet pls GAS Approx. 2 µs

an oscilloscope.
22 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery voltage
23
41
42
ECM0119 ECM0120 ECM0121

circuit tester.
Circuit Diagram
ECM0122

Injector
• Check resistance between each cylinder injector terminals 1
and 2.
Standard resistance (all cylinders): Approx. 14.5 Ω
(at room temperature)
ECM0123
EC-69
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM SST Data Monitor Display

Monitor item Fuel pump is not activated Fuel pump is operated
Fuel pump relay OFF ON

a circuit tester.
Terminal Signal name For approx. 1 second after ignition switch is turned ON At cranking, engine running
113 Fuel pump relay Approx. 1V (After approx. 1 second: Battery voltage) Approx. 1V
Circuit Diagram
ECM0124

Fuel pump
Check resistance between terminals 3 and 6.
Resistance: Approx. 1 Ω (at room temperature)
EC-70
THROTTLE CONTROL MOTOR SYSTEM
THROTTLE CONTROL ECM Input/Output Signal Specifications

MOTOR SYSTEM Measure voltage between terminals shown below and ground using
a circuit tester.
5 Throttle control motor 1 (Open) Approx. 0.1 - 0.15V

4 Throttle control motor 2 (Close) Approx. 2 - 2.5V
Circuit Diagram
ECM0100

Electric throttle control motor (Electric throttle control actuator
assembly)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 -15 Ω (at 25°C)
CAUTION:
nector. Completely wipe off water drops if there are any.
• Do not apply voltage to electric throttle control motor termi-
nal.
ECM0126
ing electric throttle control actuator. (Refer to (EC-13),
"Throttle Valve Closed Position Learning and Idle Air Vol-
ume Learning".)
EC-71
HEATED OXYGEN SENSOR HEATER SYSTEM
HEATED OXYGEN SENSOR HEATER SYSTEM SST Data Monitor Display

Monitor item At idle after warming up
Oxygen sensor heater ON

a circuit tester.
Terminal Signal name At idle after warming up Approx. 3600 rpm or more
24 Heated oxygen sensor heater open signal Approx. 0.3V Battery voltage
Circuit Diagram
ECM0099

Heated oxygen sensor 1 Heater
Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 3.3 - 3.5 Ω
ECM0128
EC-72
PCV GAS RECIRCULATION DEVICE
PCV GAS RECIRCULATION DEVICE System Diagram
ECM0143

PCV valve
1. At idle, remove PCV valve together with hoses from rocker
cover.
2. Check if hissing sound is heard from the air passage when PCV
valve is operating normally.
ECM0144
3. Check air flow through the PCV valve and sucking air to/from
the INT end.
Blowing air: No air flow
Sucking air: Air flow exists
ECM0145
EC-73
FUEL CUT FUNCTION
FUEL CUT FUNCTION Inspection Procedure

With SST
1. Check "Fuel jet pls GAS" (gasoline) or "Fuel jet pls LPG" (LPG)
in Input/Output monitor, and increase the engine speed to
approximately 2,500 rpm after warming up engine.
2. Make sure that "Fuel jet pls GAS" (gasoline) or "Fuel jet pls
LPG" (LPG) instantly drops when accelerator pedal is released.
ECM0146
Without SST
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,500 rpm or more, and confirm test lamp goes
off for a moment.
ECM0147
EC-74
REMOVAL AND INSTALLATION OF ECM COMPONENTS
REMOVAL AND INSTALLATION OF ECM COMPONENTS Removal and Installation of ECM

1. Disconnect ECM connector.
2. Remove ECM together with ECM bracket.
3. Remove ECM bracket.
4. Install in the reverse order of removal.
CAUTION:
Perform "Throttle Valve Closed Position Learning and Idle Air
Volume Learning" after installation if replacing ECM. (Refer to
(EC-12), "Throttle Valve Closed Position Learning and Idle Air
Volume Learning".)
ECM0148
Removal and Installation of Crankshaft
Position Sensor (POS)
Removal
1. Remove fan.
2. Remove harness connector.
3. Remove crankshaft position sensor (POS).
Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder block.
• Keep away from magnetized objects.
ECM0149 • Make sure that the sensor is inserted securely into chain hous-
ing before tightening bolts.
Removal and Installation of Camshaft

Position Sensor (PHASE)
Removal
1. Remove fan.
3. Remove camshaft position sensor (PHASE).
Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder head.
• Keep away from magnetized objects.
ECM0150 • Make sure that the sensor is inserted securely into cylinder
head front cover before tightening bolts.
EC-75
Removal and Installation of Mass Air Flow

Sensor
2. Remove mass air flow sensor assembly from air horn.
ECM0151
Removal and Installation of Engine Coolant

Temperature Sensor.
1. Disconnect radiator drain plug, and drain coolant.
CAUTION:
Make sure to drain when the coolant temperature is cold.
3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: Thermosensor Socket
manufactured by KTC (part No.: B20T-19)] and similar parts.
ECM0152
Removal and Installation of Heated Oxygen
Sensor (with Heated Oxygen Sensor Heater)
1. Remove harness connector from hearted oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (SST).
ECM0153
3. Remove heated oxygen sensor using a socket designed for

heated oxygen sensor removal and installation (SST).
CAUTION:
Handle it carefully and avoid impacts.
EC-76
Removal and Installation of Throttle Position

Sensor (Electric Throttle Control Actuator
Assembly)
Refer to "Removal and Installation" in EF section.
Removal and Installation of Accelerator

Pedal Position Sensor (Accelerator Pedal
Assembly)
CAUTION:
Do not disassemble accelerator pedal assembly and remove
sensors and switches.
Removal and Installation of Intake Air

Temperature Sensor (with Mass Air Flow
Sensor)
• Refer to (EC-76), "Removal and Installation of Mass Air Flow
Sensor" because intake air temperature sensor is joined with
mass air flow sensor.
Removal and Installation of Neutral Switch

(M/T Model)
1. Remove air duct and air cleaner case (upper) assembly.
3. Remove neutral switch.
Removal and Installation of Ignition Coil

(with Power Transistor)
Removal and Installation of Fuel Injector

ECM0155
Refer to "Removal and Installation" in EF section.
Removal and Installation of Fuel Pump
Removal and Installation of Throttle Control

Motor (Electric Throttle Control Actuator
Assembly)
Refer to "Removal and installation of throttle position sensor (electric
throttle control actuator assembly)" in EF section.
Removal and Installation of LPG Injector

Holder
Removal
1. Remove air duct from air horn.
2. Remove harness connectors of mass air flow sensor, LPG
injector, and LPG fuel pressure sensor.
3. Loosen air horn bolts and remove air horn.
4. Loosen and remove LPG injector holder bolt.
EC-77
Installation
NOTE:
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
when removing and installing each connector. Completely
wipe off water drops if there are any.
• Do not apply voltage to each terminal.
ECM0156
Removal and Installation of LPG Injector

Drive Unit
EC-78
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) Standard, Repair Limit

Fuel pressure [kPa (bar, kg/cm2, psi)] 0.35{3.6}
Idle speed (rpm) M/T model (at neutral) 700±50

A/T model (at N position) 700±50
Ignition timing (°BTDC/rpm) M/T model (at neutral) 0±2/700
A/T model (at N position) 0±2/700
Spark plug Manufacturer/type/gap (mm) NGK/FR2A-D/0.8 - 0.9
Ignition advance device Electronically controlled ignition advance
Density of CO at idle speed (%) /Density of HC at idle speed (ppm) 0.1/50 or less
EC-79
ENGINE LUBRICATION & COOLING SYSTEMS
SECTION LC
CONTENTS
LUBRICATION SYSTEM .................................... LC-2 ENGINE COOLANT SYSTEM ............................ LC-6
Specifications ................................................. LC-2 Specifications ..................................................LC-6
Adjustment Value ........................................... LC-2 Adjustment Value ............................................LC-6
Oil Pressure .................................................... LC-2 Tightening Torque ...........................................LC-6
Tightening Torque .......................................... LC-2 Trouble Diagnosis ...........................................LC-6
Trouble Diagnosis .......................................... LC-3 Cooling System Configuration .........................LC-7
Lubrication Schematic Diagram ..................... LC-4 Water Pump ....................................................LC-8
Oil Pump ......................................................... LC-5 Thermostat ......................................................LC-9
LC
LUBRICATION SYSTEM
LUBRICATION SYSTEM Specifications

MAIN SPECIFICATIONS
Lubrication method Pressured supply
Oil pump Spur gear type

Oil filter Total flow, cartridge type
Adjustment Value
OIL PUMP Unit: mm
Clearance between pump gear and main 0.4 or less
body
Backlash of pump gear 0.5 or less
Pump gear clearance in vertical direction 0.3 or less
Oil Pressure
OIL PRESSURE Unit: kPa (kgf/cm2)
Discharge pressure Oil temperature 80°C
At Idle 98 (1.0)
At 2,000 rpm 274 - 313 (2.8 - 3.2)
Tightening Torque
N·m kgf-m
Oil pump bolt 15.7 - 17.7 1.6 - 1.81

Oil pump cover bolt 6.37 - 7.45 0.65 - 0.76
Oil pump 6.37 - 7.45 0.65 - 0.76
Oil pan drain plug 29.4 - 39.2 3.0 - 4.0
LC-2
LUBRICATION SYSTEM
Trouble Diagnosis
Oil leakage • Cracks or damages in pump body cover Replacement

• Oil leakage from gasket and oil seal Replacement
• Oil leakage from near spindle support Replace the O-ring seals or inspect the pump body
and replace it as necessary.
• Oil leakage from near distributor Replace the O-ring seals or inspect the pump body
and replace it as necessary.
• Oil leakage between timing chain housing and Disassemble and reassemble/apply liquid packing
cylinder block again.
• Loose rocker cover retaining nuts and oil leakage. Additionally tighten.
• Loose oil pan mounting bolts and oil leakage Additionally tighten.
• Oil leakage from crankshaft front oil seal Replacement
• Oil leakage from crankshaft rear oil seal Replacement
• Oil leakage from regulator valve Additionally tighten or replace.
• Oil leakage from plugs in lubrication system Replace or additionally tighten.
MIL ON • Loose oil filter Additionally tighten.
• Use of inappropriate quality of oil Replace with specified oil.
• Oil pump regulator valve malfunction Overhaul or replace the oil pump.
• Oil pump malfunction Overhaul or replace the oil pump.
• Inappropriate oil pump installation Additionally tighten.
• Damaged oil pump gasket Replacement
• Oil filter malfunction Replacement
• Enlarged clearance between sliding parts Disassemble and replace the relevant sliding parts.
• Loose mounting of rocker shaft bracket Tighten bolts.
• Clogged oil strainer Wash.
• Malfunction of oil pressure gauge pressure switch Replacement
• Oil pressure switch malfunction Replacement
• Insufficient oil in oil pan Fill oil and identify/repair the factor causing non-
standard condition.
• Loose oil pan drain plug or damaged gasket Additionally tighten or replace.
• Incident in electrical system Inspect the electric circuits.
Noise • Excessive backlash of pump rotor Replacement
LC-3
LUBRICATION SYSTEM
Lubrication Schematic Diagram
LCM0022
LC-4
LUBRICATION SYSTEM
Oil Pump
COMPONENT PARTS LOCATION
LCM0023
INSPECTION
1. Check the following items for wear or damages.
• Pump body and cover
• Pump gear section
• Driving spindle
The pump gear section and main body have no internal compo-
nents that can be serviced separately. If the pump gear or main
body is worn or damaged, replace the drive shaft assembly or
oil pump assembly.
2. Inspect the clearance at the following points using a feeler
gauge.
If the clearance exceeds the specified limit, replace the drive
shaft assembly or oil pump assembly.
Clearance between pump gear and main body:
0.4 mm or less
Backlash of pump gear: 0.5 mm or less
Pump gear clearance in vertical direction: 0.3 mm or less
SLC136
3. Inspect the regulator valve spring of the oil pump.

If damaged, replace the spring or pump assembly.
Free length 41.5±1 mm
Repair limit 40.0 mm
LCM0024
LC-5
ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM Specifications

Cooling method Water cooled, controlled circulation
Water pump Centrifugal

Thermostat Wax pellet
Adjustment Value
WATER PUMP
Fan belt deflection
11 - 13
When pushed with a force of 98N (10 kg) [mm]
THERMOSTAT
Standard specification
Valve opening temperature (°C) 76.5

Maximum lift (mm/°C) 8/90
Tightening Torque
N·m kgf-m
Water pump retaining bolt M8 15.7 - 17.7 1.6 - 1.81
Water pump retaining bolt M6 6.37 - 7.45 0.65 - 0.76
Thermostat housing bolt 15.7 - 17.7 1.6 - 1.81
Trouble Diagnosis
Water leakage • Water leakage from water pump shaft seal Replace the water pump assembly.
• Water leakage from water pump mounting face Additionally tighten. If the leakage still remains,
packing replace the packing.
• Water leakage from radiator cap Replace the packing or assembly.
• Coolant leakage from engine coolant Additionally tighten or replace.
temperature sensor
• Loose connection Additionally tighten.
• Damaged head gasket Replace and check engine oil for contamination.
• Cracks in cylinder block Replace and check engine oil for contamination.
• Cracks in cylinder head Replacement
• Loose head bolt Additionally tighten.
Insufficient circulation of • Insufficient flow rate in coolant circuit Remove any contamination and rust from the coolant
coolant circuit, and inspect the hose clamps.
• Insufficient amount of coolant Fill.
• Thermostat malfunction Replacement
Corrosion • Excessive amount of impurities in coolant Use clean softened water.
• Insufficient cleaning of coolant circuit Perform cleaning/flushing more frequently.
LC-6
Trouble Diagnosis (Cont’d)

Engine over temperature • Thermostat malfunction Replacement

(Overheat)
• Radiator fins plugged with dirt and dust Clean with compressed air.
• Inappropriate ignition timing and valve timings Adjust the ignition timing and valve clearances.
• Contamination and sludge deposits in engine oil Clean inside the engine and refill it with oil.
• Plugged radiator Clean inside the radiator.
• Poor accuracy of coolant temperature gauge Replacement
• Insufficient amount of coolant Fill.
• Air in coolant circuit Bleeding
• Contaminated engine coolant Use clean softened water.
Overcool • Thermostat malfunction Replacement
• Malfunctioning coolant temperature sensor Replacement
Noise • Noise from water pump mechanical seal Replacement
• Wear or damage of water pump bearing Replacement
Cooling System Configuration
LCM0025
LC-7
Water Pump
1. Open the drain of the radiator and extract coolant into an
appropriate container.
CAUTION:
to get burned.
2. Remove the radiator shroud.
3. Loosen the fan belt.
• Loosen the alternator adjusting bolt.
• Fully put aside the alternator toward the engine.
• Remove fan and fan pulley.
• Remove the water pump together with the gasket.
SLC190
INSPECTION
Do not disassemble water pump. If any non-standard condition is
found, replace the water pump.
1. Check the water pump vanes for rust and pitching.
SLC070
2. Check the water pump bearing for proper end play and smooth
operation.
SLC071
ASSEMBLY
1. Install the water pump in the reverse order of removal. Always
use a new gasket.
2. Adjust the fan belt tension. For the adjustment value, refer to
page MA-section.
CAUTION:
• Before filling with coolant, always loosen the air purge plug.
• After refilling, make sure to tighten the plug.
LC-8
Thermostat
REMOVAL
1. Remove the radiator upper hose from the water outlet and
extract coolant.
WARNING:
to get burned.
2. Remove water inlet and remove thermostat.
INSPECTION
Inspect the thermostat as instructed below and replace it as
necessary.
1. Inspect valve seating status under ordinary temperature. The
valve must be seated firmly.
2. Inspect the opening temperature and maximum valve lift by
heating the valve in a container.
CAUTION:
if may be a cause to get burned. Do not touch the thermostat,
container or hot water inside until the temperature lowers
sufficiently.
3. make sure that the valve closing temperature is approx. 5°C
lower than the opening temperature. Also perform the same
inspection before installing a new thermostat.
CO097
INSTALLATION
Install in the reverse order of removal.
Always use a new water inlet gasket.
LC-9
LC-10
ENGINE FUEL
SECTION EF
CONTENTS
EMISSION CONTROL SYSTEM (ONLY FOR Removal and Installation of Gasoline Fuel Injector
ELECTRONIC CONTROLLED TYPE) ................ EF-2 (Electronic Controlled Gasoline and Combined
UNIT LAYOUT .................................................... EF-3 Use) ...............................................................EF-12
SERVICE DATA AND SPECIFICATIONS (SDS) EF-9 Injector Holder ...............................................EF-16
Electronic Control System Specifications ....... EF-9 LPG Device Components (Specifications for LPG
Carburetor Specifications ............................... EF-9 and Combined Use) ......................................EF-17
LPG FUEL SYSTEM TROUBLE DIAGNOSIS . EF-10 Components Around Carburetor and Pneumatic
DISASSEMBLY AND ASSEMBLY OF FUEL Governor (Carburetor Specifications) ............EF-18
SYSTEM ............................................................ EF-11 VAPORIZER MECHANISM AND OPERATION EF-19
Removal and Installation of LPG Injector Drive Unit Primary (Decompression) Room ...................EF-19
Connector ..................................................... EF-11 Description ....................................................EF-22
Removal and Installation of Electronic Control Secondary Valve Room .................................EF-23
Throttle Assembly ......................................... EF-11
EF
EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED TYPE)
EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC CONTROLLED

TYPE)
Engine type K15, 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
UNIT LAYOUT
UNIT LAYOUT
EFM0089
EF-3
UNIT LAYOUT

(GASOLINE)
EFM0090
EF-4
UNIT LAYOUT
K-ENGINE SYSTEM DIAGRAM (LPG)
EFM0091
EF-5
UNIT LAYOUT
VACUUM PIPING DIAGRAM
EFM0092
EF-6
UNIT LAYOUT
FUEL PIPING DIAGRAM
EFM0093
EF-7
UNIT LAYOUT
K-ENGINE SYSTEM DIAGRAM (COMBINED USE)
EFM0094
EF-8
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECI- Electronic Control System Specifications

FICATIONS (SDS) 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 N•m (1.6 - 1.8
kg-m)
Carburetor Specifications
Fuel pump ...... 1,400 ml or more (at 1,000 rpm)
Fuel pump discharge pressure ...... 16.7 - 23.5 kPa (0.17 - 0.24 kgf/cm2)
Fuel discharge pressure ...... Atmospheric pressure
Vaporizer (with secondary room, integrated with water heater)
Carburetor
Carburetor type
Starting choke type Automatic return hot-water wax ← ←
Inlet diameter (mm) 57
Outlet diameter (mm) 30
Venturi diameter 24
Large
Small (Inner diameter - Outer diameter) 12 - 16.5
Main jet 116
Main air bleed 60
Slow jet 48
Slow air bleed 80/140
Float level adjustment (mm) 22
High position (H1)
Low position (H2)
Governor (carburetor specifications)

Type Pneumatic
Speed control type Controlled by amount of mixture

Control mechanism Vacuum type
No load instantaneous allowable maximum 3,600
engine speed (rpm)
Vacuum continuous allowable maximum engine 3,000
speed (rpm)
Hunting allowable frequency 3 (Max)
EF-9
LPG FUEL SYSTEM TROUBLE DIAGNOSIS
LPG FUEL SYSTEM TROUBLE DIAGNOSIS

Fuel leakage Looseness of piping connection Tighten

Operating malfunction of vaporizer Repair and adjust
Poor connection or some inclusion is caught in between plunger Clean and rub
rubber seat and valve seat of solenoid valve
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 filter Clean and retighten
Adjusting malfunction of vaporizer primary and secondary room Adjustment
pressures
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 Adjustment
throttle valve, or operating malfunction of electric throttle control
actuator
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 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
Operating malfunction of Adjusting malfunction of vaporizer primary and secondary room Adjustment
vaporizer pressures
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 Check, clean, and adjust
circulation)
Tar deposit in valve Remove tar and clean
EF-10
DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM
DISASSEMBLY AND Removal and Installation of LPG Injector

ASSEMBLY OF FUEL Drive Unit Connector
SYSTEM 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.
EFM0095 INSTALLATION
1. Press the lever in drive unit connector while pressing it to
connector end.
2. 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.
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
EF-11
Removal and Installation of Electronic

Control Throttle Assembly (Cont’d)
EFM0099
INSTALLATION
Caution for installation
Uniformly tighten bolts diagonally in several steps.
CAUTION:
nector. Completely wipe off water drops if there are any.
• Do not apply voltage to throttle position sensor terminal.
ing 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-12

Combined Use) (Cont’d)
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 injec-
tor 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
EF-13

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 N•m (0.9 - 2.1 kgf-m)
Second tightening: 20.6 - 26.5 N•m (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-14

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
EF-15
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 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.
EFM0108 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 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-16
LPG Device Components (Specifications for

LPG and Combined Use)
EFM0109
EF-17
Components Around Carburetor and

Pneumatic Governor (Carburetor
Specifications)
EFM0111
EF-18
VAPORIZER MECHANISM Primary (Decompression) Room

AND OPERATION This is decompressed and carbureted high-pressure fuel flow from
LPG tank to approximately 0.3 kgf/cm2.
EFM0112
(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/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.
EF-19
Primary (Decompression) Room (Cont’d)

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-20
Primary (Decompression) Room (Cont’d)

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 pri-
mary side valve is placed in the proper position. Replace it
with new one if there is some leakage.
EF-21
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-22
Secondary Valve Room

This prevents excessive fuel that is not corresponding with intake air
amount of carburetor from flowing in by decompressing fuel
pressure until it nearly reaches atmospheric pressure.
(8) Secondary side valve
(9) Secondary side valve seat
(10) Secondary (decompression) room
(11) Secondary diaphragm
(12) Secondary diaphragm spring
(13) Secondary side valve lever
(14) Vacuum lock off diaphragm
(15) Vacuum lock off room
(16) Vacuum lock off diaphragm spring
(17) Balance lever
(18) Balance spring
:
LPG pipe flare nut: 18 - 26 N•m (1.8 - 2.7 kg-m)
Hot water piping clamp: 35 - 83 N•m (3.5 - 8.5 kg-cm)
Clamp between hose and adopter: 53 - 113 N•m (5.4 - 11.6 kg-cm)
EFM0116
Fuel decompressed approximately 0.3 kgf/cm2 is supplied to

secondary room (10) through the gap between secondary valve (8)
and valve seat (9) to decompress to the same pressure as
atmospheric pressure.
Vacuum from intake manifold not only lifts up secondary diaphragm
(11) but also secondary valve lever (13) while engine is running.
Secondary diaphragm (11) is moved at same time.
Therefore, secondary valve (8) opens, and them fuel flows in.
Vacuum from intake manifold does not occur while engine is
stopped. Diaphragm spring (12) pushes secondary diaphragm (11)
down. Secondary valve closes as a result, and then fuel stops
flowing in.
EF-23
Secondary Valve Room (Cont’d)

VACUUM LOCK OFF MECHANISM
Pull vacuum lock off diaphragm (14) toward vacuum lock off room
side when engine starts. Move secondary valve lever against
vacuum lock off diaphragm spring. It applies stress to not only
balance spring assembled in secondary valve balance lever (17) but
also secondary valve lever spring (12). Slightly lift up secondary
valve (8) from the valve seat (9).
Therefore, fuel flows from primary room to secondary room, and
then engine starts.
Vacuum lock off diaphragm (14) is pulled toward vacuum lock off
room side while engine is running. For this reason, secondary valve
lever operates without reference to vacuum lock off diaphragm
position.
Removal and installation

1. Fully close LPG tank outlet valve.
2. Run the engine until fuel in the fuel piping is completely
consumed.
3. Completely drain engine coolant.
4. Remove hot water piping from vaporizer.
5. Remove vaporizer connector and vacuum piping.
6. Remove the bolt installing vaporizer to bracket, and then
remove vaporizer.
7. Install in the reverse order of removal.
CAUTION:
Use the special sealant when reassembling LPG connector
after removing it from vaporizer.
• Set secondary valve lever as shown in the figure.
EFM0117
Disassembly, inspection, and assembly

1. Remove secondary valve room cover.
2. Remove primary diaphragm. Be careful not to damage it.
3. Remove secondary valve lever assembly and spring.
4. Remove vacuum lock diaphragm and spring.
5. Check whether disassembled parts are normal or not.
6. Assemble in the reverse order of disassembly.
• Make sure that secondary diaphragm securely connects with

secondary lever.
• Blow 4 kgf/cm2 air from primary room fuel inlet to make sure
that there is no leakage. Replace secondary valve lever assem-
bly if some leakage is detected.
EF-24
Secondary Valve Room (Cont’d)

CARBURETOR SPECIFICATION VAPORIZER COMPONENTS
EFM0118
EF-25
ENGINE ELECTRICAL SYSTEM
SECTION EE
CONTENTS
ADJUSTMENT VALUE ....................................... EE-2 Starter Motor Specifications ........................... EE-8
TROUBLE DIAGNOSIS ...................................... EE-3 Component Parts Location ............................. EE-9
DISTRIBUTOR (CARBURETOR TYPE) ............. EE-4 Overhaul ....................................................... EE-10
Structure ......................................................... EE-4 Assembly Inspection .................................... EE-12
Disassembly ................................................... EE-5 ALTERNATOR .................................................. EE-13
Inspection ....................................................... EE-6 Components of Alternator ............................ EE-13
Assembly ........................................................ EE-6 Disassembly ................................................. EE-14
Inspection After Assembly .............................. EE-7 Inspection ..................................................... EE-16
STARTER MOTOR ............................................. EE-8
EE
ADJUSTMENT VALUE
ADJUSTMENT VALUE
Component Items Description
Distributor • Integrated ignition coil Primary coil resistance: 0.9 - 1.2 Ω

Secondary coil resistance: 20 - 29 Ω
• Pickup assembly Pickup coil resistance: 420 - 540 Ω
• Air gap between signal rotor and pickup assembly 0.35 - 0.45 mm
Starter motor • Brush dimensions 10.0 - 18.0 mm (Wear margin 8 mm)
• Brush spring pressure 1.4 - 1.8 kg
Alternator • Stator Resistance between respective lead wires: 1 Ω or less
Resistance between stator core and lead wire: ∝
• Rotor coil Standard resistance between slip rings: 2.9 Ω
Standard resistance between slip ring and rotor core: ∝
• Snap ring Snap ring outer diameter: Standard: 14.4 mm
Repair limit: 14.0 mm
• Brush Projected length from holder:
Standard: 10.0 mm
Repair limit: 2.0 mm
EE-2
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
No or slow cranking • Battery is discharged Check and repair the charging system, check and adjust the fan belt for
tension, or replace the battery
• Incident in starter system wiring Check and repair or replace the starter switch.
• Starter motor malfunction Repair or replace.
If the light turns off or dims when the starter switch is turned to "ON" with the
headlights on:
a: Check the battery.
b: Check the electric connections and wiring.
If the light remains bright when the starter switch is turned to "ON" with the
headlights on:
a: Check the wiring between battery and starter motor.
b: Check the starter switch.
Engine is cranked but • Incident in ignition system (Ignition system diagnosis procedure)
not started. (Another possible cause is an Inspect the spark plug following the steps below
incident in the fuel system. Refer to Disconnect the high-tension cord from the No. 1 plug and keep the cord 10
the section about the fuel system) mm away from the engine metal portions. Then crank the engine. If there is
difficulty in identifying a spark, use the following approach: connect the high-
tension cord to a new spark plug that is separately prepared, contact the
thread of the plug to the engine metal and check for a spark by activating the
starter.
a: Check the spark plug.
b: Check the ignition timing.
c: Check the fuel system.
d: Check the cylinder compression.
a: Check the primary coil current.
b: If the current is too large, a short circuit may be present, replace.
c: Check coil malfunction, replace.
d: If the high-tension cable has an open circuit, Replace.
EE-3
DISTRIBUTOR (CARBURETOR TYPE)
DISTRIBUTOR (CARBURETOR TYPE) IGNITION SYSTEM
CAUTION:
Before starting the task, turn off the ignition switch and
disconnect the battery cable.
Structure
FULL SOLID-STATE TYPE
EEM0111
A low-voltage electronic distribution system is adopted for the

electronic control.
Refer to EC section.
EE-4
Disassembly
• Remove the cap assembly retaining bolts and remove the rotor
cover.
EEM0112
• Disconnect the pickup coil that connects to the IC igniter, and

remove the connector terminal screws (two each).
• Remove the retaining screws of the IC igniter and pickup coil
(two each).
• To separate the connector from the housing, slide it along the
housing.
CAUTION:
Do not place the pickup coil at a location where it may collect
iron powder.
EEM0113
• Remove the heat sink retaining bolts and those retaining the
breaker plate indicated by the arrow in the figure, and remove
the heat sink.
EEM0114
• Remove the vacuum control retaining bolts, separate the

connection between the vacuum control link and the breaker
plate, and then remove the vacuum control and breaker plate
from the housing assembly.
EEM0115
EE-5
• The figure on the left shows the housing assembly. If you also
need to disassemble the governor, first remove the pin located
at the lower end of the shaft using a punch and pull off the shaft.
If you are removing the ignition coil, additionally remove the bolt
indicated by the arrow in the figure and pull out the ignition coil.
EEM0116
Inspection
IGNITION COIL INSPECTION
• Measure the resistance of the primary and secondary coil.
Primary coil resistance [between terminals (1) and (2)]
Standard: 0.9 - 1.2 Ω
Secondary coil resistance [between terminal (1)
or (2) and secondary terminal]
Standard: 20 - 29 Ω
EEM0117
PICKUP ASSEMBLY
• Measure the pickup coil resistance using a circuit tester.
Standard: 420 - 540 Ω
• Move a screwdriver to and fro near the iron core of the pickup
assembly and make sure that the tester needle fluctuates.
CARBON CONTACT
• If the entire spherical surface at the tip is worn out, replace the
cap assembly.
EEM0118
CAP ROTOR
• Check for any cracks or damages.
SIGNAL ROTOR
• Check for any damages and bends.
VACUUM CONTROL
• Verify that the link is pulled when applying vacuum pressure to
the diaphragm with a vacuum pump.
Assembly
• Assemble in the reverse order of disassembly while observing
the following instructions.
• Apply grease to the vacuum control link.
• Tighten the M3 screws to 6 to 9 kg-cm and the M4 screws to 16
to 30 kg-cm.
• The shaft must rotate smoothly when turned by hand.
EE-6
Inspection After Assembly

• Measure the air gap between the signal rotor and the pickup
assembly.
Standard: 0.35 - 0.45 mm
EEM0120
EE-7
STARTER MOTOR
STARTER MOTOR CAUTION:

Before starting any electrical system service, make sure to turn
off the key switch and disconnect the battery cable.
Starter Motor Specifications

Items Specification
Part type M000T65381

Type Integrated reduction gears
Output 1.2 kW
EEM0122
EE-8
STARTER MOTOR
Component Parts Location

Major components of starter motor
Symbol Description
(1) Front bracket

(2) Overrunning clutch
(3) Lever
(4) Internal gear
(5) Packing
(6) Shaft gear
(7) Gear assembly
(8) Packing
(9) Armature
(10) Yoke assembly
(11) Connector brush holder assembly
(12) Rear blanket
(13) Switch assembly
(14) Hexagon head bolt
(15) Flange screw
EEM0123
EE-9
STARTER MOTOR
Overhaul
RELATED TO MAGNET SWITCH
• Plunger sliding face (rust, contamination, deformation)
• Broken or worn return spring
• Rough surface of main contact (burnout)
• Operation check of magnet switch
(Proper performance of magnet coil)
1. Plunger's drawing operation (Series coil operation)
Wire the plunger as shown in the figure on the left. The plunger
should be drawn strongly by the series coil and shunt coil.
2. Plunger's holding operation (Shunt coil operation)
EEM0124 In the above circuit, disconnect the wiring from the terminal M.
If the shunt coil is normal, the plunger should be held in place.
EEM0125
PINION MECHANISM
• Damage or wear of pinion gear tooth tops
• Visually check for damage or wear. Replace the gear if the
damage/wear is excessive.
• Pinion gear sliding face (rust, contamination, damage on spline)
• Check the pinion gear sliding motion. Replace the gear(s), if
the gear(s) drag excessively.
• Broken or worn pinion spring
• Check the pinion spring(s) and replace them if excessive
damage is present.
• Pinion spring (lever fulcrum) sliding motion
• Check the pinion spring(s) and replace them if excessive
damage is present.
• Overrunning clutch operation (slippage, seizure)
Turn the pinion gear by hand. If it turns freely in both directions
or will not turn in either direction, the overrunning clutch has
lost its proper functionality. Replace it.
FIELD COIL
Check the field coil for continuity.
Judgement
If there is continuity, the field coil is normal.
If there is no continuity, the field coil has an open circuit.
Replace it.
EEM0126
EE-10
STARTER MOTOR
• Check for continuity between the field coil and a ground.
Judgement
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.
CAUTION:
Note that, however, a compound-wound motor structurally
grounds the field coil. This means that the tester will show
continuity between the field coil and a ground.
EEM0127
ARMATURE COIL
• Check the continuity between the commutators.
Judgement
If there is continuity, the armature coil is normal.
If there is no continuity, the coil has an open circuit. Replace it.
EEM0128
• Check for continuity between the armature coil and a ground.
Judgement
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.
EEM0129
BRUSH COMMUTATOR RELATED

Brush wear (mm) 10.0 - 18.0 (Wear margin: 8 max.)
Brush spring pressure (kg) 1.4 - 1.8
• If the commutator has a rough surface, grind it using sandpaper

of #500 or #600.
• If the insulator (high mica) of the commutator is 0.2 mm or less
in thickness, replace the commutator.
EEM0130
EE-11
STARTER MOTOR
Assembly Inspection
• Inspection for abrasion between the armature core and the ball
core.
• Starter motor inspection (performance with no load)
EEM0131
PROCEDURE
• Connect an ammeter to the battery positive terminal and the B
terminal.
• Connect a test wire to the B terminal and S terminal.
• Connect a voltmeter to the B terminal and the starter motor
body.
• Connect a test wire to the battery negative terminal and the
starter motor body.
JUDGEMENT
• The pinion gear should pop out and the starter motor should
rotate.
EE-12
ALTERNATOR
ALTERNATOR
EEM0132
23100FF110
Official output 50A (0.079 in)
Components of Alternator
C144F038
EE-13
ALTERNATOR
Disassembly
PULLEY
• Secure shaft hexagonal part with a box wrench, loosen pulley
nut, and remove pulley.
CAUTION:
Hexagonal box wrench must be used. Twelve-fold box wrench
may crush shaft head and slip.
C144F030
REAR END COVER

• Remove screw and terminal B nut, and then remove rear end
cover.
C144F031
BRUSH HOLDER
• Remove screw, and then remove brush holder.
C144F032
IC REGULATOR
• Remove screw, and then remove IC regulator.
CAUTION:
Lengths of screws are difficult. Arrange removed screws, and
securely install them in the original position.
C144F033
EE-14
ALTERNATOR
Disassembly (Cont’d)
RECTIFIER
• Remove screws securing wires of rectifier and stator, and
remove rectifier.
C144F034
REAR END FRAME

• Remove bolts and nuts, and then remove rear end frame.
C144F035
ROTOR
• Keep drive end frame level using blocks, and then press out
rotor.
C095F148
RETAINER PLATE
• Remove screws, and remove retainer plate.
C144F036
EE-15
ALTERNATOR
Disassembly (Cont’d)
BEARING
Drive end side
• Keep drive end frame level using blocks, and then press out
bearing using a jig.
Snap ring side

• Pull out bearing using a puller.
CAUTION:
Bearing for high speed is specified to be used. Always use it
C095F149
when replacing, do not impact it.
C095F150
Inspection
BEARING
• Rotate bearing by hand.
• Check for noise or binding.
C095F151
STATOR
• Measure resistance between each lead wire using a circuit
tester.
Standard: 1 Ω or less
• Measure resistance between stator core and lead wire.
Standard: ∝
CAUTION:
Opening of stator coil itself is not considerable. Check the
O109F317 connection part of wires if continuity should not exist.
EE-16
ALTERNATOR
Inspection (Cont’d)
ROTOR COIL
• Measure resistance between each snap ring using a circuit
tester.
Standard: 2.9 Ω
• Measure resistance between snap ring and rotor core using a
circuit tester.
Standard: ∝
C095F153
SNAP RING
• Check snap ring for dirt and damage.
• Wipe it clean with a cloth that has been dipped in alcohol if dirty.
• Polish with sandpaper (#500 to 600) if there is slight damage.
• Measure snap ring outer diameter.
Slip ring outer diameter: Standard 14.4 mm
Usable limit 14.4 mm
• Replace if outside the usable limit.
C095F154
BRUSH
• Measure excessive brush length from brush holder.
Excessive length of brush: Standard 10.0 mm
Usable limit 2.0 mm
• Replace if outside the usable limit.
• Make sure that brush is slightly moving in brush holder.
C095F155
RECTIFIER
• Check continuity between each rectifier diode with circuit tester
in kΩ range.
• It is normal that continuity should exit in one side of diode and
continuity should not exist in another side of diode.
CAUTION:
Do not use 500V mega tester that breaks rectifier.
C144F037
EE-17
ALTERNATOR
Inspection (Cont’d)
NOTE:
Rectifier condition cannot be judged by forward resistance. One of
the characteristics of a diode is that forward current is greatly
changed by battery voltage. Indication of tester changes with
differences of tester type and resistance range. Rectifier condition is
judged by resistance differences between forward and reverse
currents.
O109F322
IC REGULATOR
Check continuity between IC regulator terminal B and F with circuit
tester in kΩ range.
• It is normal that continuity should exit in one side and continuity
should not exist in another side.
CAUTION:
Do not use 500V mega tester that breaks IC regulator.
NOTE:
IC regulator can be checked with the following procedure if there is
O109F323
constant voltage power supply that can change voltage between 10
to 20V range.
CAUTION:
Regulator may be destroyed if IC regulator misconnects only
for a moment. Perform inspection after checking wiring.
• Connect IC regulator unit with constant voltage power supply,
circuit tester, and lamps.
• (SW1 and SW2 must remain OFF.)
• Set a power supply voltage to 12V.
• Set SW1 setting to ON. Make sure that L1 turns ON brightly,
and L2 turns ON dimly at this time.
• Next, turn SW2 to NO while leaving SW1 at ON. Make sure that
L1 turns OFF, and L2 turns ON brightly at this time.
• Raise battery voltage from 12V gradually. Make sure that L2
may turn OFF when battery voltage is approximately 14.5±0.6V.
C095F158
EE-18
TECHNICAL PUBLICATIONS FEEDBACK
(Please print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
The following discrepancy or omission has been discovered in:

Operation & Maintenance Manual Option Bulletin
Part List/Manual Special Instruction
Service Manual Service Data Manual
Electronic Manual Other:
Publication # Engine model #
Truck model # Issue date #
Truck serial # Page #
(Please print)
Explanation of discrepancy or omission:
Please fax or mail completed form to:
Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2011 W. Sam Houston Parkway N. P. O. Box 30171
Houston, Texas 77043-2421 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277

99789-85100 K21 Service Manual

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Service Manual

K15, K21, K25 Gasoline Engine

For use with GP15N-GP35N, GPE15N-GPE35N

Copyright © 2003 by MCFA. All Right Reserved.

Pub. No. 99789-85100

MA MAINTENANCE ENGINE MAINTENANCE

ET ENGINE TUNE-UP SPECIFICATIONS, TIGHTENING TORQUE, TROUBLE DIAGNO-

EM ENGINE MECHANICAL PRECAUTIONS, ENGINE OUTSIDE DRAWINGS, MAIN SPECI-

EC ENGINE CONTROL PRECAUTIONS, PREPARATION, DESCRIPTION, BASIC

LC ENGINE LUBRICATION LUBRICATION SYSTEM, ENGINE COOLANT SYSTEM

EF ENGINE FUEL EMISSION CONTROL SYSTEM (ONLY FOR ELECTRONIC

EE ENGINE ELECTRICAL ADJUSTMENT VALUE, TROUBLE DIAGNOSIS, DISTRIBUTOR

HOW TO USE THIS MANUAL Description

Main unit changes

Torque, moment N•m kgf-m 9.80665

kPa mmHg 0.133322

Spring constant N/mm kgf/mm 9.80665

* The conventional unit can be used for SI.

• Do not touch any metal portions immediately after the engine is

Precautions for Radio Equipment Installation

PRECAUTIONS Precautions in Draining Engine Coolant

Precautions for Disconnecting Fuel Piping

Precautions for Removing and

Precautions for Inspection, Correction, and

Precautions for Assembly and Installation

Parts Requiring Angle Tightening

Caution for Use of Power Tools

Precautions for Liquid Ggasket Application

LIQUID GASKET APPLICATION INSTRUCTION

4. Apply a continuous bead of liquid gasket to the specified

TIGHTENING TORQUE Standard Bolt Tightening Torque

N·m 3.82 - 4.41 6.37 - 7.45 9.22 - 10.8

Hexagon head bolt and nut

(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)

Standard Bolt Tightening Torque (Cont’d)

N·m 7.8 11.8 15.7 21.6

Engine Part Tightening Torque

Cylinder head (lubricated) Separately given

Main bearing cap (lubricated) Separately given

N·m 220.5 240.1

Engine Part Tightening Torque (Cont’d)

N·m 1.27 1.67

MAIN BEARING CAP

SPECIAL SERVICE TOOLS

KV11103000 Pulley puller Removing crankshaft pulley

ST05240001 Engine attachment

ST0501S000 Engine stand assembly

KV101041S0 Crankshaft main bearing cap puller

ST12070000 Valve lifter

ST1102S000 Valve guide reamer set

ST1524S000 Front oil seal drift

KV10113700 Heated oxygen sensor wrench Removing and installing heated

ENGINE OUTSIDE DRAWINGS CARBURETOR SPECIFICATIONS

ELECTRONIC CONTROLLED SPECIFICATIONS

MAIN SPECIFICATIONS MAIN SPECIFICATIONS OF IGNITION SYSTEM

Engine type K15

Engine control system Electronic controlled specifications Carburetor specifications

Compression pressure [MPa (kg/cm )/rpm]2 1.3(13.0)/250

FUEL SYSTEM AND ENGINE SPEED CONTROL SYSTEM

Engine control system Electronic controlled specifications Carburetor specifications