Mitsubishi K21 User manual

K21
K25
Service Manual
K21, K25 Gasoline Engine
For use with FG15N-FG35N
Chassis Service Manual. 99789-57100

FOREWORD
This service manual covers K21 and K25 Gasoline Engine of Mitsubishi Forklift Trucks and
gives detailed maintenance and repair information. The instructions are grouped by systems to be
a convenient reference.
Long productive life of your forklift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. Read the respective
sections of this manual carefully and become familiar with all the truck components before
attempting any work.
All descriptions, illustrations, specifications, and serial numbers in this manual are effective as of
the printed date of this manual. Mitsubishi reserves the right to change specifications or designs
without notice and without incurring obligations.
Pub. No. 99789-57100

GROUP INDEX Items
GI GENERAL INFORMATION
HOW TO USE THIS MANUAL, PRECAUTIONS FOR SAFETY AND
QUALITY, PRECAUTIONS, TIGHTENING TORQUE,
SPECIAL SERVICE TOOLS, ENGINE OUTSIDE DRAWINGS, MAIN
SPECIFICATIONS, STANDARD AND REPAIR LIMIT, STAMPED LOCA-
TION OF ENGINE NO., TROUBLE DIAGNOSIS
MA MAINTENANCE
ENGINE MAINTENANCE
ET ENGINE TUNE-UP
SPECIFICATIONS, TIGHTENING TORQUE, TROUBLE DIAGNO-
SIS, ENGINE INSPECTION AND ADJUSTMENT
EM ENGINE MECHANICAL
PRECAUTIONS, ENGINE OUTSIDE DRAWINGS, MAIN SPECI-
FICATIONS, ADJUSTMENT VALUE, TIGHTENING TORQUE,
TROUBLEDIAGNOSIS,SPECIALSERVICE TOOLS,REMOVAL
AND INSTALLATION OF ENGINE, ENGINE SERVICE
EC ENGINE CONTROL
PRECAUTIONS, PREPARATION, DESCRIPTION, TROUBLE
DIAGNOSIS, BASIC INSPECTION, COMPONENT PARTS
INSPECTION, PCV GAS RECIRCULATION DEVICE, ECM COM-
PONENTS
LC ENGINE LUBRICATION
& COOLING SYSTEM
LUBRICATION SYSTEM, ENGINE COOLANT SYSTEM
EF ENGINE FUEL
EMISSION CONTROL SYSTEM, ENGINE OUTSIDE DRAW-
INGS,SYSTEMDIAGRAM,UNITLAYOUT,SERVICEDATA AND
SPECIFICATIONS (SDS), LPG FUEL SYSTEM TROUBLE DIAG-
NOSIS, DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM,
DISASSEMBLY AND ASSEMBLY OF VAPORIZER
EE ENGINE ELECTRICAL
ADJUSTMENT VALUE, TROUBLE DIAGNOSIS, STARTER
MOTOR, ALTERNATOR
GROUP INDEX
ET
EM
EC
LC
EF
EE
GI
MA

CONTENTS
HOW TO USE THIS MANUAL ............................. GI-2
Description ...................................................... GI-2
Definition of Terms ..........................................GI-2
Definition of Units ............................................GI-2
Description ...................................................... GI-2
PRECAUTIONS FOR SAFETY AND QUALITY ..GI-3
Safe Operation ................................................GI-3
Correct Operation ............................................GI-4
Precautions for Radio Equipment Installation .GI-4
PRECAUTIONS ................................................... GI-5
Precautions in Draining Engine Coolant ..........GI-5
Precautions for Disconnecting Fuel Piping ...... GI-5
Precautions for Removing and Disassembling GI-5
Precautions for Inspection, Correction, and
Replacement ................................................... GI-5
Precautions for Assembly and Installation ...... GI-5
Parts Requiring Angle Tightening .................... GI-6
Caution with Use of Power Tools .................... GI-6
Precautions for Liquid Gasket Application ....... GI-6
TIGHTENING TORQUE ....................................... GI-7
Standard Bolt Tightening Torque .................... GI-7
Engine Part Tightening Torque ....................... GI-8
SPECIAL SERVICE TOOLS .............................. GI-10
ENGINE OUTSIDE DRAWINGS ........................ GI-11
MAIN SPECIFICATIONS ................................... GI-12
STANDARD AND REPAIR LIMIT ..................... GI-15
STAMPED LOCATION OF ENGINE NO. .......... GI-19
TROUBLE DIAGNOSIS ..................................... GI-20
Engine Adjustment ........................................ GI-21
Engine LPG Fuel System .............................. GI-26
GENERAL INFORMATION
SECTION
GI GI

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
* 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 Special Tools (STs), 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, STs, 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.
Measure SI Conventional unit Conversion factor to SI
Acceleration m/s2G 9.80665
Torque, moment N•m kgf-m 9.80665
Force N kgf 9.80665
Pressure MPa kgf/cm20.0980665
kPa mmHg 0.133322
Power efficiency kW PS 0.735499
W kcal/h 1.16279
Volume cm3cc 1
Spring constant N/mm kgf/mm 9.80665
Fuel consumption *g/kW•h g/PS•h 1.3596
GI-2
HOW TO USE THIS MANUAL

PRECAUTIONS FOR SAFETY AND QUALITY • The following precautions must be carefully observed for safe
and appropriate service work.
• Only qualified and designated personnel must perform
inspections, repairs and adjustments.
• Always keep the workplace clean, and store tools neatly in
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
ventilation is provided for discharging any hazardous emissions.
• Do not work underneath a vehicle supported only by a jack.
Always use rectangular wood blocks 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
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.
• 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 STs
wherever required.
GIM0057
GIM0058
GIM0059
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 MITSUBISHI 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 electric 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 FOR SAFETY AND QUALITY

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. (Electric 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 STs 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 untightened in a diagonal
manner starting from an outer one. If a particular untightening
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 (ST).
• 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 with Use of Power Tools
• The use of power tools such as pneumatic air tools is 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 (ST).
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
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).
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
engine oil and coolant.
CAUTION:
Follow any directions specified in the text on the following
pages.
GIM0061
GIM0062
GIM0063
GI-6
PRECAUTIONS

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)
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
Thread size Unit 4T (Bolt) 7T (Bolt) 9T (Bolt)
Diameter Pitch
Hexagon head bolt and nut
M6 1
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)
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)
M8 1.25
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)
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)
M10
1.25
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)
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)
1.5
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)
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)
Flanged bolt
M6 1
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)
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)
M8 1.25
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)
N·m 14.7 - 18.6 24.5 - 31.4 35.3 - 45.1
(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)
M10
1.25
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)
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)
1.5
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)
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)
GI-7
TIGHTENING TORQUE

Standard Bolt Tightening Torque (Cont’d)
TAPER SCREW TIGHTENING TORQUE
Engine Part Tightening Torque
TIGHTENING TORQUE AT VARIOUS POINTS OF
ENGINE
Allowable materials
for tightening
Normal size
Unit
Aluminum Cast iron
Standard Max.
value Standard Max. value
R1/8 N·m 7.8 11.8 15.7 21.6 kg-m 0.796 1.2 1.6 2.2
ft-lb, in-lb* 69* 9 12 16
R1/4 N·m 19.6 29.4 34.3 44.1 kg-m 2.0 3.0 3.5 4.5
ft-lb 14 22 25 33
R3/8 N·m 39.2 54.9 53.9 73.5 kg-m 4.0 5.6 5.5 7.5
ft-lb 29 41 40 33
Tightening point Unit Standard Max. value
Cylinder head (lubricated) Separately given
Main bearing cap (lubricated) Separately given
Crankshaft pulley bolt N·m 220.5 240.1 kg-m 22.5 24.5
ft-lb 163 177
Flywheel bolt (lubricated) N·m 132 142 kg-m 13.47 14.49
ft-lb 94.4 104.8
Connecting rod nut (lubricated) N·m 31.4 37.3 kg-m 3.2 3.81
ft-lb 23 27.6
Rear plate bolt N·m 44.1 58.8 kg-m 4.5 6.0
ft-lb 33 43
Camshaft sprocket bolt N·m 39.2 49 kg-m 4.0 5.0
ft-lb 29 36
Oil filter stud N·m 29.4 39.2 kg-m 3.0 4.0
ft-lb 22 29
Oil filter element N·m 14.7 20.6 kg-m 1.5 2.1
ft-lb 11 15
Spark plug N·m 19.6 29.4 kg-m 2.0 3.0
ft-lb 14 22
Engine slinger bolt N·m 22.6 25.5 kg-m 2.31 2.6
ft-lb 16.7 19
Rocker cover nut N·m 14.7 16.7 kg-m 1.5 1.7
ft-lb 11 13
Water temperature gauge N·m 15.7 19.6 kg-m 1.6 2.0
ft-lb 12 14
Oil pressure switch N·m 15.7 21.6 kg-m 1.6 2.2
ft-lb 12 16
Exhaust manifold nut N·m 41.2 48.1 kg-m 4.2 4.91
ft-lb 30 35.5
Straight screw plug (For head top face) N·m 44.1 53.9 kg-m 4.5 5.5
ft-lb 33 40
Oil pan drain plug N·m 29.4 39.2 kg-m 3.0 4.0
ft-lb 22 29
GI-8
TIGHTENING TORQUE

Engine Part Tightening Torque (Cont’d)
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.
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 a pneumatic air tool for
assembly.
Tightening point Unit Standard Max. value
Mass air flow sensor mounting screw N·m 1.27 1.67
(kgf-m) 0.13 0.17
Fuel tube flare nut N·m 16.0 23.0
(kgf-m) 1.63 2.35
Crankshaft position sensor plug bolt N·m 6.37 7.45
(kgf-m) 0.65 0.76
Thermo-housing relief plug N·m 6.37 7.45
(kgf-m) 0.65 0.76
MAM0142
GIM0064
GI-9
TIGHTENING TORQUE

SPECIAL SERVICE TOOLS
Tool number Tool name
91H20-09080 Engine attachment
91H-20-09090
(1) 91H20-09091
(2) 91H20-09092
Engine stand assembly
Engine stand
Stand
91H20-09100
(1) 91H20-09110
(2) 91H20-09111
(3) 91H20-09112
Crankshaft main bearing cap puller
Crankshaft main bearing puller
Adapter
Adapter
91H20-09120 Valve lifter
91H20-09150
91H20-09160
91H20-09170
Front oil seal drift
Rear oil seal drift
Drift rod
91H20-09020 Heated oxygen sensor wrench Removing and installing heated
oxygen sensor
GIM0066
GIM0067
GIM0068
GIM0069
GIM0071
GIM0072
GI-10
SPECIAL SERVICE TOOLS

ENGINE OUTSIDE DRAWINGS ELECTRIC CONTROLLED SPECIFICATION
GI-11
ENGINE OUTSIDE DRAWINGS

MAIN SPECIFICATIONS
Note: 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 (23°F) or less, use a 100P fuel.
Engine type K21
Engine control system Electric controlled specifications
Fuel specification Gasoline LPG Combined
Total displacement (cc) 2,065
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke mm (in) 89 x 83 (3.50 x 3.27)
Compression ratio 8.7
Compression pressure [kPa (bar, kg/cm2, psi)/rpm] 1,450 (14.5, 14.79, 210.3)/250
Engine speed control system Engine Control System, electric controlled throttle
Fuel in use (Note) Unleaded regular
gasoline At 20P At 20P
Valve opening/closing timing
(degree) Intake open (ATDC) 4
Intake close (ABDC) 40
Exhaust open (BBDC) 36
Exhaust close (ATDC) 0
Valve clearance mm (in) Intake (when engine is hot) 0.38 (0.0150)
Exhaust (when engine is hot) 0.38 (0.0150)
Firing order 1-3-4-2
Ignition timing (idling) degree (BTDC°/rpm) 0±2/700
On board idle speed (rpm) ATM 700±50
MTM 700±50
PTO system Silent chain-driven/side PTO
Engine oil (originally fitted) Specification 10W-30 (Class SL)
Amount l (US qt, Imp qt) 3.8 (4, 3-3/8) (including oil filter)
GI-12
MAIN SPECIFICATIONS

Note: 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 (23°F) or less, use a 100P fuel.
Engine type K25
Engine control system Electric controlled specifications
Fuel specification Gasoline LPG Combined
Total displacement (cc) 2,488
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke mm (in) 89 x 100 (3.50 x 3.94)
Compression ratio 8.7
Compression pressure [kPa (bar, kg/cm2, psi)/rpm] 1,510 (15.1, 15.4, 219)
Engine speed control system Engine Control System, electric controlled throttle
Fuel in use (Note) Unleaded regular
gasoline At 20P At 20P
Valve opening/closing timing
(degree) Intake open (ATDC) 4
Intake close (ABDC) 40
Exhaust open (BBDC) 36
Exhaust close (ATDC) 0
Valve clearance mm (in) Intake (when engine is hot) 0.38 (0.0150)
Exhaust (when engine is hot) 0.38 (0.0150)
Firing order 1-3-4-2
Ignition timing (idling) degree (BTDC°/rpm) 0±2/700
On board idle speed (rpm) ATM 700±50
MTM 700±50
PTO system Silent chain-driven/side PTO
Engine oil (originally fitted) Specification 10W-30 (Class SL)
Amount l (US qt, Imp qt) 3.8 (4, 3-3/8) (including oil filter)
GI-13
MAIN SPECIFICATIONS

MAIN SPECIFICATIONS OF IGNITION SYSTEM
FUEL SYSTEM AND ENGINE SPEED CONTROL SYSTEM
EXHAUST GAS CLEANUP DEVICE LIST
Engine type K21 K25
Engine control system Electric controls Electric controls
Fuel specification Gasoline LPG Combined Gasoline LPG Combined
Ignition device Non-contact type (Engine Control System) Non-contact type (Engine Control System)
Ignition coil (with
power transistor)
Hanshin
Electric
type AIC-4002G AIC-4002G
Crankshaft position sensor
Crankshaft
position
sensor
(POS)
Hitachi
Unisia
Automotive A29-640 A29-640
Camshaft
position
sensor
(PHASE)
Hitachi
Unisia
Automotive A29-660 A29-660
Distributor (with
ignition coil)
Mitsubishi
Electric
type －－
Spark plug NGK type FR2A-D, FR2B-D FR2A-D, FR2B-D
Gap (mm) 0.9 0.9
Engine type K21 K25
Engine control system Electric controls Electric controls
Fuel specification Gasoline LPG Combined Gasoline LPG Combined
Fuel device standard type Electric controlled fuel injection device
(Engine Control System) Electric controlled fuel injection device (Engine Control System)
Fuel device Gasoline injector LPG injector Gasoline & LPG Gasoline injector LPG injector Gasoline & LPG
Air-fuel ratio control
device Air-fuel ratio feedback control Air-fuel ratio feedback control
Starting auxiliary device Electric throttle control actuator Electric throttle control actuator
Idle load control type Electric throttle control actuator Electric throttle control actuator
Engine speed control
type Electric throttle control actuator Electric throttle control actuator
Engine type K21 K25
Engine control system Electric controls Electric controls
Fuel specification Gasoline LPG Combined Gasoline LPG Combined
Catalytic
device
(Reducing
HC, CO, Nox)
Type Three-way catalyst (Monolith) Three-way catalyst (Monolith)
Location In counter weight with muffler separated In counter weight with muffler separated
Capacity 0.45L 0.45L
PCV gas recirculation
device Closed type Closed type
GI-14
MAIN SPECIFICATIONS

STANDARD AND REPAIR LIMIT INSPECTION AND ADJUSTMENT
• Oil capacity H line (L)
3.5
• Oil capacity L line (L)
2.5
• (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 1.45 (14.8) / 250 (K21)
1.51 (15.4) / 250 (K25)
Limit 1.25 (12.7) / 300 (K21)
1.31 (13.4) / 300 (K25)
• Difference between each cylinder [MPa (kgf/cm2)/rpm]
Repair limit 0.1 (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 ±0.03
Exhaust: 0.38 ±0.03
• Thermostat valve opening temperature (STD) (°C)
Standard 76.5
• Idle speed and ignition timing (BTDC°/rpm)
Standard 0/700±50
CYLINDER HEAD
• Cylinder head (mm)
Material Aluminum alloy
Distortion limit 0.1
CYLINDER BLOCK
• Block upper surface (mm)
Distortion limit 0.1
• Bore diameter dimension (mm)
Standard 89.00 - 89.05
• Bore diameter wear (mm)
Repair limit 0.2
• Bore diameter out-of-round (mm)
Standard 0.02 or less
• Bore diameter taper (mm)
Standard 0.02 or less
• Bore diameter out-of-round and taper (mm)
Repair limit 0.1
GI-15
STANDARD AND REPAIR LIMIT

PISTON
• Piston (mm)
Type Thermal flow type
Material Aluminum alloy
Outer diameter Standard 88.965 - 89.015
• 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
• 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)
Standard Top 0.045 - 0.080
Second 0.030 - 0.070
Oil —
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 (K21)
• Large end hole diameter (mm)
Standard 48.0 - 48.013
• Small end hole diameter (mm)
Standard 19.965 - 19.978
• 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
Repair limit 0.10
• Difference of weight (Piston combination) (g)
Standard 4 or less
GI-16
STANDARD AND REPAIR LIMIT

CRANKSHAFT
• Bend (mm)
Repair limit 0.05
• End play (mm)
Standard 0.05 - 0.18
Repair limit 0.20
• Journal dimension (mm)
Standard 62.942 - 62.955
• Pin standard dimension (mm)
Standard 44.961 - 44.974
• Journal oil clearance (mm)
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
• Camshaft height (mm)
Standard 36.750 - 36.800 (For both intake and exhaust)
Size reduction limit 36.5
• Journal dimension (mm)
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
• Journal oil clearance (mm)
Standard Front 0.025 - 0.051
Center 0.038 - 0.064
Rear 0.025 - 0.051
Repair limit Front 0.10
Center 0.15
Rear 0.10
GI-17
STANDARD AND REPAIR LIMIT