Vortec 1600 User manual

Original Issue
Dated August 2003
Publication Number 36100009
1.6L
INDUSTRIAL ENGINE
SERVICE MANUAL

Table Of Contents
General Information Section 0
Engine Mechanical Section 1
Engine Cooling Section 2
Engine Electrical Section 3
No part of this publication may be reproduced without the written
permission of Power Solutions, Inc. At the time of publication, all of
the information included in this publication is accurate to the best
of our knowledge. Power Solutions, Inc., cannot be responsible for
information that has changed after this book was published.

Industrial 1.6L General Information 0-1
FastenerNotice ........................................................ 0-2
General Information - 1.6L ..................................... 0-3
Conversion - English/Metric ...................................... 0-3
Equivalents - Decimal and Metric ............................ 0-3
Arrows and Symbols................................................. 0-4
Engine ID Location ................................................... 0-5
Fasteners ................................................................. 0-5
MetricFasteners....................................................... 0-5
FastenerStrengthIdentification ................................ 0-6
PrevailingTorqueFasteners...................................... 0-7
PrevailingTorqueSpecifications(Metric) .................. 0-8
PrevailingTorqueSpecifications(English) ................ 0-8
Thread Inserts .......................................................... 0-9
Abbreviationsand Their Meanings............................ 0-9
Maintenance and Lubrication .............................. 0-15
Initial Start Up Maintenance.................................... 0-15
RoutineMaintenance.............................................. 0-15
ScheduledPreventiveMaintenance........................ 0-15
Engine Oil Level Check........................................... 0-15
Adding Engine Oil ................................................... 0-15
Engine Oil and Filter ............................................... 0-15
Engine Oil Quality................................................... 0-15
Engine Oil Recommendation .................................. 0-16
Section 0
General Information
Oil Filter .................................................................. 0-16
Engine Air Cleaner ................................................. 0-16
SafetyElement ....................................................... 0-16
Cooling System Maintenance.............................. 0-16
CoolantLevel.......................................................... 0-16
Radiator.................................................................. 0-17
Radiator Hoses....................................................... 0-17
FanBelts ................................................................ 0-17
Serpentine Belt ....................................................... 0-17
V-TypeBelt ............................................................. 0-17
Fuel Delivery System Maintenance ..................... 0-17
Fuel Filter Replacement.......................................... 0-17
Carbureted Engines............................................. 0-17
TBI Engines .......................................................... 0-17
Zenith Z.E.E.M.S TBI Fuel Injection ...................... 0-17
Ignition Systems ..................................................... 0-18
Types of Ignition Systems ....................................... 0-18
IgnitionTiming ........................................................ 0-18
Spark Plugs ............................................................ 0-18
Maintenance Schedule - 1.6L Engine .................. 0-19
Approximate Fluid Capacities ................................. 0-19
Filter Chart - 1.6L Engine ....................................... 0-20

0-2 General Information Industrial 1.6L
Fastener Notice
NOTICE: Alwaysuse the correctfastenerinthe proper location.Whenyoureplace a fastener,useONLYthe exact part
number of that application.
UNLESSOTHERWISESPECIFIED,DoNotusesupplementalcoatings(paints,greasesorother corrosioninhibitors) on
threaded fasteners or fastener joint interfaces. Generally, such coating adversely affect the fastener torque and the joint
clampingforce,and may damage the fastener.
When you install fasteners, use the correct tightening sequence and specifications.
Following these instructions can help you avoid damage to parts and systems.

Industrial 1.6L General Information 0-3
General Information - 1.6L
Conversion - English/Metric Conversion - English/Metric (cont’d)
Equivalents - Decimal and Metric
English Multiply /
Divide by Metric
Length
in 25.4 mm
ft 0.3048 m
yd 0.9144 m
mi 1.609 km
Area
sq in 645.2 sq mm
sq in 6.45 sq cm
sq ft 0.0929 sq m
sq yd 0.8361 sq m
Volume
cu in 16,387.0 cu mm
cu in 16.397 cu cm
cu in 0.0164 L
qt 0.9464 L
gal 3.7854 L
cu yd 0.746 cu m
Mass
lb 0.4536 kg
ton 907.18 kg
ton 0.907 tonne (t)
Force
kg 9.807 newtons (N)
oz 0.2780 newtons (N)
lb 4.448 newtons (N)
Acceleration
ft/s20.3048 m/s2
in/s20.0254 m/s2
Torque
lb in 0.11296 N•m
lb ft 1.3558 N•m
Power
hp 0.745 kW
Pressure (Stress)
inches of H2O0.2491 kPa
lb/sq in 6.895 kPa
Energy (Work)
Btu 1055.0 J (J= one Ws)
lb ft 1.3558 J (J= one Ws)
kW hour 3,600,000.0 J (J= one Ws)
Light
Foot Candle 10.764 lm/m2
Fraction (in) Decimal (in) Metric (mm)
1/64 0.015625 0.39688
1/32 0.03125 0.79375
3/64 0.046875 1.19062
1/16 0.065 1.5875
5/64 0.078125 1.98437
3/32 0.09375 2.38125
7/64 0.109375 2.77812
1/8 0.125 3.175
9/64 0.140625 3.57187
5/32 0.15625 3.96875
11/64 0.171875 4.36562
3/16 0.1875 4.7625
13/64 0.203125 5.15937
7/32 0.21875 5.55625
15/64 0.234375 5.95312
1/4 0.25 6.35
17/64 0.265625 6.74687
9/32 0.28125 7.14375
19/64 0.296875 7.54062
5/16 0.3125 7.9375
21/64 0.328125 8.33437
11/32 0.34375 8.73125
23/64 0.359375 9.12812
3/8 0.375 9.525
25/64 0.390625 9.92187
13/32 0.40625 10.31875
27/64 0.421875 10.71562
7/16 0.4375 11.1125
29/64 0.453125 11.50937
15/32 0.46875 11.90625
31/64 0.484375 12.30312
1/2 0.5 12.7
English Multiply /
Divide by Metric
Velocity
mph 1.6093 km/h
Temperature
(°F-32) / 1.8 =°C
°F=(°C X 1.8) + 32
Fuel Performance
232.215/mpg = L/100 km

0-4 General Information Industrial 1.6L
Fraction (in) Decimal (in) Metric (mm)
33/64 0.515625 13.09687
17/32 0.53125 13.49375
35/64 0.546875 13.89062
9/16 0.5625 14.2875
37/64 0.578125 14.68437
19/32 0.59375 15.08125
39/64 0.609375 15.47812
5/8 0.625 15.875
41/64 0.640625 16.27187
21/32 0.65625 16.66875
43/64 0.671875 17.06562
11/16 0.6875 17.4625
45/64 0.703125 17.85937
23/32 0.71875 18.25625
47/64 0.734375 18.65312
3/4 0.75 19.05
49/64 0.765625 19.44687
25/32 0.78125 19.84375
51/64 0.796875 20.24062
3/16 0.8125 20.6375
53/64 0.828125 21.03437
27/32 0.84375 21.43125
55/64 0.859375 21.82812
7/8 0.875 22.225
57/64 0.890625 22.62187
29/32 0.90625 23.01875
59/64 0.921875 23.41562
15/16 0.9375 23.8125
61/64 0.953125 24.20937
31/32 0.96875 24.60625
63/64 0.984375 25.00312
1 1.0 25.4
Equivalents - Decimal and Metric (cont’d) Arrows and Symbols
This service manual uses various symbols in order to
describedifferentserviceoperations. You may find
some or all of these symbols used in the manual.
196216
Legend
(1) Front of Vehicle
(2) View Detail
(3) Ambient Air Mixed with Another Gas or Indicate
TemperatureChange
(4) Motion or Direction
(5) View Angle
(6) Dimension (1:2)
(7) Ambient/Clean Air Flow or Cool Air Flow
(8) Lubrication Point – Oil or Fluid
(9) TaskRelated
(10) Sectioning (1:3)
(11) Gas Other Than Ambient Air or Hot Air Flow
(12) Lubrication Point – Grease or Jelly

Industrial 1.6L General Information 0-5
Engine ID Location
To help identify the engine and its serial number, an
identification label is affixed to the top of the camshaft
housingcover.
FASTENERS
Metric Fasteners
The 1.6L engine is dimensioned in the metric system.
Most metric fasteners are very close in diameter to well
known fasteners in the English, inch system. Replace
fasteners with those of the same nominal diameter,
thread pitch, and strength.
A number marking identifies the OE metric fasteners
except cross-recess head screws. The number also
indicates the strength of the fastener material. A
Posidrive R or Type 1A cross-recess identifies a metric
cross-recess screw. For best results, use a Type 1A
cross-recess screwdriver, or equivalent, in Posidrive R
recess head screws.
General Motors Engineering and North American
Industries have adopted a portion of the ISO-defined
standard metric fastener sizes. The purpose was to
reduce the number of fastener sizes used while retain-
ing the best thread qualities in each thread size. For
example, the metric M6.0 X 1 screw with nearly the
same diameter and 25.4 threads per inch replaced the
English 1/4-20 and 1/4-28 screws. The thread pitch is
midway between the English coarse and fine thread
pitches.
The most commonly used metric fastener strength
property classes are 9.8 and 10.9. The class identifica-
tion is embossed on the head of each bolt. The English,
inch strength classes range from grade 2 to grade 8.
Radial lines are embossed on the head of each bolt in
order to identify the strength class. The number of lines
on the head of the bolt is 2 lines less than the actual
grade. For example, a grade 8 bolt will have 6 radial
lines on the bolt head. Some metric nuts are marked
with a single digit strength identification number on the
nutface.
The correct fasteners are available through PSI. Many
metric fasteners available in the aftermarket parts
channels are designed to metric standards of countries
other than the United States, and may exhibit the
followingdefects:
• Lower strength
•No numbered head marking system
•Wrong thread pitch
The metric fasteners on PSI products are designed to
new, international standards. Following are the com-
mon sizes and pitches, except for special applications:
•M6 X 1
•M8 X 1.25
•M10 X 1.5
•M12 X 1.75
The engine serial number is also stamped into the left
side of the cylinder block near the engine flywheel. The
stamp contains the engine model number (i.e. 1.6L,
3.0L, 5.7L, etc.) and a serial number which identifies
the engine from other GM Powertrain engines provided
by Power Solutions, Inc. The engine model and serial
number are required when seeking information con-
cerning the engine and/or ordering replacement
service parts.
80300001
80300002

0-6 General Information Industrial 1.6L
Fastener Strength Identification
Legend
(1) English Bolt, Grade 2 (Strength Class) (4) English Bolt, Grade 8 (Strength Class)
(2) English Bolt, Grade 5 (Strength Class) (5) Metric Nut, Strength Class 9
(3) English Bolt, Grade 7 (Strength Class) (6) Metric Bolts, Strength Class Increases as Numbers Increase
171891

Industrial 1.6L General Information 0-7
Prevailing Torque Fasteners A prevailing torque nut is designed in order to develop
an interface between the nut and bolt threads. Distor-
tion of the top of the metal nut or using a nylon patch
on the threads in the middle of the hex flat causes that
interface.
A prevailing torque bolt/nut that is clean and free of rust
may be reused. If there is any doubt, replace the
fastener:
1. Clean away all dirt or foreign material.
2. Inspect the fastener for signs of overtightening.
3. Hand start the fastener at the original location.
4. Inspect the fastener for torque development,
referring to the table below.
5. Tighten the fastener within specifications.
Legend
(1) Prevailing Torque Nut, Center Lock Type
(2) Prevailing Torque Nut,TopLock Type
(3) Prevailing Torque Nut, Nylon Patch Type
(4) Prevailing Torque Nut, Nylon Washer Insert Type
(5) Prevailing Torque Nut, Nylon Insert Type
(6) Prevailing Torque Bolt, Dry Adhesive Coating Type
(7) Prevailing Torque Bolt, Thread Profile Deformed Type
(8) Prevailing Torque Bolt, Nylon Strip Type
(9) Prevailing Torque Bolt, Out-of-Round
Thread Area Type
171892

0-8 General Information Industrial 1.6L
Specification
Application Metric English
Nuts and All Metal Bolts/Screws
0.250 in 0.4 N•m 4 lb in
0.312 in 0.6 N•m 5 lb in
0.375 in 1.4 N•m 12 lb in
0.437 in 1.6 N•m 16 lb in
0.500 in 2.4 N•m 21 lb in
0.562 in 3.2 N•m 28 lb in
0.625 in 4.2 N•m 37 lb in
0.750 in 7.0 N•m 62 lb in
Adhesive or Nylon Coated Bolts/Screws
0.250 in 0.4 N•m 4 lb in
0.312 in 0.6 N•m 5 lb in
0.375 in 1.0 N•m 9 lb in
0.437 in 1.4 N•m 12 lb in
0.500 in 1.8 N•m 16 lb in
0.562 in 2.6 N•m 23 lb in
0.625 in 3.4 N•m 30 lb in
0.750 in 5.2 N•m 49 lb in
Prevailing Torque Specifications (Metric–Size Fasteners)
Prevailing Torque Specifications (English–Size Fasteners)
Specification
Application Metric English
Nuts and All Metal Bolts/Screws
6 mm 0.4 N•m 4 lb in
6.3 mm 0.4 N•m 4 lb in
8 mm 0.6 N•m 7 lb in
10 mm 1.4 N•m 12 lb in
12 mm 2.2 N•m 18 lb in
14 mm 3.0 N•m 27 lb in
16 mm 4.2 N•m 37 lb in
20 mm 7.0 N•m 62 lb in
Adhesive or Nylon Coated Bolts/Screws
6 mm 0.4 N•m 4 lb in
6.3 mm 0.4 N•m 4 lb in
8 mm 0.6 N•m 7 lb in
10 mm 1.2 N•m 11 lb in
12 mm 1.6 N•m 14 lb in
14 mm 2.4 N•m 21 lb in
16 mm 3.4 N•m 30 lb in
20 mm 5.6 N•m 50 lb in

Industrial 1.6L General Information 0-9
THREAD INSERTS
Repair Procedure
Tools Required
General purpose thread repair kits. These kits are
availablecommercially.
Caution: Wear safety glasses in order to avoid eye
damage.
Important: Refer to the thread repair kit manufacturer’s
instructions regarding the size of the drill and tap to
use.
Avoid any buildup of chips. Back out the tap every few
turns and remove the chips.
1. Determine the size, the pitch, and the depth of the
damaged thread. If necessary, adjust the stop
collars on the cutting tool and tap to the required
depth.
2. Drill out the damaged threads. Clean out any
chips.
3. Lubricate the tap with light engine oil. Tap the
hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the
installer. Engage the tang of the insert onto the
end of the mandrel.
Important: The insert should be flush to one turn
below the surface.
5. Lubricate the insert with light engine oil, except
when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when
backing out the installer, break the tang off with a
drift.
Abbreviations and Their Meanings
Abbreviation Meaning
A
A Ampere(s)
AC Alternating Current
ACL Air Cleaner
AD Automatic Disconnect
A/D Analog to Digital
A/F Air/Fuel (Ratio)
4962
4963

0-10 General Information Industrial 1.6L
Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
APCM Accessory Power Control Module
API American Petroleum Institute
APT Adjustable Part Throttle
ASM Assembly, Accelerator and Servo
Control Module
Auto Automatic
avg Average
AWG American Wire Gage
B
B+ Battery Positive Voltage
BARO Barometric (Pressure)
BATT Battery
BLK Black
BLU Blue
BP Back Pressure
BPCM Battery Pack Control Module
BRN Brown
BTDC Before Top Dead Center
BTM Battery Thermal Module
C
ºCDegrees Celsius
Cal Calibration
Cam Camshaft
CARB California Air Resources Board
cm3Cubic Centimeters
CCM Convenience Charge Module, Chassis
Control Module
CCOT Cycling Clutch Orifice Tube CCP
Climate Control Panel
CD Compact Disc
Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
CE Commutator End
CEAB Cold Engine Air Bleed
cfm Cubic Feet per Minute
cg Center of Gravity
CID Cubic Inch Displacement
CKP Crankshaft Position
CKT Circuit
CL Closed Loop
CLS Coolant Level Switch
CMP Camshaft Position
CO Carbon Monoxide
CO2 Carbon Dioxide
Coax Coaxial
COMM Communication
Conn Connector
CPA Connector Position Assurance
CPS Central Power Supply
CPU Central Processing Unit
CS Charging System
CSFI Central Sequential Fuel Injection
CTP Closed Throttle Position
cu ft Cubic Food/Feet
cu in Cubic Inch/Inches
D
DAB Delayed Accessory Bus
dB Decibels
dBA Decibels on A–weighted Scale
DC Direct Current, Duty Cycle
DI Distributor Ignition
dia Diameter
DK Dark

Industrial 1.6L General Information 0-11
Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
DMM Digital Multimeter
DOHC Dual Overhead Camshafts
E
EC Electrical Center, Engine Control
ECL Engine Coolant Level
ECM Engine Control Module, Electronic
Control Module
ECS Emission Control System
ECT Engine Coolant Temperature
EEPROM Electrically Erasable Programmable
Read Only Memory
EFE Early Fuel Evaporation
EGR Exhaust Gas Recirculation
EGR TVV Exhaust Gas Recirculation Thermal
Vacuum Valve
EI Electronic Ignition
ELAP Elapsed
E/M English/Metric
EMF Electromotive Force
EMI Electromagnetic Interference
Eng Engine
EOP Engine Oil Pressure
EOT Engine Oil Temperature
EPA Environmental Protection Agency
EPR Exhaust Pressure Regulator
EPROM Erasable Programmable Read Only
Memory
ESD Electrostatic Discharge
ESN Electronic Serial Number
ETC Electronic Throttle Control, Electronic
Temperature Control, Electronic
Timing Control
Abbreviation Meaning
Exh Exhaust
F
ºFDegrees Fahrenheit
FC Fan Control
FDC Fuel Data Center
FED Federal (All United States except
California)
FEDS Fuel Enable Data Stream
FF Flexible Fuel
FI Fuel Injection
FMVSS Federal (U.S.) Motor Vehicle Safety
Standards
FP Fuel Pump
ft Foot/Feet
FT Fuel Trim
FW Flat Wire
G
GA Gage, Gauge
gal Gallon
gas Gasoline
Gen Generator
GL Gear Lubricant
GM General Motors
GM SPO General Motors Service Parts
Operations
gnd Ground
gpm Gallons per Minute
GRN Green
GRY Gray
H
H Hydrogen
H2O Water
Harn Harness
HC Hydrocarbons
H/CMPR High Compression

0-12 General Information Industrial 1.6L
Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
HD Heavy Duty
HDC Heavy Duty Cooling
Hg Mercury
Hi Alt High Altitude
HO2S Heated Oxygen Sensor
hp Horsepower
Hz Hertz
I
IAC Idle Air Control
IAT Intake Air Temperature
IC Integrated Circuit, Ignition Control
ICM Ignition Control Module
IDI Integrated Direct Ignition
ign Ignition
ILC Idle Load Compensator
in Inch/Inches
INJ Injection
inst Instantaneous, Instant
ISC Idle Speed Control
ISO International Standards Organization
K
kg Kilogram
kHz Kilohertz
km Kilometer
km/h Kilometers per Hour
km/l Kilometers per Liter
Abbreviation Meaning
kPa Kilopascals
KS Knock Sensor
kV Kilovolts
L
LLiter
L4 Four Cylinder Engine, In–line
lb Pound
lb ft Pound Feet (Torque)
lb in Pound Inch (Torque)
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left Hand
LT Light
M
MAF Mass Airflow
Man Manual
MAP Manifold Absolute Pressure
MAT Manifold Absolute Temperature
max Maximum
M/C Mixture Control
MDP Manifold Differential Pressure
MFI Multiport Fuel Injection
MIL Malfunction Indicator Lamp
min Minimum
mL Milliliter
mm Millimeter
ms Millisecond
MST Manifold Surface Temperature
MV Megavolt
mV Millivolt

Industrial 1.6L General Information 0-13
Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
N
NC Normally Closed
NEG Negative
Neu Neutral
NiMH Nickel Metal Hydride
NLGI National Lubricating Grease Institute
Nm Newton-meter (Torque)
NO Normally Open
NOx Oxides of Nitrogen
NPTC National Pipe Thread Coarse
NPTF National Pipe Thread Fine
O
O2 Oxygen
O2S Oxygen Sensor
OC Oxidation Converter (Catalytic)
OCS Opportunity Charge Station
OD Outside Diameter
ODM Output Drive Module
OE Original Equipment
OEM Original Equipment Manufacturer
OHC Overhead Camshaft
ohm Ohm
OL Open Loop, Out of Limits
ORC Oxidation Reduction Converter
(Catalytic)
ORN Orange
ORVR On-Board Refueling Vapor Recovery
OSS Output Shaft Speed
oz Ounce(s)
P
PAG Polyalkylene Glycol
PAIR Pulsed Secondary Air
PC Pressure Control
PCB Printed Circuit Board
PCS Pressure Control Solenoid
PCV Positive Crankcase Ventilation
Abbreviation Meaning
PIM Power Inverter Module
PM Permanent Magnet (Generator)
P/N Part Number
PNK Pink
POA Pilot Operated Absolute (Valve)
POS Positive, Position
POT Potentiometer (Variable Resistor)
PPL Purple
ppm Parts per Million
psi Pounds per Square Inch
psia Pounds per Square Inch Absolute
psig Pounds per Square Inch Gauge
pt Pint
PTC Positive Temperature Coefficient
Q
qt Quart(s)
R
Ref Reference
Rev Reverse
REX Rear Exchanger
RH Right Hand
Rly Relay
ROM Read Only Memory (Permanent
memory device, memory contents are
retained when power is removed.)

0-14 General Information Industrial 1.6L
Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d)
Abbreviation Meaning
RPM Revolutions per Minute (Engine
Speed)
RPO Regular Production Option
RR Right Rear
S
s Second(s)
SAE Society of Automotive Engineers
SEO Special Equipment Option
SFI Sequential Multiport Fuel Injection
SI System International (Modern Version
of Metric System)
sol Solenoid
SO2 Sulfur Dioxide
SP Splice Pack
SPO Service Parts Operations
sq ft, ft2Square Foot/Feet
sq in, in2Square Inch/Inches
SRI Service Reminder Indicator
Sw Switch
T
TAC Throttle Actuator Control
Tach Tachometer
TBI Throttle Body Fuel Injection
Abbreviation Meaning
TDC Top Dead Center
TEMP Temperature
Term Terminal
TP Throttle Position
TV Throttle Valve
TVV Thermal Vacuum Valve
TWC Three Way Converter (Catalytic)
TWC+OC Three Way + Oxidation Converter
(Catalytic)
TXV Thermal Expansion Valve
U
V
V Volt(s), Voltage
Vac Vacuum
V dif Voltage Difference
VDV Vacuum Delay Valve
VIO Violet

Industrial 1.6L General Information 0-15
MAINTENANCE AND LUBRICATION
Initial Start Up Maintenance
The initial start-up checks must be made before putting the engine into service.
Please refer to Maintenance Schedule - 1.6L Engine on page 0-19 and perform the initial start-up operations in the
sequence shown in column 1.
Routine Maintenance
Routine maintenance provides the best solution for making sure that the engine is ready when you are. The following
are some routine service points:
•Keep the fuel tank filled. A full tank of fuel reduces the possibility of condensation forming in the fuel
tank and moisture entering the fuel system.
•Make frequent checks of the engine oil and coolant levels.
•Repair any oil or coolant leaks immediately.
•Check battery condition and cables frequently.
•Keep the engine air filter clean.
•Monitor engine coolant temperature.
•Monitor engine oil pressure.
•Check voltmeter and charging system.
Scheduled Preventive Maintenance
Refer to the Maintenance Schedule - 1.6L Engine on page 0-19 to ensure that all of the maintenance items listed are
checked and replaced as recommended at the hours shown.
Engine Oil Level Check
The engine oil level should be checked daily. It is recommended that the oil be checked just before the engine is
started for the first time for that day. The oil level should be between the ‘Add’ and the ‘Full’ marks on the dipstick.
CAUTION: Do not operate the engine with the oil level below the bottom or ‘Add’ mark on the dipstick, or
above the top or ‘Full’ mark on the dipstick.
Adding Engine Oil
It is normal to add some oil in the period of time between oil changes. The amount will vary with the severity of
operation. When adding or replacing engine oil, be sure the oil meets or exceeds the recommended specification.
Engine Oil and Filter
The engine oil and filter must be changed every 200 hours or every 3 months whichever occurs first. Under normal
operating conditions, you do not need to change them more often if you use oil and filters of the recommended quality.
The oil and filter should be changed more often if the engine is operating in dusty or extremely dirty areas, or during
cold weather. No oil additives or break-in oil change is required.
Engine Oil Quality
To achieve proper engine performance and durability, it is important that you use only engine lubricating oils of the
correct quality in your engine. Proper quality oils also provide maximum efficiency for crankcase ventilation systems,
which reduces pollution.
Important: use only engine oils displaying the American Petroleum Institute (API) “Starburst” Certification Mark
‘FOR GASOLINE ENGINES’ on the container.
Gasoline engines that are converted for LPG or NG fuels MUST use oils labeled ‘FOR GASOLINE ENGINES’. Do
not use oils that are specifically formulated for Diesel Engines only. CC or CD classification oils, even when labeled
Heavy Duty or for Natural Gas Engines, ARE NOT ACCEPTABLE.

0-16 General Information Industrial 1.6L
Engine Oil Recommendation
Multi-viscosity oils are recommended. SAE 10W30 is recommended for your engine from 0 degrees F (-18 degrees C)
or above. If ambient temperatures are consistently below 0 degrees F, SAE 5W30 oil can be used. Synthetic oils are
not recommended for industrial or stationary engines.
Oil Filter
The PSI GM Powertrain engines use an AC Delco oil filter as original equipment. An equivalent oil filter must be used
when servicing the engine (see Engine Specifications for the recommended oil filter for your engine).
The filter protects your engine from harmful, abrasive, or sludgy particles without blocking the flow of oil to vital engine
parts.
To replace the filter, use a proper filter wrench to remove the filter.
Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil. Hand tighten the
filter until the gasket contacts the base, then tighten another ½ turn. Fill the engine with the correct amount of oil, run
the engine and check for oil leaks at the drain plug and oil filter gasket. Tighten as necessary to stop any oil leakage
noted.
Engine Air Cleaner
The engine air cleaner filters air entering the engine intake system and acts as a silencer and flame arrester when
assembled to the intake system.
Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe damage to the cylinder walls
and piston rings. Damage to the cylinder walls and piston rings will cause high oil consumption and shorten engine
life.
A restricted or dirty air cleaner will also cause a rich fuel mixture. Thus, it is extremely important that the air cleaner be
serviced properly at the recommended intervals.
CAUTION: Service the air cleaner more frequently under severe dusty or dirty conditions.
Remove the primary air cleaner element from the air cleaner assembly and inspect the element for foreign material
restrictions or signs of excessive wear or damage. Replace the element if necessary.
Remove all dust and foreign matter from the air cleaner housing.
Reinstall the air cleaner element. Reinstall the air cleaner cup, and securely fasten the retaining clips.
Safety Element
If your engine is equipped with an air cleaner which utilizes a safety element, ensure that the element is properly in
place before installing the primary element. Change the safety element annually.
COOLING SYSTEM MAINTENANCE
Coolant Level
Check the coolant level of the radiator daily and only when the engine is cool. Generally a good time to do this is just
prior to starting the engine for the first time each day.
Maintain the coolant level at ¾ to 1½ inches below the filler neck seat of the radiator when the coolant is cold. When
ever coolant level checks are made inspect the condition of the radiator cap rubber seal. Make sure it is clean and free
of any dirt particles which would keep it from seating on the filler neck seat. Rinse off with clean water if necessary.
Also make sure that the filler neck seat is free of any dirt particles.
Caution: Never remove the radiator cap under any conditions while the engine is operating. Failure to follow
these instruction could result in damage to the cooling system, engine, or cause personal injury. To avoid
having scalding hot coolant or steam blow out of the radiator, use extreme caution when removing the
radiator cap from a hot radiator. If possible, wait until the engine has cooled, then wrap a thick cloth around
the radiator cap and turn slowly to the first stop. Step back while the pressure is released from the cooling
system. When all the pressure has been released, press down on the cap and remove it slowly.
Notice: DO NOT add coolant to any engine that has become overheated until the engine cools. Adding coolant to an
extremely hot engine can result in a cracked block or cylinder head.

Industrial 1.6L General Information 0-17
Coolant Level - Continued
Use only a permanent-type coolant when refilling or flushing the coolant system.
Recommended ethylene glycol mix 52/48 is normal up to a maximum of 60% glycol, 40% water.
Refer to the mixture chart on the container for additional antifreeze protection information. DO NOT use alcohol or
methanol antifreeze, or mix them with the specified coolant.
Plain water may be used in an emergency (except in freezing temperatures), but replace it with the specified coolant
as quickly as possible to avoid damage to the system.
Radiator
Inspect the exterior of the radiator for obstructions. Remove all bugs, dirt or foreign material with a soft brush or cloth.
Use care to avoid damaging the core fins. If available, use low pressure compressed air or a stream of water in the
opposite direction of the normal air flow.
Radiator Hoses
Check all hoses and connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they must be
replaced.
Fan Belts
The water pump is usually belt driven. The same belt may also drive the fan and/or the alternator. The drive belts
should be properly adjusted at all times. A loose belt can cause improper alternator, fan and water pump operation, in
additiontooverheating.
Serpentine Belt
Some GM Powertrain engines utilize serpentine belts on the front of the engine. This type of belt system incorporates
a belt tensioning device which keeps the belt at the proper tension.
This belt should be checked routinely for cracks or ‘checking’ on the groove side of the belt. If cracks or ‘checking’ are
apparent the belt must be changed.
V-TypeBelt
V-Type belts are generally tensioned by adjusting the alternator position, or through a mechanical belt
tensioner. The belt is generally correctly tensioned when there is an ½ inch of depression on the belt between the
water pump and the crankshaft pulley.
FUEL DELIVERY SYSTEM MAINTENANCE
Fuel Filter Replacement
Carbureted Engines
On carbureted engines, an in-line fuel filter is incorporated into the fuel supply line. It is recommended that this filter be
changed every 250 hours or every 6 months which ever occurs first.
TBI Engines
On PSI Fuel Injection or Fuel Injection/Dual Fuel two fuel filters are used in the gasoline fuel supply line to the engine
TBI unit. A coarse fuel filter is located in the supply line between the fuel tank and the electric fuel pump. This filter
protects the fuel pump from debris in the fuel tank. This filter must be changed every 200 hours or every 6 months
which ever occurs first.
A primary fuel filter is located between the fuel pump and the TBI unit on the engine. This filter protects the injectors
from microscopic particles in the fuel which can cause plugging of the injectors. This filter MUST be changed every
500 hours or annually which ever occurs first.
Zenith Z.E.E.M.S. TBI Fuel Injection
Zenith Z.E.E.M.S. TBI Fuel Injection requires an in-line fuel filter in the fuel supply line from the fuel tank to the TBI
unit, ahead of the electric fuel supply pump. This filter must be changed every 400 hours or every 6 months which ever
occurs first.
On engines equipped to run on LPG, the in-line fuel filter must be replaced every 800 hours.

0-18 General Information Industrial 1.6L
Fuel Delivery System Maintenance - Continued
CAUTION: Failure to change the fuel system filters as recommended can result in premature failure of the TBI
fuel system components.
NOTE: Some original equipment manufacturers install their own fuel systems. Please refer to the manufacturers
manual if the gasoline fuel system is different than described here.
WARNING: Use extreme care when changing the fuel filters on gasoline engines. Gasoline is highly flam-
mable and should not be exposed to open flame, sparks, or hot engine components. Allow the engine to cool
to ambient temperatures prior to changing fuel filters.
Ignition Systems
Types of Ignition Systems
Three types of ignition systems are used on PSI GM Powertrain engines. Solid state electronic distributor, solid state
electronic distributor with ECU (Electronic Control Unit) and distributorless electronic ignition (DIS) with ECU.
Please refer to the Section 3, Engine Electrical, for a description of the ignition system used on your particular
engine.
Ignition Timing
Proper adjustment of the ignition timing must be obtained to provide the optimum engine power output and economy.
However, since the 1.6L engine uses a distributorless ignition system which is controlled entirely by the electronic
control unit, or ECU, the ignition timing cannot be adjusted by the user. Refer to Section 3, Engine Electrical, for a
description of the distributorless ignition system.
Spark Plugs
Spark plugs should be replaced at the recommended intervals described in the Maintenance Schedule. Use only the
recommended spark plug or an equivalent as described in Section 3, Engine Electrical.
Spark plug gap, should be adjusted as recommended in Section 3, Engine Electrical.
When removing spark plugs, always note which cylinder each plug came out of. Look at the porcelain around the
center electrode of each plug. You can detect many engine problems from the color and type of deposits that have
built up on the white porcelain. For example, if the deposits are a glossy brown, that cylinder is burning excess oil. If
the deposits are a very dark gray or sooty black color, your engine is running rich, and you are burning excess fuel.
The optimum color of the deposits on the porcelain is light tan or light brown. This shows optimum fuel mixture and
proper engine running conditions. If the deposits are almost white, the engine may be running excessively lean. Lean
running is very detrimental to your engine life, and should be corrected immediately.
If one or more cylinders are burning oil, the smoke from the engine will be a blue-gray color. Most common causes are
piston rings (worn out or not broken in) and valve stem seals (cut, nicked, or worn out). If the engine is running rich
the exhaust smoke will be a sooty black color and it will smell like gasoline (on gasoline engines).