2-1

LPG REGULATOR OVERHAUL

Page
REGULATOR (4Y-E ENGINE)................................2-2
0
REMOVAL·INSTALLATION .......................................2-8
1
DISASSEMBLY·REASSEMBLY ...............................2-10
LPG LEAK INSPECTION ........................................2-15 2
ENGINE ADJUSTMENT ..........................................2-16 3
REGULATOR (4Y-M ENGINE) .............................2-18 4
REMOVAL·INSTALLATION .....................................2-24 5
DISASSEMBLY·REASSEMBLY ...............................2-26
6
LPG LEAK INSPECTION ........................................2-31
7
ENGINE ADJUSTMENT ..........................................2-32
WIRING DIAGRAM...............................................2-33 8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
2-2

REGULATOR (4Y-E ENGINE)

General
 2-3

Components

0
First valve ASSY Idle adjust screw
1
2
O-ring

Slow solenoid valve 3

4
Second cover
5
Second Second diaphragm
6
valve
ASSY 7
8
9
First diaphragm
10
11
First cover
12
13
14
15
16
17
18
19
20
21
E
2-4

SSTs for LPG Regulator Overhaul

5
1

7
2

3 9-3
9-1

9-
9-2

No. Part No. Part Name

1 09813-26600-71 Gauge
2 09814-22000-71 Tool
3 09815-22000-71 Tool
4 80339-76026-71 Automatic choke pipe plug
5 09817-23600-71 Union
6 09819-23600-71 Gauge
7 09819-22000-71 Gauge
8 23627-22000-71 Spring
9 09820-23600-71 Tester SUB-ASSY
9-1 09823-23600-71 Union
9-2 09822-22000-71 Gauge
9-3 09821-22000-71 Bellows
 2-5

INSPECTION OF REGULATOR BEFORE DISASSEMBLY

Inspection 1
SST 1. Remove the idle adjusting screw and install the SST.

SST
SST (Union) tightening torque:
T=0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
0
SST
2. Supply compressed air at 400 kPa (4 kgf/cm2) [57 1
psi] through the IN port and maintain the air
pressure.
2
Note:

Compressed
Don't apply compressed air more than 780 kPa (8
kgf/cm2) [110 psi].
3
air
3. Check that the SST gauge indicates 0. 4
OK 0 NG More than 0
5
Slow solenoid valve defect
6
Inspection 2
SST
1. Put the SST to the injector port to prevent air from 7
blowing.

SST
SST
2. Apply 12 V to the slow solenoid valve.
8
3. See that the SST gauge indicates 24.5 to 34.3 kPa
(0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].
9
10
Compressed
air 12 V 11

0 Other than 24.5 to 34.3 kPa

12
OK 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) NG NG
(0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].
[3.6 to 5.0 psi].
13
Slow solenoid • In appropriate adjustment of first pressure
valve defect • Elastic face valve 1 defect
• Elastic face valve 2 defect 14
• First diaphragm defect
• Clogging of slow path 15
Inspection 3
SST
1. Stop supllying the compressed air in state of 16
Inspection 2.

SST
SST
2. Read the SST gauge.
17
18
19
12 V 20

The pointer stays at the same position The pointer gradually moves toward the 0
21
OK NG
as that of inspection 2. position.

To flow (1)
E
2-6

From Inspection 3

OK

Inspection 4
1. Stop supplying the compressed air in the state of
Inspection 2.

2. Breathe air into the inner vent port and read the
SST gauge.

Air

OK The pointer moves to 0 position. NG The pointer stays at the position.

Normal • Second diaphragm defect

• Elastic face valve 2 (in C chamber) defect.

Flow (1) (from inspection 3)

NG

Inspection 5
Apply soapy water on portions A to F of the regulator to
check any air leakage in state of Inspection 2.
B

Compressed D
air
E
12 V
A
F
Leak from A or F. Leak from A, C, D, or E.
Result Result
1 2
Leak from B: Re-check after retightening each part. (Since the fitting at A is
Defect of idle adjusting screw O-ring. applied with a sealing agent, reassemble it.)
OK No leak from NG Leak from D
Leak from F: any portion
Body defect.
To Inspection 3 • Elastic face valve 2 contact
defect
• First diaphragm defect
• Loosen of elastic face valve
2 mounting screw
 2-7

Individual Inspection
1. Inspect the slow solenoid.
Check that the operating sound is heard when applying 12 V to
the slow solenoid.

12 V

2. Inspect the main solenoid.

Check that the operating sound is heard when applying 12 V to
the main solenoid.

12 V
2-8

REMOVAL·INSTALLATION
Caution:
• Perform working at a well-ventilated job site and never put fire sources around the vehicle.
• Perfectly discharge LPG from the piping before starting removal.
• Disconnect the battery negative terminal before handling the fuel system.
• After installation, using soapy water, check no LPG leak from any part of each piping before starting the
engine.
• After installation, adjust the idling speed. (See page 2-15)

Removal Procedure
1 Fully discharge LPG from the fuel piping. [Point 1]
2 Disconnect the battery cable from the negative terminal.
3 Drain engine coolant.
4 Disconnect the wiring from the main and slow solenoid valves.
5 Disconnect the fuel piping.
6 Disconnect the coolant piping.
7 Remove the filter and main solenoid.
8 Remove the regulator ASSY.

Installation Procedure
The install procedure is the reverse of the removal procedure.
Note:
After installation, adjust the idling speed. (See page 2-15)
 2-9

Point Operations
[Point 1]
2 Removal:
Discharge LPG from the piping according to the procedure
below.
(1) Close the LPG supply piping valve 1 (green).
1 (2) Close the LPG outlet valve 2 (amber).
(3) Start the engine, and run the engine in the idling state until
it stops naturally.
2-10

DISASSEMBLY·REASSEMBLY
Caution:
Perform working at a well-ventilated job site and never put fire sources around the vehicle.
Note:
• Wash the outer surface of the regulator and keep the work bench clean.
• First, perform individual check of the filter for clogging and the solenoid valve for any abnormality, and
then disassemble the regulator only when its internal abnormality is found by the inspection according
to the troubleshooting given in this manual.
• Disassemble the regulator carefully, or defects such as diaphragm or valve contacts may occur.
T = N·m (kgf·cm) [ft·lbf]

T = 3.5 to 4.4
(36 to 45)
[2.6 to 3.2]
4 T = 3.5 to 4.4
(36 to 45)
[2.6 to 3.2]

T = 3.5 to 4.4
(36 to 45) 5
[2.6 to 3.2]

2
T = 3.5 to 4.4
(36 to 45)
[2.6 to 3.2]

Disassembly Procedure
1 Remove the regulator second cover and diaphragm. [Point 1]
2 Remove the second valve ASSY. [Point 2]
3 Remove the first cover, first diaphragm spring and retainer. [Point 3]
4 Remove the first valve ASSY. [Point 4]
5 Remove the slow solenoid valve.
6 Remove the idle adjust screw and O-ring. [Point 5]

Reassembly Procedure
The install procedure is the reverse of the removal procedure.
 2-11

[Point 1]
Reassembly:
4 2 1. Install the diaphragm by matching its pin with the concave
portion of the second valve lever.
2. Tighten the screws in the illustrated order.
1 Tightening torque:
3 T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Pin Concave portion

[Point 2]
Reassembly:
Seat portion Install the spring by holding it manually so as not to be freed
from the convex portion of the lever.
Spring Carefully perform the work to prevent the lever seat portion
from being pressed against the housing.

Convex portion

Reassembly:
Follow the steps below when the second valve ASSY is
Snap ring Spring washer replaced with a new one:
(1) Insert the seat.
(2) Install the spring washer.
(3) Install the snap ring.
(4) Perform valve airtightness test in the state of step 3
Seat above. (See page 2-14)
(5) Apply adhesive agent (Castle Super Cement) on the snap
ring and spring washer. Do not let the adhesive agent
adhere on the valve seat portion.

Inspection:
B Inspect the second valve lever height.
SST
Check contact with the lever when passing through the A side
A of the SST, and no contact when passing through the B side.
SST 09819-23600-71
2-12

If not satisfied, use the SST to bend the lever for adjustment.
SST (2)
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
During lever height adjustment, do not push the valve seat
SST (1) against the port.

8 [Point 3]
1 5 Disassembly:
9 Since the spring force is applied at each portion, do not try
3 7 quick removal but loosen each bolt equally for removal.
Reassembly:
Tighten each bolt equally step by step so as not to let springs
6 4 be fallen. Tighten in the illustrated order for final tightening.

2 Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Disassembly:
Diaphragm hook Since the diaphragm hook is engaged with the first valve lever,
move the diaphragm in the direction of the arrow in the
illustration for removal.
Reassembly:
Engage the diaphragm hook onto the first valve lever tip.

First valve lever

[Point 4]
Disassembly:
1. Remove the first valve ASSY.
2. Disassemble the first valve.

Reassembly:
1. Reassemble the first valve ASSY.
Note:
O-ring Replace the O-ring with a new one.
2. Install the first valve ASSY.
Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.3 ft·lbf]
 2-13

3. Check the first valve air-tightness.

(1) Put the SST (spring) between the lever tip and regulator
body.
SST 23627-22000-71

SST

(2) Connect the SST (gauge) to the fuel inlet.

SST SST 09820-23600-71

(3) Check that the air does not leak from the valve until air
pressure become in the range of 49.0 to 58.8 kPa (0.5 to
0.6 kg/cm2) [2.7 to 7.0 psi]. If air leaks before the air
pressure reaches at the range, replace the elastic face
valve 1.

4. Check and adjust the first lever height.

SST (1) Push the first valve at the elastic face valve side.

T (2) Check contact with the lever when passing through the S
side of the SST, and no contact when passing through the
S T side.
SST 09813-26600-71
Reference height:
11.8 to 12.3 mm (0.47 to 0.48 in) from the regulator contact
surface.

5. Using SSTs, adjust the first valve lever height if it is not within
the specified range.
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
Note:
SST (2) • Do not apply force to the valve seat, or the valve seat will
be damaged.
• Be sure to set the SST with a cut on the valve lever.
SST (1)

6. Hang the diaphragm hook at the tip of the first valve lever and
set the diaphragm to the regulator body.
7. Install the regulator first cover to the body, with pushing the
diaphragm spring manually.
Tightening torque:
T = 3.5 to 4.4 N·m (36 o 45 kgf·cm) [2.6 to 3.3 ft·lbf]
2-14

8. Adjust the first diaphragm adjust screw.

(1) Loosen the adjust screw nut.
SST
(2) Using SST, adjust the protrusion of the screw.
SST 09819-22000-71
Reference height: 13.9 mm (0.5 in)
9. Adjust the pressure of first reducing chamber. (See page 2-16)

[Point 5]
Idle adjusting screw Reassembly:
Temporarily adjust the idle adjusting screw.
15.2 mm (0.6 in)
After tightening until the tip end of the adjusting screw come
into contact with the body loosen the screw, and adjust the
screw protrusion to 15.2 mm (0.6 in) for the regulator upper
surface.
Note:
• Do not tighten the adjusting screw too hard.
• After installing the regulator on the vehicle, be sure to
adjust the VF voltage. (See page 2-18)

Second Valve Airtightness Check

SST (2)
1. Temporarily install the second valve ASSY.
SST (1)
2. Remove the idle adjusting screw and install the SSTs.
SST (3)
SST (union) tightening torque:
T = 0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
SST 09817-23600-71................................. (1)
09820-23600-71................................. (2)
3. Put the SST to the injector port.
SST 80339-76026-71................................. (3)
4. Apply 12 V to the slow solenoid valve.

5. Inject compressed air through the SSTs and make adjustment

of the seat position to ensure no air leakage by tilting the valve,
as shown in the illustration.
 2-15

LPG LEAK INSPECTION

Caution:
• After repairing each part of the LPG system, use soapy water to check no LPG leakage from any part
before starting the engine.
• Never use fire for inspecting gas leakage.
• Never use a match or lighter for illumination at the time of inspection at night.
1. Open the valve between the LPG cylinder and hose. (The LPG is led to the regulator by this operation.)
2. Remove the idle adjust screw and install the SST.
SST 09817-23600-71
3. Turn the ignition switch ON.
Note:
Do not start the engine.
4. Apply 12 V to the main and slow solenoid valves.
5. Using soapy water or aqueous solution of a neutral detergent, check no gas leakage from each joint (illustrated
below).
6. Be sure to wipe the liquid off after the leak check.
2-16

ENGINE ADJUSTMENT
Note:
To measure values described below, use the multifunction
display or plug-in analyzer.
1. Warm up the engine until the coolant temperature be 80°C
(176°F) or higher.
2. Check the engine idle speed.
Standard: 750 ± 150 rpm

3. Check the initial advanced ignition timing.

(1) Using SST, connect the terminal TC and E1 of the
diagnosis connector.
SST 09238-13130-71
Notice:
Be sure to connect the correct terminals.
If connecting wrong terminals, malfunction may occur.

(2) Using a timing light, check the ignition timing.

Standard: 7° BTDC/750 rpm

4. Adjust the initial advaced ignition timing.

(1) If the ignition timing is not as specified above, loosen the
two distributor clamp bolts and turn the distributor for
adjustment.
When delayed: Turn counterclockwise.
When advanced: Turn clockwise.
(2) After adjustment, tighten the bolts and check the ignition
timing again.

5. Check LPG regurator primary pressure

SST (2) (1) Install the SST to the LPG regulator.
SST 09817-23600-71................................. (1)
SST (1)
09820-23600-71................................. (2)
(2) Start the engine.
(3) Check the LPG regulator primary pressure.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]
Note:
The pressure remains as above one.
 2-17

6. Adjust LPG regurator primary pressure

(1) Start the engine.
(2) Loosen the adjust screw nut and adjust the primary
pressure by turning the screw.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.5 to 5.0 psi]

7. Check and adjust VF voltage

(1) Warm up the heated oxygen sensor by maintaining the
engine speed at 1800 rpm for approximately 2 minutes.
(2) Check the oxygen sensor feedback signal (OX) value
changes alternately between 0 and 1.
Standard:
The feedback signal (OX) value changes alternately more
than 4 times for 20 seconds.
Note:
Maintain the engine rpm at 1800 rpm.
(3) Measure the VF voltage while engine idling.
Standard: 2.5 ± 0.5 V

(4) If the standard condition is not satisfied adjust the VF

voltage into the specified range by turning the idle adjust
screw of the regulator slowly.
Reference:
COUNTERCLOCKWISE CLOCKWISE
VF
Condition Measures
voltage
Air fuel ratio: Turn the screw
0V
RICH CLOCKWISE
Air fuel ratio: Turn the screw
5V
LEAN COUNTERCLOCKWISE

(5) After racing the engine several times, check that the VF
voltage is within the specified range.
Note:
• Adjust the VF voltage to the 2.5 V as possible.
• If VF voltage is 2.5 V, but OX signal value is not changed
alternately, disconnect and reconnect the battery negative
cable, and perform this step (7) again.
2-18

REGULATOR (4Y-M ENGINE)

General
 2-19

Components

First valve ASSY Idle adjust screw

O-ring

Slow solenoid valve

Second cover

Second Second diaphragm

valve
ASSY

Spring
First diaphragm
Retainer

First cover
2-20

SSTs for LPG Regulator Overhaul

4
5

7
2

3 8-1
8-2

8-3

No. Part No. Part Name

1 09813-26600-71 Gauge
2 09814-22000-71 Tool
3 09815-22000-71 Tool
4 23627-22000-71 Spring
5 09817-23600-71 Union
6 09819-23600-71 Gauge
7 09819-22000-71 Gauge
8 09820-23600-71 Tester SUB-ASSY
8-1 09823-23600-71 Union
8-2 09822-22000-71 Gauge
8-3 09821-22000-71 Bellows
 2-21

INSPECTION OF REGULATOR BEFORE DISASSEMBLY

Inspection 1
SST 1. Remove the idle adjusting screw and install the SST.
SST (Union) tightening torque:
T=0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
2. Supply compressed air at 400 kPa (4 kgf/cm2) [57
psi] through the IN port and maintain the air
pressure.
Note:
Compressed Don't apply compressed air more than 780 kPa (8
air kgf/cm2) [110 psi].
3. Check that the SST gauge indicates 0.
OK 0 NG More than 0

Slow solenoid valve defect

Inspection 2
SST
1. Apply 12 V to the slow solenoid valve.
2. See that the SST gauge indicates 24.5 to 34.3 kPa
(0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].

Compressed
air 12 V

OK 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) NG 0 NG Other than 24.5 to 34.3 kPa
[3.6 to 5.0 psi]. (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].
Slow solenoid • In appropriate adjustment of first pressure
valve defect • Elastic face valve 1 defect
• Elastic face valve 2 defect
• First diaphragm defect
• Clogging of slow path
Inspection 3
1. Stop supllying the compressed air in state of
Inspection 2.

2. Read the SST gauge.

12 V

OK The pointer stays at the same position NG The pointer gradually moves toward the 0
as that of inspection 2. position.

To flow (1)
• Check second diaphragm
• Check elastic face valve 2
2-22

Flow (1) (from inspection 3)

NG

Inspection 5
Apply soapy water on portions A to F of the regulator to
SST check any air leakage in state of Inspection 2.

Compressed
air

Leak from A or F. Leak from A, C, D, or E.

Result Result
1 2
Leak from B: Re-check after retightening each part. (Since the fitting at A is
Defect of idle adjusting screw O-ring. applied with a sealing agent, reassemble it.)
OK No leak from NG Leak from D
Leak from F: any portion
Body defect.
To Inspection 3 • Elastic face valve 2 contact
defect
• First diaphragm defect
• Loosen of elastic face valve
2 mounting screw
 2-23

Individual Inspection
1. Inspect the slow solenoid.
Check that the operating sound is heard when applying 12 V to
the slow solenoid.

12 V

2. Inspect the main solenoid.

Check that the operating sound is heard when applying 12 V to
the main solenoid.

12 V
2-24

REMOVAL·INSTALLATION
Caution:
• Perform working at a well-ventilated job site and never put fire sources around the vehicle.
• Perfectly discharge LPG from the piping before starting removal.
• Disconnect the battery negative terminal before handling the fuel system.
• After installation, using soapy water, check no LPG leak from any part of each piping before starting the
engine.
• After installation, adjust the idling speed. (See page 2-32)

Removal Procedure
1 Fully discharge LPG from the fuel piping. [Point 1]
2 Disconnect the battery cable from the negative terminal.
3 Drain engine coolant.
4 Disconnect the wiring from the main and slow solenoid valves.
5 Disconnect the fuel piping.
6 Disconnect the coolant piping.
7 Remove the filter and main solenoid.
8 Remove the regulator ASSY.

Installation Procedure
The install procedure is the reverse of the removal procedure.
Note:
After installation, adjust the idling speed. (See page 2-32)
 2-25

Point Operations
[Point 1]
2 Removal:
Discharge LPG from the piping according to the procedure
below.
(1) Close the LPG supply piping valve 1 (green).
1 (2) Close the LPG outlet valve 2 (amber).
(3) Start the engine, and run the engine in the idling state until
it stops naturally.
2-26

DISASSEMBLY·REASSEMBLY
Caution:
Perform working at a well-ventilated job site and never put fire sources around the vehicle.
Note:
• Wash the outer surface of the regulator and keep the work bench clean.
• First, perform individual check of the filter for clogging and the solenoid valve for any abnormality, and
then disassemble the regulator only when its internal abnormality is found by the inspection according
to the troubleshooting given in this manual.
• Disassemble the regulator carefully, or defects such as diaphragm or valve contacts may occur.
T = N·m (kgf·cm) [ft·lbf]

T = 3.5 to 4.4
(36 to 45)
4 [2.6 to 3.2]
T = 3.5 to 4.4
(36 to 45)
[2.6 to 3.2]
6

T = 3.5 to 4.4
(36 to 45) 5
[2.6 to 3.2]

2
T = 3.5 to 4.4
(36 to 45)
[2.6 to 3.2]

Disassembly Procedure
1 Remove the regulator second cover and diaphragm. [Point 1]
2 Remove the second valve ASSY. [Point 2]
3 Remove the first cover, first diaphragm spring and retainer. [Point 3]
4 Remove the first valve ASSY. [Point 4]
5 Remove the slow solenoid valve.
6 Remove the idle adjust screw and O-ring. [Point 5]

Reassembly Procedure
The install procedure is the reverse of the removal procedure.
 2-27

[Point 1]
Reassembly:
1. Install the diaphragm by matching its pin with the concaved
portion of the second valve lever.
2. Tighten the screws in the illustrated order.
Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Pin Concaved portion

[Point 2]
Reassembly:
Seat portion Install the spring by holding it manually so as not to be freed
from the convex portion of the lever.
Spring Carefully perform the work to prevent the lever seat portion
from being pressed against the housing.

Convex portion

Reassembly:
Follow the steps below when the second valve ASSY is
Snap ring Spring washer replaced with a new one:
(1) Insert the seat.
(2) Install the spring washer.
(3) Install the snap ring.
(4) Perform valve airtightness test in the state of step 3
Seat above. (See page 2-30)
(5) Apply adhesive agent (Castle Super Cement) on the snap
ring and spring washer. Do not let the adhesive agent
adhere on the valve seat portion.

Inspection:
B Inspect the second valve lever height.
SST
Check contact with the lever when passing through the A side
A of the SST, and no contact when passing through the B side.
SST 09819-23600-71
2-28

If not satisfied, use the SST to bend the lever for adjustment.
SST (2)
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
During lever height adjustment, do not push the valve seat
SST (1) against the port.

[Point 3]
Disassembly:
1 5 Since the spring force is applied at each portion, do not try
7 quick removal but loosen each bolt equally for removal.
3
Reassembly:
Tighten each bolt equally step by step so as not to let springs
4 be fallen. Tighten in the illustrated order for final tightening.
6
2 Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Disassembly:
Diaphragm hook Since the diaphragm hook is engaged with the first valve lever,
move the diaphragm in the direction of the arrow in the
illustration for removal.
Reassembly:
Engage the diaphragm hook onto the first valve lever tip.

First valve lever

[Point 4]
Disassembly:
1. Remove the first valve ASSY.
2. Disassemble the first valve.

Reassembly:
1. Reassemble the first valve ASSY.
Note:
O-ring Replace the O-ring with a new one.
2. Install the first valve ASSY.
Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.3 ft·lbf]
 2-29

3. Check the first valve air-tightness.

(1) Put the SST (spring) between the lever tip and regulator
body.
SST 23627-22000-71

SST

(2) Connect the SST (gauge) to the fuel inlet.

SST SST 09820-23600-71

(3) Check that the air does not leak from the valve until air
pressure become in the range of 49.0 to 58.8 kPa (0.5 to
0.6 kg/cm2) [2.7 to 7.0 psi]. If air leaks before the air
pressure reaches at the range, replace the elastic face
valve 1.

4. Check and adjust the first lever height.

SST (1) Push the first valve at the elastic face valve side.

T (2) Check contact with the lever when passing through the S
side of the SST, and no contact when passing through the
S T side.
SST 09813-26600-71
Reference height:
11.8 to 12.3 mm (0.47 to 0.48 in) from the regulator contact
surface.

5. Using SSTs, adjust the first valve lever height if it is not within
the specified range.
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
Note:
SST (2) • Do not apply force to the valve seat, or the valve seat will
be damaged.
• Be sure to set the SST with a cut on the valve lever.
SST (1)

6. Hang the diaphragm hook at the tip of the first valve lever and
set the diaphragm to the regulator body.
7. Install the regulator first cover to the body, with pushing the
diaphragm spring manually.
Tightening torque:
T = 3.5 to 4.4 N·m (36 o 45 kgf·cm) [2.6 to 3.3 ft·lbf]
2-30

8. Adjust the first diaphragm adjust screw.

(1) Loosen the adjust screw nut.
SST
(2) Using SST, adjust the protrusion of the screw.
SST 09819-22000-71
Reference height: 13.9 mm (0.5 in)
9. Adjust the pressure of first reducing chamber. (See page 2-32)

[Point 5]
Idle adjusting screw Reassembly:
Temporarily adjust the idle adjusting screw.
15.2 mm (0.6 in)
After tightening until the tip end of the adjusting screw come
into contact with the body loosen the screw, and adjust the
screw protrusion to 15.2 mm (0.6 in) for the regulator upper
surface.
Note:
• Do not tighten the adjusting screw too hard.
• After installing the regulator on the vehicle, be sure to
adjust the VF voltage. (See page 2-18)

Second Valve Airtightness Check

SST (2)
1. Temporarily install the second valve ASSY.
SST (1)
2. Remove the idle adjusting screw and install the SSTs.
SST (union) tightening torque:
T = 0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
SST 09817-23600-71................................. (1)
09820-23600-71................................. (2)
3. Apply 12 V to the slow solenoid valve.

4. Inject compressed air through the SSTs and make adjustment

of the seat position to ensure no air leakage by tilting the valve,
as shown in the illustration.
 2-31

LPG LEAK INSPECTION

Caution:
• After repairing each part of the LPG system, use soapy water to check no LPG leakage from any part
before starting the engine.
• Never use fire for inspecting gas leakage.
• Never use a match or lighter for illumination at the time of inspection at night.
1. Open the valve between the LPG cylinder and hose. (The LPG is led to the regulator by this operation.)
2. Remove the idle adjust screw and install the SST.
SST 09817-23600-71
3. Turn the ignition switch ON.
Note:
Do not start the engine.
4. Apply 12 V to the main and slow solenoid valves.
5. Using soapy water or aqueous solution of a neutral detergent, check no gas leakage from each joint (illustrated
below).
6. Be sure to wipe the liquid off after the leak check.
2-32

ENGINE ADJUSTMENT
1. Warm up the engine until the coolant temperature be 80°C
(176°F) or higher.
2. Install a tachometer.
3. Check the engine idle speed.
Standard: 750 ± 150 rpm
4. Adjust the engine idle speed. (Refer to LPG DEVICE repair
manual (Pub No. CE610-4))

5. Check the ignition timing.

(1) Install a timing light.
(2) Using a timing light, check the ignition timing.
Standard: 7° BTDC/750 rpm
6. Adjust the ignition timing.
(1) If the ignition timing is not as specified above, loosen the
two distributor clamp bolts and turn the distributor for
adjustment.
When delayed: Turn counterclockwise.
When advanced: Turn clockwise.
(2) After adjustment, tighten the bolts and check the ignition
timing again.

7. Check LPG regurator primary pressure

SST (2) (1) Install the SST to the LPG regulator.

SST (1) SST 09817-23600-71................................. (1)

09820-23600-71................................. (2)
(2) Start the engine.
(3) Check the LPG regulator primary pressure.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]
Note:
The pressure remains as above one.

8. Adjust LPG regurator primary pressure

(1) Start the engine.
(2) Loosen the adjust screw nut and adjust the primary
pressure by turning the screw.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.5 to 5.0 psi]
 2-33

WIRING DIAGRAM
WIRING DIAGRAM (4Y-E ENGINE)
Refer to WIRING DIAGRAM (4Y-E ENGINE) on page 4-5.

WIRING DIAGRAM (4Y-M ENGINE)

IGNITION FUEL

LPG/GASOLINE
SELECT SWITCH
Fuse
GAS LPG

IGNITION
COIL
MAIN SLOW
SOLENOID SOLENOID
ENGINE
REVOLUTION
SWITCH FROM
IGNITER

TO LPG
ENGINE RELAY
IGNITER DISTRIBUTOR
REVOLUTION
SWITCH