2002 GM 4.3L V6 Engine Service & Repair Manual
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Service Manual
Liquefied Petroleum Gas Supplement
4G63 AA0001-ZZ9999
4G64 AA0001-ZZ9999
6G72 0A0001-0Z9999
99729-75100 For use with 4G63, 4G64 & 6G72 Engine Service Manuals.
CAUTION Indicates items that users must always
observe in order to prevent injuries and
damage to the vehicle and surrounding
area.
Note Supplementary explanation
INTRODUCTION
LP-gas (Liquefied Petroleum gas) forklift trucks are superior to gasoline forklift trucks in many
ways including cleaner emissions and higher fuel efficiency.
LP-gas is, however, more dangerous than gasoline when handled improperly.
This Service Manual contains operating instructions and maintenance procedures for the LP-gas
device of Mitsubishi LP-gas fuel forklift trucks. To ensure safety and maximize the superb fea-
tures of your forklift truck, read this manual thoroughly.
The following mark and designation are used in this manual to call your attention to important
instructions and cautions.
< Warning indication >
99729-75100
TABLE OF CONTENTS
Types of LP-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Guideline for selecting LP-gas for forklift-truck engines . . . . . . . . . . . . . . . . . . . . . . . . . .1
LP-gas knock rating and octane number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Adverse effects of olefins on LP-gas fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Vapor pressure vs. temperature for mixture of propane
and normal butane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Structure and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1. Outline of LP-gas device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. LP-gas device layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Main component structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1. LP-gas tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.1. Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.2. Fixed liquid level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1.3. Service valve (LP-gas outlet valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1.4. Fuel level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.2. Filter (Vacuum fuel lock filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.3. Hydrostatic relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.4. Converter (vaporizer) and LP-gas carburetor . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.4.1. Converter (vaporizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.4..2. LP-gas carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Actions to be taken in the event of a failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1. Main components of LP-gas device (4G63, 4G64) . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2. Main components of LP-gas device (6G72) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3. Disassembly and reassembly of LP-gas carburetor /mixer . . . . . . . . . . . . . . . . . . . . . . .19
4. Disassembly and reassembly of converter/regulator (vaporizer) . . . . . . . . . . . . . . . . . .21
5.Disassembly and reassembly of LP-gas filter, Fuel lock . . . . . . . . . . . . . . . . . . . . . . . .27
Inspection and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1. LP-gas tank inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2. Filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3. Converter (vaporizer) inspection and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4. Idle speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5. Output power adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6. Gas leak check procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
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CARB Tier 1 Emissions Control System (S-15G, 2001-2002 Model Year)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1. Outline of CARB Tier 1 LP-gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2. CARB Tier 1 LP-gas layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3. Main Component Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3.1. Electronic Control Units (ECU) (Version 1 & 2) . . . . . . . . . . . . . . . . . . . . . . . .40
3.2. Electronic Control Unit Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3.3. Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
3.4. Pedal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
3.5. Engine Block Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
3.6. Mixer and Throttle Body Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.7. Three Way Catalytic Convertor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.8. Dash Light Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.9. Exploded view for use with Pneumatic type models . . . . . . . . . . . . . . . . . . . . .44
3.10. Exploded view for use with cushion type models . . . . . . . . . . . . . . . . . . . . . . .45
Systems Operations
1. Explanation of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2. Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Sub-system Operating Principles
1. Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2. Fuel Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3. Throttle and Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4. Throttle and Governor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
System Adjustments
1. Diagnostic Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3. S15G Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.1 Adjustment Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
3.2 Diagnostic Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
S-15G Troubleshooting
1. Troubleshooting Problem Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2. Troubleshooting Tree Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3. Check Engine Light Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
4. System Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5. Effects of Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
ii
Vacuum System Diagram and Wiring Schematics
1. Vacuum System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
2. S-15G Fuel System Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
3. ECU Pin Location and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Inspection and Adjustment
1. Periodic Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
iii
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What's Included?
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This Workshop Manual is a comprehensive guide for servicing personnel working with the GM 4.3L V6 2002 engine. It is divided into three parts: General, Mechanism, and Servicing.
The manual provides essential information for maintaining the engine, including details on regular maintenance intervals, technical data, and guidance. All information, illustrations, and specifications are based on the latest product information available at the time of publication.
In this GM 4.3L V6 2002 ENGINE MANUAL, you can find:
- Safety information
- Product details
- Detailed substeps for operation and repair procedures
- Notes, cautions, and warnings throughout each chapter
- Maintenance information including refill capacities, fluid recommendations, and maintenance procedures
- Numbered instructions and detailed illustrations to guide you through every repair procedure
- Enlarged insets to help you identify and examine parts in detail
- Numbered table of contents for easy navigation
- Troubleshooting and electrical service procedures combined with detailed wiring diagrams
Product Details:
- File Format: .PDF
- Language: English
- Specifications: Full Printable
- Zoom IN/OUT: YES
- Delivery: Instant
- Requirements: Adobe Reader & Win
- Compatible: All Versions of Windows & Mac
The manual comes in .PDF format, compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and burned to CD-ROM. All pages are printable, eliminating the need for shipping and waiting for physical copies to arrive.
