OPERATION AND MAINTENANCE MANUAL

CERTIFIED MOBILE PRODUCT

2.0L 2.4L

3.0 L 4.3L

5.0L 5.7L

4.3L

Certified Mobile Operations Manual Revision B

 Table of Contents
TOPIC PAGE

Introduction 4
How to Use This Manual 4
Engine Identification 4
Parts and Service 5
Service Literature 5
Certified Engine Emissions Information 6
Example MOR Label 6
PSI Certified Engine Emission Warranty 7
Operating Instructions 12
Fuel Systems 12
Governors 12
Oil Pressure Reading 12
Temperature Reading 12
Voltage Reading 13
Tachometer/Hourmeter 13
Starting the Engine 13
LPG or NG Fuel Systems 13
Stopping the Engine 14
Fuel Recommendations 14
Fuel Quality LPG and NG 14
Fuel Quality Gasoline 14
Anti-Knock Index (Octane Rating) 15
Gasohol and Alcohol/Gasoline Fuels 15
Power Loss at Higher Elevations 16
Maintenance Instructions 16
Initial Start Up Maintenance 16
Routine Maintenance 16
Scheduled Preventive Maintenance 16
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TOPIC PAGE

Engine Oil Level Check 16

Adding Engine Oil 17
Changing Engine Oil and Filter 17
Engine Oil Quality 17
Engine Oil Recommendation 18
Oil Filter 18
Engine Air Cleaner 18
Safety Element 18
Cooling System 19
Coolant Level 19
Radiator 19
Fan Belts 20
Serpentine Belt 20
V-Type Belt 20
Fuel Filter 20
Fuel Shut Off 20
Ignition Systems 21
Types of Ignition Systems 21
Ignition Timing 21
Spark Plugs 21
Storage 22
One to Six Months 22
Extended Periods 22
Removing the Engine From Storage 22
Maintenance Schedule (Mitsubishi and GM) 23
General Specification (Mitsubishi and GM) 24
General Specifications (GM and PSI) 25

No part of this publication may be reproduced without written permission from Power Solutions International, Inc. At the
time of publication, all of the information included in this publication is accurate to the best of our knowledge. Power
Solutions International, Inc. cannot be responsible for information that has changed after this book was published.
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Introduction

Power Solutions International, Inc. is pleased that you have selected our engine for your requirements.
Power Solutions International, Inc. takes great pride in our tradition of quality products produced from
our line of industrial gasoline and alternative fuel engines.

Prior to starting the engine at your facility, certain checks should be made. Please read the Initial Start-
Up inspection requirements in the Maintenance Section of this manual. If you have further questions
please contact your PSI account representative or Customer Support Engineer

How to Use this Manual

This manual contains instructions on the safe operation and preventive maintenance of your PSI
industrial engine. We urge you to read this manual prior to start up or operation of the engine.

The Table of Contents permits you to quickly open the manual to any section.

Power Solutions International, Inc., engines are built with a variety of standard and/or optional
components to suit a broad range of customer requirements. This manual does not identify equipment as
standard or optional. All the equipment described in this manual may not be found on your engine or
power unit.

Please pay special attention to the NOTES, CAUTIONS, and WARNINGS. WARNINGS remind you
to be careful in areas where carelessness can cause personal injury. CAUTIONS are given to prevent
you from error that could cause damage to the equipment. NOTES give you added information designed
to help you.

The descriptions and specifications contained in this manual were in effect at the time of publication.
Power Solutions International, Inc. reserves the right to discontinue models at any time, or to change
specifications or design without notice and without incurring obligation.

Engine Identification

An identification label is affixed to the right side

of the engine on the rocker cover when looking at
the engine from the flywheel end. (The engine
serial number is also stamped into the left side of
the cylinder block near the engine flywheel.) The
label contains the engine family number and a
serial number which identifies the engine from
other PSI engines. The engine model and serial
number are required when seeking information
concerning the engine and/or ordering replace-
ment service parts.

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Parts and Service

Replacement parts can be obtained from Power Solutions International, Inc. by calling the Aftermarket
Parts Department at 888-331-5769 or via email at [email protected]. The engine model and serial
number will be required when seeking information and/or ordering parts.

Service and technical support for PSI engines can be obtained by contacting the Service Department at
888-331-5764 or via email at [email protected].

Service Literature

Additional operator manuals and service manuals for specific PSI engines can be obtained by contacting
the Parts or Service Department at 888-331-5769 or [email protected].

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Certified Engine Emissions Information

The engine installed in your equipment is certified by POWER SOLUTIONS, INTERNATIONAL, INC.
with the U.S. Environmental Protection Agency and the California Air Resources Board. The engine
assembly is certified by PSI and is installed into your equipment by the equipment manufacturer
following PSI’s installation guidelines. The PSI certified engines have an emission label on or near the
valve cover that identifies the engine emission family and the standards the engine is certified to. The
label also provides some information regarding the maintenance of your engine.

Example Label:

The engine’s emission control system does not require any adjustments, but the engine does require
Preventative Maintenance (PM). Your obligation as the owner of the engine/equipment is to follow the
engine’s PM requirements outlined in this manual and to keep the engine in the proper working order.
The equipment your engine is installed in will have a malfunction indicator lamp (MIL) for diagnosis of
the engine’s emission control system. If this lamp is illuminated it is important to have the engine
repaired. Failure to keep the engine in the proper state of repair can affect the performance of the
engine’s emission control system. Any unapproved modification to the engine’s emission control system
may potentially violate the engine’s emission certification and may be subject to civil penalty.

The equipment manufacturer and/or equipment dealer will be your best resource regarding the proper
support and information pertaining to the PSI certified engine and the equipment. Please contact the
equipment manufacturer or equipment dealer first for questions and further information. You may
contact PSI directly if you are unable to reach the equipment manufacturer or dealer. The PSI Service
Department can be contacted at 888-331-5764.

Your PSI certified engine is covered by an Emission Control System Warranty (Warranty Statement
contained in this section). Your equipment and engine is warranted to you by the equipment
manufacturer. In the event you are unable to receive warranty from the equipment manufacturer or
equipment dealer you can contact PSI directly for assistance with your PSI certified engine emission
control system warranty. The PSI Warranty Department can be contacted at 888-331-5764.

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 PSI Certified Engine Emission Warranty
Statement

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Operating Instructions

Fuel Systems

The fuel system installed on your engine operates with an Electronic Pressure Regulator (EPR) and a
diaphragm style variable venturi mixer. The EPR will regulate the fuel pressure being delivered to the
mixer; these parts are not adjustable and should not be tampered with. Proper inlet fuel pressure is
critical to the proper operation of the fuel system and engine; you should the review the pressure, volume,
and BTU recommendations prior to commissioning the engine.

Governors

PSI engines have an isochronous governor installed. The governor controls the movement of the
throttle plate via a 0-12 volt signal and a ground provided by the Engine Control Module. The throttle
plate allows the correct amount of air to enter the engine; this movement is monitored by using 2 throttle
position sensors located internal to the governor. The ECM monitors various engine sensors to
determine what the correct throttle position should be.

Oil Pressure Reading

The oil pressure reading shows the engine lubrication system pressure in pounds per square inch (psi)
and should be checked frequently to ensure that the system is functioning correctly. Should the
pressure fluctuate or drop, stop the engine and find the cause. Do not operate the engine at lower than
normal oil pressure (see maintenance schedule for minimum engine oil pressure).

CAUTION: Do not continue to operate your engine below the normal operating range. Severe engine
damage could occur.

Temperature Reading

The coolant temperature reading will indicate overheating which may arise from low coolant level,
plugged radiator, loose fan belt or faulty thermostat. Coolant level should be checked daily.

CAUTION: If the engine continues to overheat, have the cooling system checked and serviced.

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Voltage Reading

The voltage reading indicates the battery charging voltage. If the meter consistently indicates less than
13 volts or more than 15.7 volts under normal operating conditions, you should have the engine electrical
system checked by a qualified service technician.

Tachometer/Hourmeter

The tachometer indicates the engine speed in hundreds of revolutions per minute (rpm). It serves, as a
guide to insure that engine speed is set correctly.

The hour meter records the hours of operation and is used to determine when periodic maintenance is
required.

Starting the Engine

Warning: All internal combustion engines give off various fumes and gases while running. Do not start
or run the engine in a closed or poorly ventilated building where exhaust gases can accumulate. Avoid
breathing these gases as they may contain poisonous carbon monoxide, which can endanger your health
or life if inhaled steadily for even a few minutes.

If the engine is equipped with a manual clutch it must be disengaged prior to starting the engine. Starting
the engine with the clutch engaged imposes unnecessary strain on the battery, starter, and driven
components.

CAUTION: If the engine stalls or falters during starting, wait 3 to 4 seconds before re-engaging the
starter. This will prevent possible damage to the starter or the engine. DO NOT operate the starter for
periods longer than 30 seconds at a time. An interval of at least 1-minute should be observed between
cranking periods to protect the starter from overheating.

LPG or NG Fuel Systems

Turn on the gas supply to the engine. Turn the ignition key to the START position. After the engine
starts release the key to the ON position.

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Stopping the Engine

Return the engine to idle speed. If the machine is equipped with a clutch, move the clutch lever to the
disengaged position. Run engine for a few minutes at idle to allow the coolant system to cool down
before turning the ignition switch to the OFF position.

Note: Gasoline fuel injected engines will generally shut off immediately when the key is switched to the
off position. When the key is switched off, power to the fuel injector(s), fuel pump and engine control
module (ECM) is removed.

Note: LPG engines equipped with a distributor less ignition system (DIS) may run on several seconds
after the key is switched to the off position. This may be a normal function of the engine control system
running fuel out of the vapor hose to prevent engine backfiring on restart. The engine may run up to 5
seconds after the key is switched to off. Check with the Equipment Manufacture for proper shut down
operation.

WARNING: Avoid injury when checking a Hot Engine. Allow the engine to cool down before
removing the radiator cap.

CAUTION: Before restarting the engine ensure that both the coolant system and the engine oil level
have been checked and re-filled if necessary.

Fuel Recommendations

LPG and NG Fuel Quality

PSI NG engines are designed to operate on pipeline quality natural gas with a heat value of 1050 BTU
or higher. LPG engines and fuel systems are designed to operate on HD-5 or HD-10 specification LPG
fuel. Fuel other than HD-5 or HD-10 may cause harm to the engine’s emission control system and a
warranty claim may be denied on this basis if operators can readily find the proper fuel. Gasoline fuel
systems should u

Gasoline

Using a high quality unleaded gasoline will help maintain the power, fuel economy and emissions
performance of your engine. A properly formulated gasoline will be comprised of well refined
hydrocarbons and chemical additives and will perform the following functions:

1. • Minimize varnish, lacquer, and other induction system deposits.

2. • Prevent gum formation or other deterioration during storage.
3. • Protect fuel tank and other fuel system components from corrosion or degradation.
4. • Provide the correct seasonally and geographically adjusted volatility which should provide
easy starting in the winter and summer.

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5. • Avoid fuel system icing.
In addition, the fuel must be free of water, debris, and other impurities. It is recommended that the fuel
supply be kept fresh when the engine is in storage (especially in hot weather).

The fuel tank should be kept at least ¾ full. Fuel stored for more than two months should be
drained, properly discarded, and the fuel tank re-filled.

Anti-Knock Index (Octane Rating)

This engine is designed to operate on unleaded 87 or 89 octane gasoline with an (R + M)/2 minimum
anti-knock index. Federal regulations require that each retail gasoline dispensing pump must display a
label bearing the minimum index rating.

Use of unleaded gasoline with anti-knock index rating lower than 87 can cause persistent, heavy spark
knock, which can lead to engine damage. If your engine knocks heavily when you use gasoline with an
anti-knock index rating of 87 or higher, or if you hear continuous spark knock while maintaining
constant operating speeds, consult a dealer or qualified technician.

Gasohol and Alcohol/Gasoline Fuels

Gasohol, a mixture of gasoline and ethanol (grain alcohol), is available in some areas. PSI, GM
Powertrain engines should operate satisfactorily on gasohol blends containing no more than 10%
ethanol by volume and having and anti-knock index of 87 or 89. CAUTION: In some cases, methanol
(wood alcohol) or other alcohol’s may be added to gasoline. PSI GM Powertrain engines should
operate satisfactorily on blends containing up to 5% methanol by volume when cosolvents and other
necessary additives are used. DO NOT USE blends containing more than 5% methanol by volume or
blends that do not contain cosolvents and corrosion inhibitors.

CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if fuel system problems
occur. Do not use such fuels unless they are UNLEADED.

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Power Loss at Higher Elevations

All engines will experience power loss when operated at elevations above sea level, unless they are
turbocharged or supercharged. Turbochargers and superchargers are mechanical pumps that put
extra air into the engine to make up for the lower air density at higher elevations.

MAINTENANCE INSTRUCTIONS

Initial Start Up Maintenance

The initial start-up checks must be made before putting the engine into service. Please refer to the
Maintenance Schedule 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:

• Make daily 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 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.

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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.

Changing Engine Oil and Filter

The engine oil and filter must be changed every 150 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.

PSI recommends using engine oils that have an API rating of SM or newer. 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 classifications oils, even when
labeled Heavy Duty or for Natural Gas Engines, ARE NOT ACCEPTABLE.

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Engine Oil Recommendation

Multi-viscosity oils are recommended. SAE 10W-30 is recommended for your engine from 0 degrees
F (-18 degrees C) or above. If ambient temperatures are consistently below 0 degrees F, SAE 5W-30
oil can be used. Synthetic oils are not required for industrial or stationary engines.

Oil Filter

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 and run the engine. Verify oil pressure is okay 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.

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Cooling System

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.

WARNING: Never remove the radiator cap under any conditions while the engine is operating. Failure
to follow these instructions 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.

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.

The engine manufacturer recommends the cooling system be filled with a 50/50 mixture of coolant and
water. The use of “Long Life” type coolant is required. This coolant is typically a bright orange in color
and should meet the requirements outlined in engineering standard GM6277M (hard copy of
GM6277M is available by contacting PSI Technical Support). Coolant should have a minimum boiling
point of 300F (149c) and a freezing point no higher than -34F (-37c).

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. Check all hoses and
connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they must be replaced.

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Fan Belts

The water pump is 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 addition to overheating.

Serpentine Belt

Some PSI engines utilize serpentine belts on the front of the engine. This type of belt system incor-
porates 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-Type Belt

V-Type belts are generally tensioned by adjusting the

alternator, or through a mechanical belt tensioner. The belt is
generally correctly tensioned when there is 7-10mm of
deflection on the belt between the water pump and alternator.

Fuel Filter

LPG Engines

LP, fuel like all other motor fuels is subject to contamination from outside sources. Refueling of the
equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other
foreign matter into the fuel system. It is therefore necessary to filter the fuel prior to entering the fuel
system components down stream of the tank. An inline fuel filter has been installed in the fuel system to
remove the dirt and foreign matter from the fuel, which is replaceable as a unit only. Maintenance of
the filter is critical to proper operation of the fuel system and should be replaced according to the
maintenance schedule or more frequently under severe operating conditions.

Fuel Shut-Off

LPG and NG engines are equipped with a fuel shut-off. The fuel shut-off is located between the fuel
supply and the IEPR/DEPR. The purpose of the fuel shut off is to prevent or allow fuel flow from the
supply source to the engine fuel system. The shut off is a 12 volt solenoid (Normally closed) that is
controlled by the engine ECM.

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Ignition Systems

Types of Ignition Systems

PSI engines use two types of ignition systems. 1) Distributor-less electronic ignition and 2) High
Voltage Switch (HVS) ignition. Both types of ignition are controlled by the engine ECU. Distributor-
less electronic ignition is utilized on the 1.6L, 8.1L, and 8.8L engines. All other engine models use a
HVS ignition system which consists of a distributor and HVS ignition coil.

Ignition Timing

Proper adjustment of the ignition timing must be obtained to provide the optimum engine power
output and economy. Ignition timing for both the Distributor-less and HVS systems are controlled
by the ECU and is not adjustable.

NOTE: Do not attempt to adjust timing on the ignition systems. Timing is not adjustable.

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 the General Specifications.

Spark plug gap should be adjusted as recommended in the General Specifications.

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).

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Storage

One to Six Months

If the engine or machine is to be placed in storage for a period of one to six months it is recommended
that the following steps be followed:

• Protect the air cleaner inlet from water entry

• Protect the exhaust outlet or muffler outlet from water entry
• Check the coolant protection and top off radiator
• Store indoors if possible

For Extended Periods

Follow the above recommended procedures, plus do the following:

• Drain the engine crankcase and refill with recommended oil

• Change the oil filter
• Disconnect and remove the battery
• Clean exterior surface of the engine
• If the engine is equipped with an automotive type clutch or PTO clutch, make sure that the clutch is
disengaged

Removing the Engine From Extended Storage

When removing the engine from extended storage:

• Install a fully charged battery

• Remove all protective coverings from the air inlet, air cleaner, exhaust, and muffler openings
• Check the coolant level in the radiator and verify the protection level of the coolant
• Check the engine oil level.
• Start the engine and allow it to run at slow idle. Verify engine oil pressure
• Run the engine at idle until the coolant temperature approaches 120 degrees F (49 degrees C)
• Run the engine a various speeds for approximately 15 minutes
• Shut the engine down, drain the oil, change the oil filter, and re-fill with the recommended grade of oil

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 PSI, MITSUBISHI, & GM ENGINE MAINTENANCE
CERTIFIED MOBILE ENGINE MAINTENANCE REQUIREMENTS
Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter.
Interval Hours
Daily 200 400 800 1000 1250 1500 1750 2000 3000 5000
General Maintenance Section
Visual check for fluid leaks X
Check engine oil level X
Check coolant level X
5
Change engine oil and filter (Severe duty) Every 150 hours or 120 days of operation
5
Change engine oil and filter (Standard duty) Every 250 hours or 120 days of operation
Check LPG system for leaks Prior to any service or maintenance activity
Inspect accessory drive belts for cracks, breaks, splits or glazing1 X
Inspect electrical system wiring for cuts, abrasions or corrosion X
Inspect all vacuum lines and fittings for cracks, breaks or hardening X
Engine Coolant Section
Clean debris from radiator core Every 100 hours or 60 days of operation
2&4
Change Coolant X
1
Inspect coolant hoses for cracks, swelling or deterioration X
Engine Ignition System
Replace spark plugs - Standard Duty X
3
Replace spark plugs - Severe Duty X
6
Replace Distributor CAP and Rotor X
6
Replace spark plug wires X
Inspect battery case for damage X
Base Engine System
Replace camshaft belt (Mitsubishi Engine) X
Replace balance shaft belt (Mitsubishi Engine) X
Inspect PCV system X
Fuel System Maintenance
Inspect air cleaner Every 200 hours, or every 100 hours in dusty environment
Replace filter element Every 400 hours, or every 200 hours in dusty environment
Replace fuel filter X
Inspect Shut-off Valve for leaks and closing X
Leak check fuel lines X
Check air induction for leaks X
Check manifold for vacuum leaks X
Drain LPG Vaporizer oil build up Every 150 hours or 120 days of operation
Engine Exhaust System
Inspect exhaust manifold for leaks X
Inspect exhaust piping for leaks X
Check HEGO sensor(s) connector and w ires for burns, cuts or damage X
Inspect catalyst for mechanical damage X
The Maintenance schedule represents manufacturers recommended maintenance intervals to maintain proper engine/equipment function. Specified state
and federal regulations may require equipment operators to conduct comprehensive engine/equipment inspections at more periodic intervals than those
specified above.
Special Notes Section
Note 1 = Item should be checked yearly, replace as needed
Note 2 = PSI requires the use of coolant meeting GM specification GM6277M. When used, this coolant change interval is 5,000 hours or 5 years (whichever
occurs first). Changing of coolant types (typically indicated by color) and mixing of coolants is not allowed as this can result in a loss of coolant protection
during the engine life. Consult the OEM for the correct replacement interval if you use coolant other than GM6277M
Note 3 = Severe duty applications are units that receive high load, full throttle operation for the majority of its operational life.
Note 4 = 5,000 hour or 5 years whichever occurs first
Note 5 = Oil life is highly dependent on oil quality, operating enviroment, and engine use.
Note 6 = GM Product Only

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 GENERAL SPECIFICATIONS
Power Solutions International, Inc.

Engine Mitsubishi 2.0L Mitsubishi 2.4L GMPT 3.0L

Type 2.0L L4 2.4L L4 3.0L L4
Displacement cc (c.i.d.) 1997 (122) 2351 (143) 2966 (181)

Compression Ratio 9.5:1 9.5:1 10.5:1

Valve Configuration 4V SOHC 4V SOHC Push Rod Actuated

Overhead Valve
Valve Lifters Hydraulic Hydraulic Flat Follower
Bore x Stroke mm (inches) 85x88 (3.35x3.46) 86.5x100 (3.41x3.94) 101.60x91.44 (4.00x3.60)

Main Bearing Caps 2 Bolt 2 Bolt 2 Bolt

Firing Order 1-3-4-2 1-3-4-2 1-3-4-2
Oil Capacity 4.75 qts. (4.5L) 4.75 qts. (4.5L) 4 qts. (3.8L)
With Oil Filter 5 qts. (4.7L) non-remote oil 5 qts. (4.7L) non-remote oil 5 qts. (4.7L)
filter system filter system

Oil Filter PSI 801002 PSI 801002 PF-25 or Equivalent

Minimum Oil Pressure 10 psi @ 800 rpm 10 psi @ 800 rpm 6 psi @ 1000 rpm
(Hot)
18 psi @ 2000 rpm

Coolant Capacity (Engine) Confirm with Equipment Confirm with Equipment OEM 4 qts. (3.78L)
OEM
Coolant Capacity (W/PSI NA NA 12 qts. (11.4L)
Rad)
Fuel Type LPG, NG, Gasoline LPG, NG, Gasoline LPG, NG, Gasoline

Engine Rotation (Flywheel CCW CCW CCW

End)
Ignition System Coil on Plug Coil on Plug High Voltage Switch (HVS)

Ignition Timing ECM Controlled ECM Controlled ECM Controlled

Not Adjustable Not Adjustable Not Adjustable
Spark Plugs Torch, PSI # 800300 (14 Torch, PSI # 800300 (14 MM) AC Delco R42LTS or R44LTS
MM) or PSI # 801001 (12 or PSI # 801001 (12 MM)
MM)
Spark Plug Gap 14 mm Plug - 0.040” 12 14 mm Plug - 0.040” 12 mm 0.035”
mm Plug = 0.035" Plug = 0.035"

Valve Clearance (Lash)

Intake No Adjustment No Adjustment ½ to 1 Turn Down From

Exhaust OHC Engine OHC Engine 0 Lash

Manufactured Shenyang, China Shenyang, China Toluca, Mexico

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 GENERAL SPECIFICATIONS
Power Solutions International, Inc.

Engine GMPT 4.3L PSI 4.3L (4X) GMPT 5.0L/5.7L

Type 4.3L V-6 4.3L V-6 5.7L V-8 GEN-1E
Displacement cc (c.i.d.) 4294 (262) 4294 (262) 5735 (350)

Compression Ratio 9.4:1 9.8:1 9.4:1

Valve Configuration Push Rod Actuated Overhead Push Rod Actuated Overhead Push Rod Actuated
Valve Valve
Overhead Valve
Valve Lifters Hydraulic Roller Hydraulic Roller Hydraulic Roller
Bore x Stroke mm (inches) 101.60x88.39 (4.00x3.48) 101.60x88.39 (4.00x3.48) 101.60x88.39 (4.00x3.48)

Main Bearing Caps 2 Bolt 2 Bolt 2 Bolt

Firing Order 1-6-5-4-3-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2
Oil Capacity 4.5 qts. (4.3L) 4.5 qts. (4.3L) 4.5 qts. (4.3L)
With Oil Filter 5 qts. (4.7L) 5 qts. (4.7L) 5 qts. (4.7L)

Oil Filter PF-47/PF-52 or Equivalent PF-47/PF-52 or Equivalent PF-1218 or Equivalent

Minimum Oil Pressure (Hot) 6 psi @1000 rpm 6 psi @1000 rpm 6 psi @ 1000 rpm

18 psi @ 2000 rpm 18 psi @ 2000 rpm 18 psi @ 2000 rpm

Coolant Capacity (Engine) 7.75 qts. (7.3L) 7.75 qts. (7.3L) 8.1 qts (7.8L)

Coolant Capacity (W/PSI Rad) 17 qts. (16L) 17 qts. (16L) 17.5 qts. (16.6L)

Fuel Type LPG, NG, Gasoline LPG, NG, Gasoline LPG, NG

Engine Rotation (Flywheel End) CCW CCW CCW

Ignition System High Voltage Switch (HVS) High Voltage Switch (HVS) High Voltage Switch (HVS)

Ignition Timing ECM Controlled ECM Controlled ECM Controlled

Not Adjustable Not Adjustable Not Adjustable
Spark Plugs AC Delco R42LTS or R44LTS AC Delco R42LTS or R44LTS AC Delco R42LTS or R44LTS

Spark Plug Gap 0.035” 0.035” 0.035”

Valve Clearance (Lash)

Intake Net Lash Net Lash 1 Turn Down From
Exhaust No Adjustment No Adjustment 0 Lash

Manufactured Tonawanda, NY Wood Dale, IL Toluca, Mexico

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