Power Solutions International PSI 2.0L, 2.4L Service Manual with Wiring Diagrams

Name: Power Solutions International PSI 2.0L, 2.4L Service Manual with Wiring Diagrams
Author: Power Solutions International

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$29.99 USD · one-time payment

Model: PSI 2.0L | PSI 2.4L

Type: Engine

409 Pages·11 MB·Searchable PDF·English·Print-Ready

✓ Wiring Diagrams
✓ Torque Specs
✓ Multi-Level Bookmarks (2-level navigation)

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A timing belt that jumped a tooth or a MIL flashing codes nobody can read is the trouble this 409-page Power Solutions International PSI 2.0L, PSI 2.4L service manual PDF (OEM ID 76502675) was written to fix, covering four 4G63 and 4G64 engine variants. Wiring diagrams trace your engine harness and ECM header connectors, while DTC charts run from code 11 through 2229 with SPN/FMI references and blink code function. Timing belt, cylinder head, silent shaft, piston, rod and crankshaft sections each close with installation service points, and LPG and gasoline fuel theory explains the lock-off valve and vaporizer. Set auto-tensioner rod projection at 12 mm, then take the head bolts to 78 Nm, back them off to zero and finish at 20 Nm plus 90° plus 90°. Silent shaft timing by memory rarely ends well. Bookmarked and text-searchable, the file is yours to keep once bought, with every torque sequence there before your block goes back together.

What's Inside This Manual

System	Pages	Key Topics
General Information	5-11	Engine Models, Service Specifications, Torque Specifications, Maintenance Schedule
Form in Place Gasket	12-16	Removal of FIPG Sealed Parts, Cleaning FIPG Application Surface, Application of FIPG
Timing Belt	17-28	Removal and Installation, Inspection, Installation Service Points
Water Pump	29-30	Water Inlet Fitting, Thermostat, Water Outlet Fitting, Water Inlet Pipe, O-Ring
Rocker Arms and Camshaft	31-35	Rocker Arms, Rocker Arm Shaft, Lash Adjuster, Camshaft, Oil Seal, Rocker Shaft Spring
Cylinder Head and Valves	36-42	Removal and Installation, Inspection, Valve Seat Replacement Procedure
Front Case, Silent Shaft and Oil Pan	43-53	Oil Pump Gears, Counterbalance Shafts and Bearings, Oil Pressure Switch, Oil Pan, Installation Service Points
Piston and Connecting Rod	54-62	Connecting Rod Cap and Bearings, Piston Rings, Piston Pin, Installation Service Points, Inspection
Crankshaft	63-75	Oil Seal Case, Oil Seal, Bearing Cap, Crankshaft Bearing, Crankshaft Thrust Bearing
Engine Compression Test	76-79	Engine Warm Up, Spark Plug Removal, Compression Gauge Connection, Pressure Reading, Cylinder Compression
Maintenance Information	80-85	Cooling System, Serpentine Belt System, Engine Electrical System, Engine Crankcase Oil, Fuel System Inspection, Exhaust System Inspection
Lpg Fuel System Theory and Operation	86-92	Electric Fuel Lock-Off Valve, Direct Electronic Pressure Regulator, Air Fuel Mixer, Light Duty 2-Stage Vaporizer, Electronic Throttle Control Device, Three-Way Catalytic Converter
Gasoline Fuel System Theory and Operation	93-96	Gasoline Fuel Storage Tank, Gasoline Fuel Pump, Gasoline Pressure and Temperature Sensor Manifold, Fuel Filter, Fuel Injector Rail, Fuel Injector
Emissions Control System Theory and Operation	97-112	Fuel System, Diagnostic Scan Tool, Fuel Pressure, Fuel Injectors, Throttle Position Sensor, Oxygen Sensors
Electrical Section	113-114	ECM Header Connectors, Diagnostic Scan Tool, Engine Wire Harness, Malfunction Indicator Lamp, Diagnostic Trouble Codes, Blink Code Function
Diagnostic Service Tool (Dst)	115-137	Dst Installation Instructions, Password Login, Dst Service Pages
Engine Wire Harness Repair	138-141	Connectors and Terminals
Diagnostic Trouble Codes (DTC) Overview and Charts	142-151	MIL Operation, DTC Charts, SPN/FMI Codes, Blink Code Function
OBD System Check and Starter Circuit Diagnostics	152-155	OBD System Check, MIL Operation, Starter Circuit Diagnostics
Engine Sensor and System Diagnostics (DTC 11-129)	156-203	Intake Cam Position, Crank Sync, Fuel Pressure, IAT Sensor, MAP Sensor, Barometric Pressure
Exhaust and Fuel System Diagnostics (DTC 134-1152)	204-315	EGO Sensor, Adaptive Learn, Catalyst Monitor, Fuel Injector Driver, Fuel Run-Out
Advanced System and Communication Diagnostics (DTC 1155-2229)	316-403	Closed Loop Multiplier, EPR Communication, Internal Actuator Fault, FPP Redundancy, TPS Voltage
Definitions	404-409	Air Valve Vacuum, Air/Fuel Ratio, Closed Loop Operation, Fuel Injector, Manifold Absolute Pressure, Throttle Position Sensor

Quick Reference Specifications

Specification	Value	Page
Cylinder head bolts torque	78Nm → 0Nm, 20Nm + 90° + 90°	p. 9
Water pump pulley bolts torque	8.9 Nm (7 ft.lbs)	p. 9
Water pump bolts torque	13.8 Nm (10 ft.lbs)	p. 9
Auto-tensioner rod projection length	12 mm	p. 6
Auto-tensioner bolts torque	23.6 Nm (18 ft.lbs)	p. 9
Spark plugs 14mm torque	27 Nm (20 ft.lbs)	p. 9
Spark plugs 12mm torque	17 Nm (12 ft.lbs)	p. 9
Cylinder head bolt tightening torque	First 20 ± 2 N·m, then 90 degrees, then another 90 degrees	p. 39
Allowable resistance on the injectors	12.0 ± 0.6 ohms	p. 96
CKP sensor voltage	5.0 volts	p. 239
Crankshaft pulley bolts torque	24.5 Nm	p. 9

Brand	Power Solutions International
Model	PSI 2.0L, PSI 2.4L
Machine Type	Engine
Manual Type	Service Manual
Language	English
Format	Searchable PDF (Digital Download)
Pages	409
File Size	11 MB
Manual No.	76502675
Wiring Diagrams	Yes
Hydraulic Schematics	No
Torque Specifications	Yes
Bookmarked / Indexed	Yes

Power Solutions International PSI 2.0L, 2.4L Service Manual with Wiring Diagrams

What's Inside This Manual

Quick Reference Specifications

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