Work
Projects- 3D Printing Projects
- Amateur Radio
- Automotive Projects
- Electronics Projects
- Gaming Projects
- Homelab Projects
- Horticulture Projects
- Other Projects
- Project Projects
- Software Projects
- Tumblr (photography)
-
Sidebar
projects:automotive:kancil:k4_660_service
This is an old revision of the document!
Table of Contents
Perodua Kancil K4 660 Service
General Information
Vehicle Models
- L200RS-GKRSM
- L200RS-KMDSM
- Engine: EF-CL
- Catalyzer: Without
- Fuel system: Carburetor
- Fuel evaporative canister: Without
- Destination: Malaysia
Explanation of Vehicle Model Code
| L2 | Kancil |
|---|---|
| 0 | Drive 2WD |
| 0 | Engine 660cc |
| R | Right hand drive |
| S | Sedan |
| G | 5-door with hatch back |
| K/M | K: 4-speed manual transmission M: 5-speed manual transmission |
| D/R | D: Deluxe R: Standard |
| S | Carburetor equipped engine |
| M | Malaysia |
Body Colors Information
| Color Code | Color |
|---|---|
| W14 | Crystal White |
| S01 | Sparkling Silver |
| Y03 | Fantasy Green |
| B01 | Nautica Blue |
| G33 | Elegant Green |
Factory paintwork by Sime Kansai Paints Sdn Bhd.
Specifications
Pre-delivery Inspection Specifications
| Item | Specifications | |
|---|---|---|
| Tire inflation pressure front/rear; 145/70R12; kpa (kg/cm²) | 220 (2.2) | |
| Wheel nut tightening torque; N⋅m (kgf⋅m, ft-lb) | 88–11.7 (9–12, 65–87) | |
| Accelerator cable free play; mm (inch) | 0.5–1.0 (0.020–0.039) | |
| Idle speed; rpm | EF-CL | 900 (+100/-50) |
| Engine oil | Capacity | 2.6 (whole) |
| Grade | API SE or higher | |
| Manual transmission oil | Grade | Castrol MTEC, API GL 4 |
| Viscosity | SAE 80 W | |
| Capacity | 1.42 (4-speed) | |
| 1.60 (5-speed) | ||
| Brake fluid | Grade | DOT 3 or SEA J1703 |
| Brake pedal free play; mm (inch) | 7–12 (0.27–0.47) while engine is stopped | |
| Clutch pedal free play; mm (inch) | 10–30 (0.40–1.18) | |
| Parking brake lever | Should “set” within 2–6 notdches when apply 20 kgf by hand | |
| Exhaust emission concentration | 1.5 (+1.0/-0.5) | |
| (At tail pipe) | 800 | |
Vehicle Specifications
| Item | Specifications | ||
|---|---|---|---|
| EF-CL | |||
| Engine | Type | Carburetor, 4-cycle | |
| Displacement; cc | 659 | ||
| Bore × Stroke; mm (inch) | 68.0 × 60.5 (2.68 × 2.38) | ||
| Compression ratio | 9.5 | ||
| Firing order | 1-2-3 | ||
| Ignition timing | 7 ± 2° BTDC/900 rpm | ||
| Valve mechanism | Overhead camshaft | ||
| Valve clearance; Hot; mm (inch) | Intake | 0.25 ± 0.05 (0.0098 ± 0.0020) | |
| Exhaust | 0.30 ± 0.05 (0.0118 ± 0.0020) | ||
| Spark plug type | Denso | W16EX-U, W16EXR-U | |
| NGK | BP5ES, BPR5ES | ||
| Spark plug gap; mm (inch) | Denso | 0.7–0.8 (0.0275–0.0315) | |
| NGK | 0.7–0.8 (0.0275–0.0315) | ||
| Coolant capacity (w/o reserve tank) | 2.6 | ||
| Collant reserve tank (Low, full) | 0.15, 0.35 | ||
| Max. output power; kW/rpm | 22.8/6400 | ||
| Max. output torque; N⋅m/rpm | 49/3200 | ||
| Recommendation fuel | Octane No. 90 (RON) or higher | ||
| Fuel tank capacity | 32 | ||
| Clutch | Type | Dry single plate, diaphragm | |
| Operation | Mechanical | ||
| Transmission | Type | 4 or 5-speed M/T | |
| Gear ratio | 1st | 3.500 | |
| 2nd | 2.111 | ||
| 3rd | 1.392 | ||
| 4th | 0.971 | ||
| 5th | 0.794 | ||
| Reverse | 3.538 | ||
| Final drive ratio | 4.722 | ||
| Suspension | Front suspension | Independent, Macpherson strut with stabilizer | |
| Rear suspension | Independent, semi-trailing | ||
| Steering | Type | Rack & Pinion (Constant gear) | |
| Gear ratio | 20.2 (Overall) | ||
| Brakes | System | Power-assisted, front/rear split hydraulic circuits | |
| Type | Front disc, Rear drum | ||
| Wheel & Tyre | Tire size | 145/70R12 | |
| Wheel size | 4.00 B × 12 | ||
| Wheel offset | +50 | ||
| Headlights; mm | 60/55 | ||
| Clearance lights (w) | 5 | ||
| Front turn signal lights (w) | 21 | ||
| Front side turn signal lights (w) | 5 | ||
| Rear turn signal lights (w) | 21 | ||
| Tail lights (w) | 5 | ||
| Stop lights (w) | 21 | ||
| Back-up lights (w) | 21 | ||
| License plate lights (w) | 5 | ||
| Interior lights (w) | 5 | ||
| High-mounted stop lights (w) | 21 | ||
Engine Mechanicals
Incomplete
Charging
Components of Alternator
- Alternator assembly
- Pulley lock nut
- Alternator pulley
- Spacer
- Drive end frame assembly
- Stud bolt
- Bearing
- Retainer plate
- Alternator rotor assembly
- Spacer
- Bearing
- Bearing cover
- Rectifier end frame assembly
- Nut
- Rectifier holder
- Regulator assembly
- Brush
- Spring
- Brush holder
- Rear end cover
Charging System Circuit
Troubleshooting
| Problem | Possible cause | Remedies |
|---|---|---|
| Charge warning lamp will not glow even if ignition switch is turned ON. | Fuse blown | Check gauge fuse. |
| Lamp bulb burnt | Replace bulb. | |
| Poor connection of wiring | Repair poor connection of wiring | |
| Open wire | Repair or replace. | |
| IC regulator faulty | Replace regulator assembly. | |
| Charge warning lamp will not go out even if engine has started. | Drive belt loose or worn | Adjust or replace. |
| Battery cables loose, corroded or worn | Repair or replace cables. | |
| Fuse blown | Check gauge fuse. | |
| Fusible link blown | Replace Fusible link. | |
| IC regulator or alternator faulty | Check charging system. | |
| Wiring taulty | Repair or replace. |
CH00004-00000
Description
Incomplete
Tools Required for Alternator Repair
- Prior to the inspection, make sure that the battery cables are connected securely.
- When a quick charging operation is carried out, first be sure to disconnect the battery cables.
- Never use a high-voltage insulation resistance tester for the purpose of conducting this inspection.
- Under no circumstances should the battery cables be disconnected while the engine is rotating.
- Box wrench, 8 × 10 mm
- Box wrench, 10 × 12 mm
- Box wrench, 12 × 14 mm
- Philips screwdriver, 200 mm
- Nose pliers
- Socket wrench, 22 mm
- Air impact wrench
- Adjustable wrench, 300 mm
- Torque wrench
- Circuit tester
- Vernier calipers, 150 mm
- SSTs
- 09820-06010-000
- 09820-06020-000
In-vehicle Inspection
- Prior to the in-vehicle inspection, be sure to perform the following checks.
- Specific gravity of battery electrolyte
- Installation of battery terminals
- Tension of V-belt
- Fuse
- Wiring harness
- Abnormal noise emitted from alternator while engine is rotating
- Output test under unloaded state
- Ensure that all switches are turned OFF so that no unnecessary electric load may be applied.
- Headlamps
- Heater blower
- Radio
- Rear defogger
- Room lamp, etc.
- Raise the engine revolution speed gradually to 2500 грm.
Measure the current and voltage at 2500 rpm.
Specifications:- 10 A or more
- 14.2 - 14.8 V
- NOTE:
- Immediately after the engine starting, the current may jump to 10 A or more momentarily. This is not an abnormal phenomenon.
- If the voltage reading i s less than the standard voltage, ground the terminal F as indicated in the right figure. Proceed to start the engine.
- If the voltage reading becomes greater than the standard voltage under this setting, replace the IC regulator.
- If the voltage reading is still less than the standard voltage under this setting, check the alternator.
- Output test under loaded state
- To apply electric load, perform the following operation.
- Set the headlamps to the upper-beam position.
- Set the heater blower to the “High” position.
- Measure the output current of the alternator at the engine speed of 2500 rpm.
- Specified Value: 20 A or more
- NOTE:
- When the battery is fully charged, the measured current may be below the specified value. This is not an abnormal phenomenon.
- At this time, increase the electric load, for example, by turning ON the rear defogger.
- Then, check to see if the output current rises or not.
Appendix
Some Part Numbers
| Description | Perodua/Daihatsu P/N | OEM / OE P/N | Notes |
|---|---|---|---|
| Front hood meter | 55421-87Z01 | ABS, Black | |
| Rear hood meter | 55422-87Z03 | ABS, Gray | |
| Combination meter M/T | 83200-87Z83 | VDO Malaysia / 76801 DOM M/T | A/T probably uses the same meter? |
| For Perodua Kancil 1994 Blower Motor without Blower Wheel | Denso / 272500-0090 | Seems applicable to both Kancil lampu petak and lampu bulat | |
| For Perodua Kancil Blower Wheel | Denso / 116221-0200 | ||
| For Perodua Kancil & Kembara Cabin Air Filter Bracket | Denso / 995000-2010 | Not installed by default; highly recommended for air quality and longevity | |
| For Perodua Kancil, Kelisa, Kenari & Kembara Cabin Air Filter | Denso / 994000-1110 | Not installed by default; highly recommended for air quality and longevity | |
| Alternator Assembly | Denso / 100211-4831 | ||
| Brake Rotor, Front | TRW / DF2633 |
Connector Part Numbers
| Description | Mount | Housing OEM / OE P/N | Pins OEM / OE P/N | Notes |
|---|---|---|---|---|
| Combination Meter | Cable | TE Connectivity / 929053-1 (Shield) TE Connectivity / 968265-1 (Housing) | TE Connectivity / 5-963715-1 | |
| ETR Tuner | Cable | Tokai Rika / 4F1250-000 (Toyota / 90980-10803) | Tokai Rika / 4R1190-000 (Toyota / 90980-09264) (0.3–0.5mm²) Tokai Rika / 4R1191-000 (Toyota / 90980-09265) (0.5–1.25mm²) Tokai Rika / 4R1192-000 (Toyota / 90980-09266) (2mm²) | |
| IG Coil | Cable | TE Connectivity / 2-172132-2 | TE Connectivity / 170342-2 | For 3-pin coil with resistor (Kancil 660/contact point distributor) |
projects/automotive/kancil/k4_660_service.1775406833.txt.gz · Last modified: by Andrew Yong
Except where otherwise noted, content on this wiki is licensed under the following license: GNU Free Documentation License 1.3
