HIGH-ALTITUDE ADJUSTMENT MANUAL FOR LOW-ALTITUDE VEHICLES RADIAN CORPORATION ------- RADIAN CORPORATION HIGH-ALTITUDE ADJUSTMENT MANUAL FOR LOW-ALTITUDE VEHICLES Prepared For: Technical Support Staff Office of Mobile Source Air Pollution Control 2565 Plymouth Road Ann Arbor, MI 48105 Prepared By: Carolyn S. Smith Radian Corporation Austin, Texas September 1984 8501 Mo-Pac Blvd. I P.O. Box 99481 Austin, Texas 78766-09481 (512) 454-4797 ------- TABLE OF CONTENTS Page INTRODUCTION 1 LIGHT DUTY VEHICLES Alfa Romeo 3 American Motors (Renault) Applications 4 Procedures 5 Aston Martin 13 Aurora 14 BMW 15 Chrysler Applications 16 Procedures 30 Datsun 40 Ferrari 41 Fiat Lancia 42 Ford Applications 43 Procedures 53 General Motors Applications 60 Procedures 66 Isuzu Applications 71 Procedures 72 Maserati Quattroporte 73 Mazda Applications 74 Procedures 78 Mercedes 80 Mitsubishi 81 ii ------- Page LIGHT DUTY VEHICLES continued Peugeot 82 Rolls Royce (Bentley) 83 Saab 84 Subaru 85 Toyota Applications 86 Procedures 93 Volkswagen/Audi 95 Volvo 97 HEAVY DUTY TRUCKS Bluebird 98 Caterpillar 99 Chrysler Applications 102 Procedures 104 International Harvester 108 Cummins 110 Ford Applications 112 Procedures 114 General Motors Applications 115 Procedures 121 Hino 123 International Harvester 125 Isuzu 129 Iveco 130 iii ------- Page HEAVY DUTY TRUCKS continued Mitsubishi 131 Perkins 132 CYCLES Cushman 133 Harley Davidson 134 Laverda 135 Triumph 136 iv ------- INTRODUCTION This manual provides instructions for adapting to high-altitude use those vehicles which were originally intended for low-altitude use. Although in some cases a procedure may be similar to or the same as that for preparing new vehicles for high-altitude use, this manual is not intended for that purpose. These instructions assume that you have access to and are familiar with the shop manuals. With few exceptions, details are given only for unusual procedures. References to shop manuals are given for some procedures. A typical format consists of first a table which lists a manufacturer's engine types by year. For each engine, the table lists the procedures to be performed on that engine — in order. Specifications and/or part numbers may also be given. After the table, the procedures are described . As an example, consider the following entry: Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1982 C1G5.0T4HGH2 C1G5.7T4HAC5 C1G5.7T4HHC8 3 Advance Timing 4° 10 Advance Choke Vacuum Break to 26° 4 Adjust Idle: Curb: MT: 700rpm, NEUTRAL AT: 600rpm, DRIVE Solenoid: MT: 700rpm, NEUTRAL For any one of the three engines listed, first advance the timing 4° according to Procedure 3, then advance the choke vacuum break to 26° according to Procedure 10, then adjust the idle to the given specifications according to Procedure 4. The following abbreviations are used uniformly: MT - Manual Transmission AT - Automatic Transmission 5/MT - 5-speed Manual Transmission FED - Designed for 49-state or 50-state use. CAL - Designed especially for sale in California. Figures, if given, usually follow the procedure descriptions. The figure number "Figure 2-1" refers to the number one item on Figure 2. 1 ------- When the high-altitude adjustments are complete, attach a Vehicle Emission Control Information Update Label: o Obtain the appropriate label from the dealer. o If necessary, briefly describe on the label the adjustments that were made. o Clean a place for the label in a prominent place adjacent to the Vehicle Emission Control Information Label. - DO NOT attach the label to any component that can be easily removed from the vehicle. - DO NOT remove the original Emission Control Information Label, o Attach the label. o If a clear plastic decal shield is supplied, apply it on top of the label. 2 ------- ALFA ROMEO Year Engine Family Applicable Procedures 84 EAR152 V5 F6V0 none 83 DAR152 V5 F49X i 1 DAR120 V5 F414 2,1 DAR152 V5 F6VX J 1 82 j CAR152 V5 F6V9 ! 1 | CAR120 V5 F4L3 j 2,1 ' PROCEDURE 1: Reset Idle, o Warm the engine, o Put the transmission in neutral, o Turn off all accessories, o Loosen the clamp on the throttle body, o Adjust the idle speed by turning the bhreaded ring, o Tighten the clamp on the throttle body. PROCEDURE 2: Insert Connector Plug in Electronic Module Circuit. o Remove the panel covering the electronic control unit (ECU). behind the rear seat. o Insert the connector plug into the circuit of the electronic module. o Replace the cover panel. 3 ------- AMERICAN MOTORS (RENAULT) Applicable Year Engine Family Procedures 84 EAM 258 T2 HEAX (automatic) 1,3,4 EAM 258 T2 HEAX (manual) 1,3,4,5 EAM 2.8 T2 AXE2 1,3 ERE 2.2 V5 FGAO (Renault 18 i and fuego) none EAM 2.8 T2 F4C9 none 83 DRE 1.6 V5 FZB9 (Renault 1.8 i and fuego) 6 DRE 1.6 V5 FTC9 Code A (Fuego Turbo) 7 DRE 1.4 V2 A4B1 (Le Car) 2,3 DRE 1.4 V2 FRA6 (LeCar-California) none DAM 151 T2 ABCO 1,3 DAM 151 T2 FCA4 1,3 DAM 258 V2 HDA6 1,3,4 DAM 258 T2 HEBX 1,3,4 DAM 360 T2 AAX8 2,3 DAM 1.4 V5 FLD8 none DAM 1.4 V5 FKD6 none DAM 1.4 V5 F6D5 none DAM 150 TI FHE8 1,3,4 81 Renault 1.8 i 8 LeCar 9 68-80 All AMC cars and jeeps 2,3 All Renaults (49 states) 10 4 ------- AMERICAN MOTORS (RENAULT) PROCEDURE 1: Advance Timing. o o Advance initial timing by 7 . PROCEDURE 2: Advance Timing. o Advance initial timing 5°. PROCEDURE 3: Reset Idle. o Reset the idle speed to original specifications on the VECI label and according to the procedures in the service manual. PROCEDURE 4a (Jeep): Ground High-Altitude Input Circuit to Microprocessor. o Untape the jumper wire from the harness of the fuel feedback microcomputer unit (MCU) in the engine compartment. o Connect the jumper wire to the engine ground screw. PROCEDURE 4b (Cars): Ground High-Altitude Input Circuit to Microprocessor. o Move the carpeting away from the front passenger toeboard to expose the harness of the fuel feedback microcomputer unit (MCU). o Untape the two-terminal connector from the MCU harness. o Connect jumper wire 318 6890 (893600386 on earlier models) to the two-terminal connector. o Reinstall the carpet. PROCEDURE 5: Connect Idle/Decel Switch Vacuum Signal to Carburetor EGR Port. o Disconnect the vacuum line (Figure 1-1) from the idle/decel switch and from the tee connector (Figure 1-2). Put this line in the glove box and inform the owner. DO NOT discard. o Install cap 323 9420 over the open end of the tee connector (Figure 1-2). o Cut the vacuum line (Figure 1-3) about 1-1/4 inches from the EGR CTO end of the line. Install tee connector 321 0891. o Connect a 75-inch, 1/8 inch ID vacuum line (Figure 1-4) to the idle/decel switch and to the new tee connector in the vacuum line to the EGR CTO. 5 continued ------- AMERICAN MOTORS (RENAULT) continued PROCEDURE 6: Install Jumper Wire. o Connect a jumper wire between pins 4 and 5 on the fuel injection diagnostic socket. (This connects pins 9 and 12 on the ECU and activates the altitude compensation component.) PROCEDURE 7: Install Resistor Connecter Board. o Install a resistor connector board into the plug receptacle at the left front of the gear shift console. PROCEDURE 8: Cancel the Full Throttle Contact Switch. o Disconnect the electrical wiring connector from the throttle plate assembly (Figure 4-1). o Remove the rubber boot (Figure 5-1). o Hold the assembly so that the two locator grooves (Figure 5-2) on the connector are facing down as shown in Figure 5. o Cut the signal wire (Figure 5-2) approximately 1-1/2 inch from the connector. o Insulate the cut ends. o Replace the rubber boot on the connector. o Replace the connector on the throttle plate assembly. PROCEDURE 9: Change the Air Compensating Jet. o Disconnect and remove the air intake filter. o Remove the top bowl of the carburetor. o Remove the 1.60 mm diameter air compensating jet (Figure 6-1) from the first barrel. o Insert in its place a 1.80 mm diameter jet, RNUR 08701 102 303 (Weber 77201-180). o Reinstall the top bowl (replace gasket if necessary). o Reinstall the air intake filter. continued 6 ------- AMERICAN MOTORS (RENAULT) continued PROCEDURE 10: Replace Carburetor Jets. o Remove the carburetor air intake tube or air cleaner, o Remove the carburetor top bowl. o Replace the carburetor jets indicated in Figures 2 and 3. o Reinstall the top bowl with a new gasket, o Reinstall the air cleaner or air intake tube. 7 ------- EGR-CTO CZJ roo> ooo vOQ> Idle/Decel Swires AMERICAN MOTORS Figure 1. Modifying Low Altitude Model for High Altitude Operation. 8 ------- ENQINE FAMILY CODE VEHICLE TYPE MOOEL YEAR CARBURETOR fONfTtON TIMINQ ¦Nomi MAKE ma MODIFICATIONS 111 Buret ^-~-"~|2nd Barrel CHANGED JET FART NUMBER TOP BOWL GASKET FART NUMBER DISTRIBUTOR CURVES Low AlUltrf^—^MIgh AlllbMlo UPOATE LABEL FART NUMBER RENAULT 10 USA 1190 HiWuH 10 mum mm n-ti 8 S 1 1 flrtu soosuobas Ootta nos oioeA io Ofl (A) 00OSM0420 ISO (0) M 4M ISO (A| n oi ooo om R242CM of R240CM %* ATOC I* ATOC Mgfc AIMiiOo M SS 000 020 un Uw AUtuda Oo ISO «A| M IS 0M 4SS tsr (0) 60 4» 119 (O) onrsoii R240CS4 0* —-*— r otoc RENAULT 10 USA ttoa fUA*un to BMW 71 oto-oo Botes seaaooiDAS • 1M ^,^"•110 (A| M02 0I4U0 A 01011110 |A| n 01 000020 (t) trtraois RIMCH °* roioc (A| MOSOMMO ^^-^Olttl M00 4M11I RENAULT 10 MANUAL RinawW «• mitt MW* ttl'N lotu MO] 0CD6A S Ooiu teaaotooAO • 1» (AIM OS 014 M0 in (B) 01 Oil in |A) If 01 OMOM (B) M TO Ots RS4IOM o* S'OTOC wrreio2oiM |^^0«1M (8) M4M ISO RENAULT It AUTOMATIC KMi TO ruu r»-ri 02101 Oofca SU3SINOOAI • 110 (A)MM014M1 (B) 01 012 ISO |A) tt01 OMOM (B) ii in on R241DM 0* BTDC 10* OTOC Ofl 106(A| M0S0M *S0 IM (B) M 450 IDC RENAULT U MANUAL RmwM IS Burt MSS1 n mio 011-11 loin ssosocia&A ¦ 140 1*0 (A) tt 01 020 101 nOIOHOM I ^>-^Qq1S0 (B1 IS Ml ISO M3RAC Rtnauii 1} fWnawH || hum RISK RIS0I n n rt MS 11 MS tO mbm SI OARA 1 SS OARA tl S3 OARA IS Og 1» (A) ft 01 010 rio ^-"-"""ogita mis mi 122 IA) IT 01 010 044 - Unehonged Og 140|A| tt 01 010 200 ^-^OglSO miSMIIU (B) 41 TOO 060 110 Hmimn • R1220 n 110 tt W«twf S2 0IR40 QfllJO (AIIIOlOirOM ^—Oq 110 tons Ml HI |A) ft 01 Oil 044 (B) 41 TM009 H2MCS4 o* S* BTOC •10 R RiniiiR 0 Riaao n*n ItOtt VMM S3 MR 00 «•»» (A) 11 01 010 ISO Its W » Ml IS! R240CS4 0* S' BTOC |o« 130 (A) MIO 102 Ml | 110 IB) W Ml 1» m 41 100 060 (AJ fWnMiQ Pm Nu#wb* AMEHIrAN MOTORS oo HatnfM 0 ItftaM • Ah CampMiilliig Jit MOII. l9aOKmuHLiCvMl}N Mottot* i tllltwd* Mod*t* do not mmiU* Mgft moOlflctikMU Figure 2. High Altitude Modifications Chart - 1968-80 Renault Vehicles ------- SOLEX 26/32 DIDSA - 26/32 SDIDA WEBER 32 OIR • 32 DARA 2Bd BARREL T'BARREL 1"BARREL © fl T 77C 2"* BARREL SOLEX 32/32 SEIEMA 1n BARREL 2nd BARREL & «ut AMERICAN MOTORS Main jet Gg Air compensating jet Idling jet Figure 3. Carburetors. 10 ------- AMERICAN MOTORS Figure 4 AMERICAN MOTORS Figure 5 11 ------- AMERICAN MOTORS Figure 6 12 ------- ASTON MARTIN All 1982 models meet high altitude specifications, modifications are required. 13 ------- AURORA All 1983 models meet high altitude specifications. No modifications are required. 14 ------- BMW Year Engine Family Applicable Procedure 82 CBM2.7 V5 FAB4 Adjust to low altitude idle CO- value. 15 ------- CHRYSLER Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 84 Ram 50 Power Ram 50 1 Adjust timing 2.0L: 10° BTDC 2.6L: 12° BTDC 2 New Primary Main Metering Jel 2.0L: MD608004//105 (Kit //MD081661) 2.6L/AT: MD600613#120 (Kit #MD081662) 2.6L/MT: MD608010#125 (Kit #MD081663) 83 1.6L (PSA) MT 3 New Carburetor 4227389 4 New EGR Valve 4267246 5 New ESA Unit 5213876 6 Adjust Idle Curb: 925 rpm Idle Set: 900 rpm Propane: 900 rpm 1.7L MT 6 Adjust Idle 1 Adjust Timing 2.2L AT 3 New Carburetor W/AC: 4227376 WO/AC: 4227375 5 New ESA Unit 5213840 7 New Coolant Temp. Switch 4145348 1 Adjust Timing 6°BTC (Running Timing 16° BTDC) continued 16 ------- CHRYSLER continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1983 cont'd 6 Adjust Idle Curb: 850 rpm Idle Set: 850 rpm Propane: 900 rpm 8 Remove Vacuum Delay Valve 9a New Vacuum Reducer Valve 4104184 2.2L MT 3 New Carburetor 4227374 5 New ESA Unit 5213862 1 Adjust Timing 6°BTDC (Running Timing 16° BTDC) 6 Adjust Idle Curb: 900 rpm Idle Set: 900 rpm Propane: 975 rpm 8 Remove Vacuum Delay Valve 9a Install Vacuum Reducer Valve 4104184 7 New Coolant Temp. Switch 4145348 2.6L (MMC) AT 3 New Carburetor MD017307 Flange Gasket: MD025344 10 Install High Altitude Com- pensator MD026708 Bracket: 5214335 Hose Harness: MD025243 11 Install Hose Harness on EGR MDO 23646 Hose Clamp MD001843 continued 17 ------- CHRYSLER continued Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1983 cont'd 3.7L 1BBL 5 Install ESA Module 4289059 4 Install EGR Valve 4287554 6 Adjust Idle: Idle Set: 730 rpm Propane: 805 rpm Fast Idle: 1800 rpm SIS Adjustment: 900 rpm 12 Install Vacuum Kick Valve 13 Install Chock Pull-Off Valve 4167046 or 4173433 5.2L 1, 6 Adjust Idle Set, Propane Idle, & Timing to Low Altitude Specifica- tions Rampage Scamp 2.2L 2 New Primary Main Metering Jet 4131173 96 Install Vacuum Reducer Packages 4293794 6 Adjust Idle AT MT Idle Set: 900 rpm 775 rpn Propane: 975 rpm 850 rpn H.F.I.: 1500 1500 (S—3) (S-3) rruck 3.7L 225-1BBL 9 Install Vacuum Reducer Pckg. 4293798 6 Adjust Idle AT MT Idle Set: 650 rpm 600 rpii Propane: 725 rpm 675 rpn H.F.I. 1600 1600 (S—2) (S-2) 18 continued ------- CHRYSLER continued Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1983 cont'd Truck w/aspira- tors 5.2L 318-2BBL 6 Adjust Idle Idle Set: 750 rpm Propane: 850 rpm H.F.I.: 1500 (S-2) Truck 5.2L 318-4BBL 14 New Secondary Metering Jets 3744772 (2 required) 13 New Step-Up Spring 3621172 4 * New EGR Valve 4287675 - 6 Adjust Idle Idle Set: 750 rpm Propane: 840 rpm H.F.I.: 1600 (S-2) Colt Challenger Sapporo 16 Modify Hose Harness Kit #MD069088 1 Adjust Timing Basic: Colt: 10°BTDC Challenger/Sapporo: 12 BTDC 6 Adjust Curb Idle Truck 2.0L 2.6L 2 New Primary Main Metering Jet 2.0L: #80 Kit //MD069089 2.6L, 5/MT: #95 Kit #MD069090 2.6L, AT: #100 Kit #MD069091 1 Adjust Timing 2.0L: 10°BTDC 2.6L: 12°BTDC 6 Adjust Curb Idle continued 19 ------- CHRYSLER continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1983 cont'd Colt Ram-50 2.3L Turbo Diesel 17 Adjust Fuel Flow Rate Kit #MD064454 18 Adjust Ignition Timing to TDC 6 Adjust Idle to 750 + 50 rpm Caution: do not disturb other screws 82 Miser 1.7L MT 6 Adjust Curb Idler to 810 rpm 5 New ESA/EFC Module 5213542 4 New EGR Valve 4287354 Gaskets: 4201313 4201384 6 Adjust Propane Idle & Hot Fast Idle to Specifications Miser 1.7L 19 Remove Secondary Choke Blades A1 6 Adjust Curb, Propane, & Hot Fast Idles to Specificatior M, Z, P, D, C, V 2.2L 5 New ESA/EFC Module MT: 5213544 AT: 5213546 20 (MT only) Remove Choke Vacuum Kick Delayer 21 (AT only) New Choke Vacuum Kick Delayer 4173433 7 (AT only) New Coolant Temp. Switch 4091719 6 Adjust Propane and Hot Fast Idles to Specifications 20 continued ------- CHRYSLER continued Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1982 cont'd P, D, C, V 2.6L Install Kit # MD034560 (Includes items below) 3 New Carburetor MD026705 Flange Gasket: MD023544 'io Install High Altitude Com- pensation MD026708 Bracket (not in kit): 5214335 Hose Harness: MD025243 11 Install Hose Harness on EGR MD023646 Hose Clamp: MD001843 6 Adjust CO Idle to Specifica- tions B, F, G, S , X 3.7L 225 - 1BBL 3 New Carburetor 4227258 10 Install High Altitude Com- pensator 4268561 Bracket: 4268499 Screw: 0181065 Nut: 6025004 6 Adjust Propane, Curb, & Hot Fast Idles to Specification B, F, G, X, S 5.2L 318 - 2BBL 5 New ESA/EFC Module 4145980 6 Adjust Propane, Curb & Hot Fast Idles to Specification EFI "Y" Body 318 New EFI. Computer 4145701 6 Reset "Idle in Drive" to Specifications continued 21 ------- CHRYSLER continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1982 cont'd Truck Miser Truck 3.7L 225-1BBL 225-2BBL 1 Adjust Timing to 16°BTDC 6 Adjust Propane, Curb & Hot Fast Idle to Specifications Truck 5.2L 318-4BBL AT 3.5:1 Axle 22 Bypass OSAC Valve Connector: 4095598 6 Adjust Propage, Curb, & Hot Fast Idle to Specifications Rampage 2.2L Truck 3.7L (AT) 6 Adjust Propane, Curb, & Hot Fast Idles to Specificatior Truck 5.2L w/aspirator or AT Truck 5.2L-4BBL MT 1981 1.7L 4 cylinder 1 (AT only) Adjust Timing to 12°BTDC 6 Adjust Propane Curb, & Hot Fast Idle to Specifications All cars 2.2L 1 Adjust Timing to 12°BTDC h cylinder Remove Secondary Choke Blade (if equipped) 6 \ Adjust Propane, Curb, & Hot Fast Idles to Specifica- tions "K" Cars 2.6L 1 Adjust Timing to 12°BTDC 17b Modify EGR Hose Harness 6 Adjust Curb Idle, CO Mixture & AC Idle Up Speed to Specifications continued 22 ------- CHRYSLER continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1981 cont'd All Cars All LDT 225-1BBL 22 (AT cars only) Bypass OSAC Valve Connector: 4095598 1 Adjust Timing to 16°BTDC 6 Adjust Propane, Curb, Hot Fast, & AC (if equipped) Idles to Specifications LDT 318-2BBL 318-4BBL 360-4BBL 1 (2BBL/AT only) Adjust Timing to 12°BTDC 22 Bypass OSAC Valve Connector: 4095598 1968- 1980 Cars & Trucks 1 Adjust Timing According to Following Table 6 Adjust Curb Idle, Idle Mix- ture, & Fast Idle to Specifications 6A (1975-1979 only) Adjust Propane Idle 22 (225-6 cyl. only) Bypass OSAC or Vacuum Spark • Advance Solenoid if so equipped. Connector: 4095598 1980 Mitsubishi None 1977 Mitsubishi 23 Turn the Manual Switch on the: High Altitude Compensator II II to on 1971- 1980 Mitsubishi All (except listed above) 1 Adjust Ignition Timing Ac- cording to Attached Sche- dule 23 continued ------- CnlO slkr 1968-1980 FEDERAL PASSENGER CAR HIGH ALTITUDE TIMING SETTINGS MODEL YEAH - TMANS. 68 69 70 71 72 73 21 75 2k 11 170-1 Mail. Auto. 5°B 7.5°B 5°B 7. 5°B 11)8-1 M.iii. AuLo. 12°B 12°B 12°B 12°B 12°B 12°B 12°B 12°B 12°B 12°B 225-1 M.in. AuLo. 10° 11 10°U 10°B 10°B 10"B 10°B 10° B 10°B 10eB 10°B 10°B 10°B 10° B 10° B 10°B 10° B 12°B 12°B 12°B 12°B 273-2 Mun. AuLo. 5°B 7. 5°B 5°B 7.5°B 318-2 Mdii. Auto. 5°B 7.5'B 10°B 10°B 10°B 10°B 10°B 10°B 10°B 10" B 10°B 10"B 10°B 10°B 12°B 12°B 12°B 12°B 12°B 12°B 318-2(Alr l'uiup) Auto. 8°B 8°B 340-4 Mail. Auto. 10°U J2°B 10°B 12°B 10#B 12#B 10°B 12"B 10°B 12°B 10 °B 12°B 340-'6' I'll. Mun. Auto. 12°B 12°B 360-2 M.iii. AuLo. 10° B 10°B 10°B 10°B 10°B 10°B 12°B 12°B 360-4 Man. AuLo. 12°B 12°B 12°B 12° B 12°B 12*B 12°B 12°B 383-2 E 4-S3L Man. AuLo. I0°B 12°B 10°B 12°B 10° B 12°B 10" B 12°B 400-2 AuLo. 12°B 12°B 12° B 12"B 12° B 400-4 Mail. Auto. 10°B 12°B 10°B 12°B 10°B 12°B 12°B 12°B 12BU ------- ru R> SLPR 1968-1080 PTDITRAL PASSISNGER CAR HIGH ALTITUDE TIMING SETTINGS MODEL YEAR l.nc. - than;;. 60 69 70 71 72 11 U 75 76 77 21i 4'i0(A120) Auto. 12° h 12"B 12"B 12"D 12°B 12°B 12°B 12° B 12°B 12°il 12°U 4't()(Al34) H-p- Man. 10° 11 10°B 10* B 10°B 10°B Auto. J2eB 12°B 12® J) 12°U 12°B i5°b 12°B 12"B 12#B J 2"U A/(n- *6" I'k. Man. 10°D 10° b 10° B Auto. 12°B 12°K 12°B 426-2-4BBLS Man. 10oB 10°IJ 10°B 10°B Street Hemi Auto. 10°B 10°B J0°B 10°li ------- CHRYSLER 1972-1980 CALIFORNIA PASSENGER CAR HIGH ALTITUDE TIMING SETTINGS MODEI. YEAU liHfi. - TRANS. 11 73 74 75 76 21 70 21 198-1 Man. Auto. 12°B 12°B 225-1 Man. Aulo. 12°B 12°B 10°B 10° U I0°B 10°B 10° B 10° B 12°B 12°B 12°B 12°B 12°B 12°B I2°B 12" B 3J0-2 Man. AllLO. 10° B 10°B 10?B 10°B 10"B 10°B 10°B 10°B 108B 10° B 10°B 10°B 340-4 H.P Man. AuLo. 10UB 10° B 10° B 10°B 360-2 Aulo. 10 °B 12°B 360-4 Man. An 1 o 12°B 12"B 12°B 12°B 12°B 12°B 400-2 Auto. 12aB 12° B 400-4 Man. Aulo. 12°B 12° B 12"B 12°B 12°B 12°B 12°B 12°B 12°B 12°B 440(A120) Aulo. 12°T1 I2°B 12°B 12°B 12*B 12° B o > u> II. P«Man • Aulo. 12° B 12° B 12°B 12° B 12°B 12°B 12°B 12° B 12°B 12°B 12°B 12° B 12°B 12 °B ------- CHRYSLER 196 8-1980 FEDERAL LIGHT DUTY TRUCK HIGH ALTITUDE TIMING SETTINGS MODEL YEAR LNC. - TltANS. 68 69 70 71 21 11 Ul 75 Ik 11 78 11 170-1 Man. Auto. 5°B 7.5°B 5° B 7.5°B 19B-1 Man. AiiLu. 10°B 10° B 10°B 10° B 225-1 Man. Auto. 10° B 10° B 10°b 10° B 10° B 10°B 10° B 10 °B 10° B 10° B 10° B 10° B 10° B 10° B 10° B 10° B 12°B 12°B 12° B 1 2°B 1IB-2 Man. Auto. 5°B 7.5°B 10°B 10°B 7. 5° B 7.5°B 7. 5°B 7.5°B 10°B 10° B 10°B 10°B 10°B 10°B 12°B 12°B 12°B 12°B 1 2" B 12°B J60-2 Man. AuLo. 10°B 10 "B 10" B 10°B 10"B 10°B 10°B J0°B 12°B 12 °B 1 2°B 12°B 12°B 12'B 12°B 12°B J60-4 Auto. 12°B J8J-2 Man. Auto. 10°B 12°B 10° B 12° 11 10°B 12°B 10°B 12°B A 00-2 Auto. 12'B 12° B <¦*0-4 An to. 12*B ------- CUOTSLF.r, 1972-1980 CALIFORNIA LPT HIGH ALTITUDE TIMING SETTINGS MODEL YE Alt KNfl. ~ TRAIIS. 11 11 Ul 11 11 11 11 11 225-1 Hun. 10°b 10°B 10°fl 10°B J0°B 10°B AuLo. 10° B 10°B 10°B 10°B 10°B 10°B 225-2 Han. ]2°B AuLo. 12°U 318-2 Han. 10°B 10°B 10°B 12°B 12°B 12°B Auto. 10°B 10°B 10°B 10° B 10°B 10°B 3 IB-A Han. 12°B Auto. 12° B 360-2 Man. 10°B 10°B Auto. 10° B 10°B 360-4 Man. 12°B 12°B 12°B 12°B 12°B 12°B Auto. 12°B 12°B 12° B 12°B 12°B 12°B 400-2 Auto. 12°B 12°B 440-4 AuLo. 12°B 12°B 12°B 12°B 12°B ------- CHRYSLER ^ "" Altitude Model\^ Liter (CIDT~~~—— Ignition timing at curb idle speed* Low-Altitude High-Altitude 1971 1.6 (97.5) TDC±1°BTDC 5°±1°BTDC 1972 TDC±1°BTDC 5 °±1°BTDC 1973 TDC±1°BTDC 5°±1°BTDC 1974 2.0 (121.75) 3°±1°BTDC 8°±1°BTDC 1975 1976 1.6 (97.5) TDC±1°BTDC 5°±1°BTDC 2.0 (121.75) 3°±1°BTDC 8°rl°BTDC 1977 1.6 (97.5) 2.0 (121.75) 5°±1°BTDC 10°tl°BTDC 1978 1979 2.6 (155.92) 7°±1°BTDC 12°±1°BTDC 1980 1.4 (86.0) 1.6 (97.5) 2.0(121.75) 5°rl°BTDC 10 °±1°BTDC 1 2.6 (155.92) 7 °±1°BTDC 12 °±1°BTDC * The curb idle speed remains unchanged between low- and high- altitudes. Refer to the Vehicle Emission Control Information LaDel affixed to the underhood of the vehicles. ------- CHRYSLER NOTE: All procedures are optional and an owner expense unless otherwise noted. PROCEDURE 1: Adjust Timing. o Adjust the timing to the given specifications. PROCEDURE 2: Replace Primary Main Metering Jet. o Remove the existing primary main metering jet and give it to the customer. o Install a new primary main metering jet of the part number listed. Use a screwdriver with a blade width less than 4.5 mm. An expandable tip is recommended to prevent air bleed from being dropped into the carburetor bore. PROCEDURE 3: Replace Carburetor. o Remove the existing carburetor and give it to the customer. o Install a new carburetor of the part number listed. A new flange gasket may be required. PROCEDURE 4: Install EGR Valve. o Install an EGR valve of the part number listed. PROCEDURE 5: Install ESA Unit. o Install an ESA unit of the part number listed. PROCEDURE 6: Adjust Idle. o Adjust the idle to the low-altitude specifications on the original VECI or to the alternative specifications given. PROCEDURE 7: Replace Coolant Temperature Switch. o Remove the existing coolant temperature switch and give it to the customer, o Install a new coolant temperature switch of the part number listed. continued 30 ------- CHRYSLER continued PROCEDURE 8: Remove Vacuum Delay Valve. o Remove the vacuum delay valve from the vacuum kick diaphragm hose. PROCEDURE 9a: Install Vacuum Reducer Valve. o Install in the EGR hose a vacuum reducer valve of the part number listed. PROCEDURE 9b: Install Vacuum Reducer Package (Nylon Vacuum Hose Harness). o Carefully cut the tape from around the vacuum harness convoluted tubing at the end closest to the coolant switch. o Peel the convoluted tubing away from the nylon tubes and cut 2 inches from the front of the engine clip that mounts the vacuum harness to the air pump pulley cover. Discard the cut piece of convoluted tubing. o Locate the nylon vacuum tube running from the CVSCC (CCEGR) coolant switch on the side of the water control box nearest to the white dot on the connector. o Cut the tube located in the previous step 2.5 inches from the CVSCC and 2.5 inches from the vacuum harness mounting clip. When cutting the nylon hose, use a sharp razor so the hose won't kink. Discard the unused hose. o Install the small end of the in-line connector, PN 4179391, on the cut end of the nylon tube closest to the CVSCC. o Install the small end of the elbow connector, PN 4213774, on the cut end of the nylon tube closest to the harness mounting clip. Orient the elbow connector so that the 3/16 inch end is pointed toward the CVSCC. o Install the vacuum reducer valve, PN 4104184, white nipple, between the connectors installed in the previous steps. Position the vacuum reducer valve so that the third nipple points downward. o Locate the blue striped vacuum hose in front of the carburetor. o Cut the blue striped hose 2.5 inches from the air pump pulley cover, approximately in front of the air cleaner mounting bracket. Insert a tee, PN 4104172. o Cut an 18 inch length of 3/16 rubber hose, bulk stock PN 3780507, and install it on the tee. Route this hose over the valve cover next to the air pump pulley cover. Between the engine and the vacuum harness, loop the hose about 2.5 inches from the vacuum reducer valve. o Connect the hose to the remaining nipple. o Tape the four nylon vacuum tubes together at the edge on the in-line connector. continued 31 ------- CHRYSLER continued PROCEDURE 9c: Install Vacuum Reducer Package (3.7L Engine). o Cut two 1.5(inch sections of 3/16 inch hose, bulk stock PN 3780507, and install them on the white nipples of the vacuum reducer valve, PN 4114184. o Install the in-line connectors on the hoses with the large end to the hose. o Cut one 8 inch length of 3/16 inch hose and install it on the remaining nipple of the vacuum reducer valve. o Install the tee, PN 4104172, at the other end on the 8 inch hose. o Locate the orange striped hose connecting the vacuum amplifier in the vacuum solenoid. Cut this hose 2.5 inches from the solenoid and install the tee of the vacuum reducer subassembly. o Locate the vacuum hose harness bundle running along the inside of the valve cover. Cut the yellow striped hose midway between the two tape wraps. o Install the vacuum reducer sub-assembly. PROCEDURE 10: Install High-Altitude Compensator. o Install a high-altitude compensator of the part number listed. See Figure 1 for 1982 models B, F, G, S, and X. PROCEDURE 11: Install EGR Hose Harness. o Install on the EGR a hose harness of the part number listed. PROCEDURE 12: Install ESA Module. o Install an ESA module of the part number listed. PROCEDURE 13: Install Vacuum Kick Valve. o Install a vacuum kick valve in the vacuum hose. PROCEDURE 14: Install Choke Pull-Off Valve. o Install in the vacuum hose a choke pull-off valve of the part number listed. continued 32 ------- CHRYSLER continued PROCEDURE 15: Replace Secondary Metering Jets. o Remove the existing secondary metering jets and give them to the customer, o Install new secondary metering jet's of the part number listed. PROCEDURE 16: Install Step-Up Spring. o Remove the step-up piston cover plate attaching screw and cover plate, o Remove the rod connecting the choke shafts, o Remove the metering rod cover plates. o Remove the step-up piston and link assembly with the step-up rods, o Remove the step-up piston spring, o Install step-up spring. o Reassemble the carburetor in reverse order. o Readjust the secondary air valve spring wrap-up tension adjustment to 4-1/2 turns after valve contact with the stop. Use the air door adjust- ment procedure outlined in the service manual. PROCEDURE 17a: Modify Hose Harness. NOTE: Refer to Figures 2,3, and 4. o Remove the connector "I" from thermo valve "A", o Cut all three hoses off of connector "I". o Reinstall upper vacuum hose "E" on thermo valve nipple "E". o Cap nipple "A" on thermo valve "A" with the supplied rubber cap. o Cut vacuum hose "B" 2-23/64 inches from the end of the hose at connector "I" and install the supplied vacuum hose terminal. o Connect the vacuum hose "A" on hose terminal (tee) nipple "B". continued 33 ------- CHRYSLER continued PROCEDURE 17b: Modify Hose Harness. NOTE: Refer to Figures 5 and 6. o Remove the yellow and blue striped vacuum hose connector "I" from thermo valve "A". o Cut the molded rubber connector off of the yellow and boue striped hoses just removed. o Reattach the yellow striped vacuum hose to the outside nipple of thermo valve "A". o Cap the inside nipple of thermo valve "A" with the rubber cap, PNMD part number MD062284 ordered separately. o Cut vacuum hose "E" (blue striped) about 1-1/4 inch from the hose harness bracket and install the "T" connector in MD062284. o Install the" loose blue striped vacuum hose from the first step above on the open nipple of the tee just installed in vacuum hose "E". PROCEDURE 18: Adjust Fuel Flow Rate. o Loosen the nut on the fuel flow adjustment screw on the injection pump. o Insert the adjusting shim from the kit between the nut and the washer. DO NOT REMOVE the not or the screw. o Turn the adjusting screw inward to the stop and, while holding the screw, thghten the nut to a torque of 4.3 to 6.5 foot pounds. NOTE: Make sure the nut and the locking sleeve are tight against one another. Otherwise, the engine will not run properly. PROCEDURE 19: Adjust Injection Timing. o Loosen (DO NOT remove) the nuts and bolts securing the injection pump. o Loosen (DO NOT remove) the nuts securing the injection pipes (4 in all) on the side of the injection pump. When loosening the nuts, hold the delivery valve holder with a spanner to prevent it from rotating with the nut. continued 34 ------- CHRYSLER continued PROCEDURE 19 continued o Make sure that the push rod is protruding by 10 mm (0.4 inch). The protrusion of the push rod can be adjusted with an inner nut. o Remove the plug from the rear of the injection pump and attach the prestroke measuring adapter and a dial indicator. DO NOT overtighten the gauge to the adapter; if you do, the readings will be erratic. o Turn the crank pulley to such a position that the notch on the pulley is at approximately 30 before TDC. o Set the dial indicator to zaro. o Slightly turn the crank pulley clockwise and counterclockwise to make sure that the dial indicator does not deviate from the zero position. If it does, readjust the pulley position so that the notch on the pulley is at 30° before TDC. o Turn the crankshaft in the normal direction (clockwise) to bring the notch to specification. o Make sure that the dial indicator reads 1+ 0.03 mm (0.0394 + 0.0011 inch) . If the dial indicator does not indicate the specified value, tilt the injection pump body to the right or left until the the above reading is reached. o Temporarily tighten the bolts securing the injection pump. o Repeat steps 2 through 7 above to check that the adjustment has been made correctly. o Remove the prestroke measuring adapter, fit the plug, and tighten both the plug and the four injection pipe nuts. PROCEDURE 20: Remove Choke Vacuum Kick Delayer. o Remove the choke vacuum kick delayer. PROCEDURE 21: Replace Choke Vacuum Kick Delayer. o Remove the existing choke vacuum kick delayer. o Install a new vacuum kick delayer of the part number listed. PROCEDURE 22: Bypass OSAC Valve. o Bypass the OSAC valve by removing the two hoses at the valve and connecting them with the connector of the part number listed. 35 ------- ANEROID BRACKET RED STRIPED MAIN V4' HOSE TO RED NIPPLE YELLOW STRIPED IDLE V,,' HOSE MAIN-RED STRIPED IDLE-YELLOW STRIPED ANEROID ATTACHMENT NUTS & SCREWS 3' HOSE SUPPLIED WITH CAR8 */,«' HOSE WITH Y STRAP ANEROID FUEL LINE s/18* HOSE EGR BRACKET BOLT P/N 6022258 ROCKER COVER CHRYSLER FIGURE 1: Installation of 225-.1 Altitude Compensator on Models B, F, G, S, and X 36 ------- CUTTING POINT OF VACUUM HOSE "C" VACUUM HOSE 'E* FOR MODIFICATION VACUUM HOSE "B" STEP 1 (YELLOW STRIP) 60 MM —(2 36 IN) CONNECTOR "I" VACUUM HOSE"D" (BLUE STRIP) THERMO VALVE "A" VACUUM NIPPLE 'E' NIPPLE "B" VACUUM HOSE "B" FIGURE 3 NIPPLE "B" >RUBBER CAP (MD026761) NIPPLE "A VACUUM HOSE TERMINAL (MD001865) THERMO VALVE "A" VACUUM HOSE "B" (YELLOW STRIP) FIGURE A VACUUM HOSE"A" (BLUE STRIP) RUBBER CAP VACUUM HOSE TERMINAL VACUUM HCSE "D" (BLUE STRIP) CHRYSLER: Modification of Thermo Valve Vacuum Hose Assembly. 37 ------- T CONNECTOR FROM P N. MD062284 ADDITIONAL VACUUM HOSE TERMINAL THERMO VALVE "B ADDITIONAL RUBBER CAP FROM P N MD062284 NIPPLE "A" ABOUT 30 MM VACUUM HOSE "D (BLUE) ABOUT 120 MM VACUUM HOSE "E* NIPPLE "B" VACUUM HOSE "C" (YELLOW) CONNECTOR "II" THERMO VALVE "A" PRIMARY EGR VALVE CHRYSLER FIGURE 5: Hose Modification 38 ------- VACUUM HOSE "E" MEASURE AEOUT 30 MM (11//) CUTTING POINT OF VACUUM HOSE "E" (BLUE) MEASURE ABOUT 120 MM (43/4") THERMO VALVE "B" VACUUM HOSE "D" (BLUE) VACUUM HOSE "C" (YELLOW) THERMO VALVE "A" CONNECTOR " CONNECTOR "I" PRIMARY EGR VALV CHRYSLER FIGURE 6: Hose Modification 39 ------- DATSUN 1981 Diesel 810 PROCEDURE: Replace EGR Guide Tube. o Remove the nut which secures the EGR tube to the EGR control valve, o Disconnect the tube from the valve, o Disconnect the vacuum hose. o Remove the nuts which mount the EGR control valve to the intake manifold, o Remove the EGR control valve, o Remove the EGR guide tube. o Install a high-altitude EGR guide tube, which has a smaller EGR flow restriction to reduce the EGR flow rate. o Reinstall the EGR control valve. NOTE: ALWAYS replace the EGR gaskets. o Reconnect the vacuum hose. o Reinstall the EGR tube to the EGR control valve. o Make sure the exhaust gas does not leak from the gasket or the tube connection. 40 ------- FERRARI PROCEDURE: o Replace the warm-up and control pressure regulator (0 438 140 083) with a new regulator (B 438 149 474). o Warm up the engine. o Check the idle speed. If necessary, adjust it according to the procedure in Section 17.02.00.00, page 06.01-8 in the manual. 41 ------- FIAT LANCIA Year Electronic Control Unit Applicable Procedures 82 0.280.000.207 1,3 0.280.000.208 1,3 0.280.000.190 2a,1,3 0.280.000.191 2b,1,3 81 All none L PROCEDURE 1: Join Electrical Leads. o Join the free leads near the electronic control unit (see detail in owner's manual). PROCEDURE 2a: Replace Electronic Control Unit. o Replace the existing electronic control unit with part number 0.280.000.207. PROCEDURE 2b: Replace Electronic Control Unit. o Replace the existing electronic control unit with part number 0.280.000.208. PROCEDURE 3: Check and Adjust Idle, o Warm up the engine. o Check the idle speed. Adjust the idle speed, if necessary, according - to the instructions in the manual. 42 ------- FORD Year Engine Family/ Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 84 4.9L 1 New PCV valve: EV-49 (D8TZ-6A666-B) 2 Advance timing 4° 3 New transmission diaphragm: D8AZ-78377-A Clip: D7FZ-7F006-A 13 Adjust idle 5.0L TAF 4.53 F,G,K,L 4.54 E,F,L,J 1 (except Canadian) New PCV valve: EV-68 (D90Z-6A666-A) 5 (except Canadian) New air pump pulley: D4ZZ-9B447-A 6 (except Canadian) New air pump drive belt: 40-60 amp alternator: D5PZ-8620-C 70-100 amp alternator: EOPZ-8620-C 2 Advance timing 4° 3 New transmission diaphragm: D8AZ-7A3777-A 13 Adjust idle 83 2.3L 3.05 A,H 3.06 A,H (non-feedback) 2 Adjust timing to 14° BTDC 12 Insert T-bl'eed and filter: E1ZZ-6C600-A 2.3L 3-5 C,N,P 3-6 N 4 Connect MCU i 2(3-6 N only) Advance timing 5° cont'd 1 New PCV valve: EV-94-6A666- continued 43 ------- FORD continued if ear Engine Family/ Calibration Applicable Procedures Replacement Part Number/ j Specification/Notes | 83 3.8L 2-55 D 2-56 D 3-55 D 3-56 D 7 New accelerator pump rod: E1PZ-9F687-A 8 Remove pullover air bleed 9(2-55 D only) Reposition choke rod/lever 2 Advance timing 6° 3 New transmission diaphragm: D7DZ-7A377-A Clip: D8BZ-7F006-A 1 1 l J 13 Adjust idle 4.9L Under 8500 lbs except CA 1 New PCV valve: EV-49 (D8TZ-6A666-B) 2 Advance timing 4° 3 New transmission diaphragm: D7DZ-7A377-A Clip: D7FZ-7F006-A 13 Adjust idle 5.0L Under 8500 lbs except CA 1 New PCV valve: D90Z-6A666-A 5 New air pump pulley: D5FZ-9B447-D 6 New air pump drive belt: 40-60 amp alternator: D5PZ-8620-C 70-100 amp alternator: EOPZ-8620-A 1 1 1 2 Advance timing 4° 3 New transmission diaphragm: D8AZ-7A377-A cont'd 13 Adiust idle continued 44 ------- FORD (continued) Year Engine Family/ Calibration Applicable Procedures Replacement Part Number/ j Specification/Notes 1 83 5.8W Under 8500 lbs except CA 5.8 W "NQ" 5.8 M "NA" 9 i Reposition choke rod/lever 2 Advance timing 6° 1 New PCV valve: D7AZ-6A666-A 13 Adjust idle D2.2KAF D4.9TCG D5.0TCG D5.8TBF none 82 1.6L Escort/EXP/LNX 11a New high speed air bleeds: Primary: 1.85 mm (TBD) Secondary (Man TX): 2.40 mm (TBD) (Auto TX): 2.20 mm (TBD) ¦ 14 To improve cold start and drive away: Install choke index plate and cap Adjust breather angle CI.6LVAC C1.6LVAF lib New high speed air bleeds: Primary: 1.90 mm (TBD) Secondary: 1.95 mm (TBD) C2.3LVAC C2.3LVAF 4 Connect MCU C2.3LVBB 2-05A,B Manual 49,5 15 Replace primary main metering jet: Jet: D8PZ-9533-E Bowl cover gasket: EOPZ-9560-B 2-06A Automatic 495 (non- feedback) 12 Install T-bleed and filter: EIZE-6C600-AA 13 Adjust idle cont'd 3(2-06A) only) New transmission diaphragm: EIZZ-7A377-A HAD (black dipped end cap) continued 45 ------- FORD (continued) Year |Engine Family/ Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 82 3.3L 2-12 T-R 2-12 B-R C3.3VXF C3.3VXC 2 Adjust timing to 12° BTDC 1 New PCV valve: EV-49 (D8TE-6A666-BA) 3 New transmission diaphragm: 7A377 Clip: 7F006 C3.8VXF C3.8VWF Granada, Cougar, T-Bird, XR-7 with C-5 trans mission 9 Reposition choke rod/lever 2 Advance timing 4° 1 New PCV valve: EV-76 (6A666) 3 New transmission diaphragm: VXF: 7A377 VWF: D70P-7A377-AA Clip: 7F006 Note: Save the TV rod. It is matched to the case. 13 Adjust idle C3.8VXF C3.8VWF Continental, T-Bird, XR-7 with AOD transmission 9 Reposition choke rod/lever 16 Disconnect vacuum switch 2 Advance timing 4° 1 New PCV valve: EV-76 (6A666) cont ' c 13 Adjust idle. Also reset hi-cam speed. continued 46 ------- FORD (continued) Year Engine Family/ Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 82 C3.8TAF 2-55D 2-56D ROOA/N R10A/N 7 New accelerator pump rod: EIPE-9F687-AA 8 Remove pullover air bleed 9(2-55D only) Reposition choke rod/lever 2 Advance 6° 3 New transmission diaphragm: D70P-7A377-AA Clip: D8BP-7F006-AA 13 Adjust idle 82 C4.2/5.OLVGF 2.-18B.C 2-20D 2-21E 2-22S (C5.AOD or SROD trans.) 9 Reposition choke rod/lever 17 Install vacuum delay valve: D3FZ-12A091-A 2(C5+SROD) Advance timing 4° 18(A0D only) New vacuum check valve: D9AZ-12A197-A l 82 cont 'd 4.2L Under 8500 lbs except CA (light trucks) 1 New PCV valve: EV-49 (D8TE-68890--AA) 5 New air pump pulley: D4ZE-9480-AA 6 New air pump drive belt: D5UE-8620-JA 2 Advance timing 4° 3 New transmission diaphragm: D70P-7A377-AA Clip: D7EP-F006-AB 13 Adjust idle continued 47 ------- FORD (continued) Year Engine Family/ Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 82 4.9L Under 8500 lbs except CA (light trucks) 1 New PVC valve: EV-49(D8TE-6C317-CB) 2 Advance timing 4° 3 New transmission diaphragm: D7AP-7A377-AA 13 Adjust idle 5.0L Under 8500 lbs except CA (light trucks) i New PCV valve: EV-68(D8TE-6B890-BA) 5 New air pump pulley: D4ZE-DC480-AA 6 New air pump drive belt: 40-60 amp alternator: D5UE-9620-JA 70-100 amp alternator: EOTE-8620-CA 2 Advance timing 4° 3 New transmission diaphragm: D7AP-7A377-AA 13 Adjust idle 5.8WL Under 8500 lbs except CA (light trucks) 1 New PCV valve: D7AZ-6A666A 2 Advance timing 6° 9 Reposition choke rod/lever 3 New transmission diaphragm: D7AP-7A377-AA cont'd 13 Adjust idle continued 48 ------- FORD (continued) Year Engine Family/ Calibration Applicable Replacement Part Number/ Procedures Specification/Notes 82 3.8LVBC none C4.2/5.0VDF 4.2/5.OLVDC 4.2/5.OLVCB 4.2/5.0TAF 2-53X ROOA/N 4.2/5.OLTCC 4.2/5.OLLDV C4 ._9TDF 4.9TDF 2051Y ROOA/N 5.OLVEF C5.0VEC 5.8WTAF 2-64X ROOA/N CFM5.8T2HBF9 C5.8LVAF continued 49 ------- FORD (continued) Year Engine Family/ Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 81 1.6L 1-03A,C,D 1-04A,C,Q 11a New high-speed air bleeds: Primary: 1.85 mm (TBD) Secondary (manual): 2.40 mm (TBD) (auto) : 2.40 mm (TBD) 2.3L AHF (except CA) 15 New primary main jet: D8FZ-9533-E Gasket: EOPZ-9561-B 12 Insert T-bleed and filter 13 Adjust idle 3.3L all 2 Adjust timing to 12° BTDC 1 New PCV valve: EV-49 (6A666) 19 New carburetor choke pulldown motor Motor: -9S514- Setting: 0.110 + 0.02 in. 4.2/5.0 MAF C4 or AOD transmission 9 Reposition choke rod/level 17 Install vacuum delay valve: D32E-12A189-AA 2(C4 only) Advance timing 4° 18(AOD only) New vacuum check valve: D9AE-12A197-AA 4.2/5.0L NA except CA 1 New PCV valve: D8T2-6A666-B 2 Advance timing 4° 3 New transmission diaphragm: D7DZ-7A377-A Clip: D7FZ-7F006-A cont 'd 13 Adjust idle coiitinued 50 ------- FORD (continued) Year Engine Family Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 81 4.9L NR except CA 1 New PCV valve: D7AZ-6A666-A 2 Advance timing 4° 13 Adjust idle 5.8W NQ 5.8M/6.6L NA 9 Reposition choke rod/lever 2 Advance timing 6° 1 New PCV valve: D7AZ-6A666-A 13 Adjust idle 4.2-/5.0GCC 4.2/5.0NP 4.9NK 5.8W NG none 72-74 4-cylinder 2 Advance timing 4° Passenger car 20 Reset choke specifications: Lean choke setting up to 3 notches from spec 75-80 4-cylinder Passenger car 2 (carb. spark port only) Advance timing 4° 13 Adjust idle Also carb fuel/air ratio 20 Reset choke specifications: Pulldown: 7mm, Cam set: 4mm Lean choke setting up to 3 notches from spec K/D speeds to spec 68-74 6-cylinder 2 Advance timing 4° Passenger car 13 Also carb fuel/air ratio cont'd 20 Reset choke specifcations: Lean choke setting up to 3 notches from spec continued 51 ------- FORD (continued) Year Engine Family Calibration Applicable Procedures Replacement Part Number/ Specification/Notes 75-80 6-cylinder 2 Advance timing 4° Passenger car 13 Adjust idle Also carb fuel/air ratio 68-80 V8 Passenger car 20 Reset choke specifications: Incr.choke pulldown setting 0.020" 68-80 Light duty trucks 2 Advance timing 4° 13 Adjust idle Also carb fuel/air ratio 52 ------- FORD PROCEDURE 1: Replace PCV Valve. o Remove the existing PCV valve and give it to the customer, o Install a new PCV valve of the part number listed. PROCEDURE 2: Adjust Ignition Timing. o Settings given in the table are either final high-altitude specifications or an adnustment (advance or retard( from low-altitude specifications. PROCEDURE 3: Automatic Only: Replace Transmission Vacuum Diaphragm and Clip, o Lift vehicle. o Remove the transmission vacuum diaphragm and the attaching bolt, clip, and vacuum hose. The diaphragm does not need to be saved. o Install a new diaphragm (and sometimes clip) of the part number(s) listed. o Reinstall the attaching clip, bolt and vacuum hose. o Torque to specifications. The hose may require shortening or a longer hose may be required. o Lower the vehicle. PROCEDURE 4: Connect MCU. o Locate the MCU harness. o Locate two unconnected wires extending 4-6 inches from the back of the harness. - On Mustang, Capri, Fairmont, and Zephyr, one is green with green stripe, the other black with a green dot. - On LTD, Marquis, Granada and Cougar, one is black, the other blue, o Gently pull the taped ends out of the bundle. o Remove the tapes from the ends. o Remove 1/4" insulation from the end of each wire. continued 51 ------- FORD continued PROCEDURE 4 continued o Splice the wires together and solder securely (not cold solder). o Wrap the connection with electrical tape, o Secure the wires to the harness. PROCEDURE 5: Manual Only: Replace Air Pump Pulley. o Remove the existing air pump pulley and give it to the customer, o Install a new pulley of the part number listed. PROCEDURE 6: Replace Air Pump Drive Belt. o Remove the existing air pump drive belt and give it to the customer, o Install a new belt of the part number listed, o Tension the belt to 120-160 pounds. PROCEDURE 7: Replace Accelerator Pump Rod. o Remove the existing accelerator pump rod and give it to the customer, o Install a new rod of the part number listed. PROCEDURE 8: Remove Pullover Air Bleed. o Use a small plug remover or a sheet metal screw to remove the pullover air bleed from the top front of the air horn. PROCEDURE 9: Reposition Choke Lever. o Remove the choke plate lever screw, o Reposition the rod to the altitude hole, o Reinstall the screw. continued 54 ------- FORD continued PROCEDURE 10: Adjust Carburetor Idle Mix. o Perform the carburetor idle mix adjustment according to the propane enrichment method in the shop manual. If the propane gain is not 10-30 rpm, reset it to 20 rpm. o Reinstall the adjustment limiting feature. PROCEDURE 11a: Replace Primary High Speed Air Bleeds. o Remove air cleaner assembly and set it aside. o Remove the air cleaner bail retaining pin by using a pliers with a firm grip to disengage the light pin press. o Remove the air cleaner bail and stud as an assembly. o Unscrew the primary and secondary high speed air bleed, main well tube and main jet assembly. o Using a thin needle nose pliers, carefully lift the assemblies out of the carburetor, distinguishing between primary and secondary air bleeds. o Take apart by hand the air bleeds, the main well tubes, and the main jets. (They are press fit.) o Install new primary and secondary high speed air bleeds of the part numbers listed. o Install both air bleed assemblies into position. Torque to 5.3 lb. in. o Install the air cleaner bail, stud, and retaining pin. o Check all idle speeds according to PROCEDURE 13. o Install the air cleaner assembly. PROCEDURE lib: Replace Primary and Secondary High Speed Air Bleeds. o Remove the air cleaner assembly and set it aside. o Remove the air cleaner bail retaining pin by using a pliers with a firm grip to disengage the light pin press. o Remove the air cleaner bail. continued 55 ------- FORD continued PROCEDURE lib continued o Unscrew the primary and high speed air bleed, main well tube and main jet assembly. NOTE: This assembly is staked in production and therefore may resist removal. Do not allow any chips to fall into the main well. o Use a thin needle nose pliers to carefully lift the assembly from the carburetor. o Take apart by hand the high speed air bleed, main will tube and main jet assembly. (It is press fit.) o Install a new primary high speed air bleed of the part number listed and reassemble the assembly. o Apply one drop of Ford Spec ESE-M4G-204-A3 (Loctite 262 or equivalent) on the threads of the assembly. o Install the assembly into the carburetor. Torque to 17 in. lbs. NOTE: If you have trouble reinstalling the assembly, refer to Technical Letter PTC-2-071-E for an alternative installation procedure. o Unscrew the secondary high speed air bleed, main well tube and main jet assembly. o Use a thin needle nose pliers to carefully lift the assembly out of the carburetor. fr o Take apart the assembly by hand. (It is press fit.) o Install a new secondary high-speed air bleed of the part number listed. o Apply one drop of Ford Spec ESE-M4G-204-A3 (loctite 262 or equivalent) on the threads of the assembly. o Install the assembly into the carburetor (See note above.) Torque to 17 in. lbs. o Install the air cleaner bail and the retaining pin. o Check all idle speeds according to specifications. o Install the air cleaner assembly. continued 56 ------- FORD continued PROCEDURE 12: Install T-Bleed and Filter Assembly. o Remove the PVC tube from the carburetor spacer to the crankcase vent valve. o Cut the tube at midlength. o Install the T-Bleed and filter assembly of the part number listed, o Reinstall the modified PCV tube, o Start the engine and check for fuel leaks. PROCEDURE 13: Adjust Idle Speeds. AFTER all other modifications have been completed: o Check and adjust idle speeds to low-altitude specifications. o Whenever the idle speed is increased by more than 100 rpm or decreased, automatic transmission throttle linkage may have to be adjusted. PROCEDURE 14: Install Choke Index Plate and Cap; Adjust Breather Angle, o Remove the air cleaner assembly and set it aside, o Remove the thermostatic housing (choke cap part number 24-05-7). o Remove the choke index plate. o Determine whether the carburetor has a "C" spring. o Install a new choke index plate. No "C" spring: E1PZ-9A539-H "C" spring: E1PZ-9A539-J o If the carburetor has a "C" spring, check and adjust the choke breather angle (Note: This is not normally checked. Do not confuse it with choke pulldown, de-choke, or cam set.): Place the throttle on high cam position. Close the choke plates by hand and secure with a small strong rubber band. - Manually open the choke plates to overcome the light closing pressure but not to the point where the bimetal lever begins to move. continued 57 ------- FORD continued PROCEDURE 14 continued - Measure the distance from the downward side of the primary choke plate to the air horn wall (breather angle). Spec is 1.8 mm (#50 drill 0.070 + 0.001). - Rotating the index plate clockwise increases breather angle distance, and vice versa. A small amount may have to be removed from the index plate choke housing locking tab. o Install a new thermostatic housing (choke cap E2PZ-9848-D) and attaching hardware. NOTE: On all automatic transmission applications, the cold choke delay system must be removed. Attach the main wiring harness choke connection directly to the choke cap and connect the two overlay connections (male-female) together. o Reinstall the air cleaner assembly. PROCEDURE 15: Replace Primary Main Metering Jet, o Remove the air cleaner assembly, o Remove the fuel line at the filter, o Remove the bowl vent line, o Remove the 5 bowl cover screws and washers. o Carefully lift the bowl cover and disengage the choke rod from the choke lever adjacent to the fast idle cam. o Invert the bowl cover and set it aside. o Remove the primary main metering jet (choke side). o Install a new primary main metering jet of the part number listed. o Inspect and clean the bowl cover and main body gasket sealing surface. o Position a new bowl cover gasket of the part number listed on the main body. o Reinstall the bowl cover by engaging the choke rod into the choke lever. continued 58 ------- FORD continued PROCEDURE 15 continued o Reinstall the 5 retaining screws and washers. Torque screws to 20 in. lb. o Reinstall the bowl vent line and fuel line, o Start the car and check for fuel leaks. PROCEDURE 16: Disconnect Vacuum Switch. o Cut the wires between the vacuum switch assembly and the ignition module. o Solder the wires together to form a jumper at the ignition module. Tape the soldered joint. PROCEDURE 17: Install Vacuum Delay Valve. o Install a vacuum delay valve of the part number listed into the hose routed to the thermactor air control valve. (Replace the existing valve if there is one.) NOTE: The thermactor air control valve is of a dual diaphragm design. Make sure that the delay valve is installed with its brown side facing the diaphragm that does not have vent holes. (The vent holes have cotton showing through.) PROCEDURE 18: Install Vacuum Check Valve. o Install a vacuum check valve of the part number listed into the hose routed to the ignition timing vacuum switch, mounted near the ignition module. Make sure the blue side of the vacuum check valve faces the ignition timing vacuum switch. o Ensure that all hose connections are secure and that there are no vacuum leaks. PROCEDURE 19: Replace Carburetor Choke Pulldown Motor. o Replace the carburetor choke pulldown motor with a new one of the part number listed. Use the procedure in Section 24-09-7 of the 1981 Car Shop Manual. o Adjust the motor to the listed pulldown setting. Use the procedure in Section 2, 20-02-9 of the above manual. PROCEDURE 20: Adjust Choke Specifications. o Reset choke specifications to the values listed. 59 ------- GENERAL MOTORS Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1984 E1G1.6W2NEA6 E1G1.9T2TBA8 E1G2.0W5XAJX E1G2.8W2NNA4 E4G3.8W2NEY5 E4G4.1W5AGAX E6G4.1W5NKA1 E3G5.0W4NBA2 E1G5.0W4NEAX none 1983 Chevrolet Pontiac D1G1.6V2NEA0 D1G1.6V2NEA5 1 Install Altitude Harness Jumper Chevrolet Diesel D1G1.8D7ZZ90 2 Adjust Full Load Screw D1G1.9T2HEC8 3 Advance Timing 4° D1G2.0T2HJC9 4 Adjust Idle 3 (MT) Advance Timing 2° Chevrolet Truck D1G2.8T2HJC2 4 Adjust Idle to 700rpm MT: Neutral AT: Drive 3 Advance Timing 4° D1G4.1T2HHS0 D1G4.1T2HHD2 5 Adjust Primary Vacuum Break. 4 Adjust Idle (HA) 6 New EGR Vacuum Control Assembly: 22519396 7 Remove EGR Trim Control Vacuum Modulator Valve Oldsmobile D3G4.3D7ZZT8 8 Adjust Pump Timing -6° Cutlass Diesel D3G4.3D7ZZK7 4 Adjust Idle 9a Adjust Metering Valve Stop Screw 2-1/8 Turns Counterclockwise continued 60 ------- GENERAL MOTORS continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1983 cont'd - D1G5.0T4HGH3 3 Advance Timing 4° 10 Adjust Choke Vacuum Break to 26° 4 Adjust Idle Curb: MT: 700rpm, NEUTRAL AT: 600rpm, DRIVE Solenoid: MT: 700rpm, NEUTRAL Oldsmobile Diesel D3G5.7D7ZZT7 6 New EGR Vacuum Control Assembly: 22515542 8 Adjust Pump Timing -4° 4 Adjust Idle 9b Install Metering Valve Stop Screw Adjust 2-1/2 Turns Counterclockwise Kit #22516487 Chevrolet/ GMC Truck Diesel D1G6.2K7ZZ40 11 Have Injection Pump Adjusted D2G1.8V5TDGX D1G1.9T2TBA7 D1G2.0W5XAJ9 D2G2.5V5TPG6 D1G2.8T2TRA1 D1G2.8W2NNA3 D4G3.0W2NEA4 D4G3.8W2TMA0 D4G4.1W4AEA3 D6G4.1V5AGA4 D6G4.1W5AGA9 D1G4.1T2TMA9 D1G5.0W4NDA7 D1G5.0W4NEA9 D1G5.0W4TMA1 D3G5.0W4ARA3 D3G5.0W4NBA1 D1G5.7W5NBM8 D1G5.7T4TYA3 none continued 61 ------- GENERAL MOTORS continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1982 Chevette Pontiac C1G1.6V2TNR1 C1G1.6V2NEAX FED: 4/MT CAL: AT 1 Install Altitude Harness Jumper FED & CAL 5/MT 12 Install Service PROM Chevrolet Diesel C1G1.8D7ZZ9X 2 Adjust Fuel Load Screw Chevrolet S Truck C1G1.9T2HEC7 3 Advance Timing 4° C1G2.8T2HJC1 4 Adjust Idle Chevrolet C1G3.8V2ACA0 12 Install Service PROM Chevrolet Truck C1G4.1T2HHD1 3 Advance Timing 4° C1G4.1T2HHSX 4 Adjust Idle Oldsmobile Diesel 6 New EGR Valve Vacuum Control Assembly: 25515542 Adjust to 2.5 in HG + 0.5 7 New Vacuum Modulator Valve: 22516009 Adjust to 9 in Hg + 1 Adjust Metering Valve Stop Screw 3 Turns Counterclockwise Chevrolet C1G4.4V2ACA6 (w/o closed loop fuel control) 12 Install Service PROM C1G5.0T4HGH2 C1G5.7T4HAC5 C1G5.7T4HHC8 3 Advance Timing 4° 10 Advance Choke Vacuum Break to 26° 4 Adjust Idle: Curb: MT: 700rpm, NEUTRAL AT: 600rpm, DRIVE Solenoid: MT: 700rpm, NEUTRAL continued 62 ------- GENERAL MOTORS continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1982 cont'd Chevrolet Diesel C3G5.7D7ZZT6 6 New EGR Vacuum Control Assembly: 88 Wagon, 3/AT: 22515167 All Others: 22515542 9b Install Metering Valve Stop Screw Adjust Counterclockwise: 88 Wagon: 3 Turns All Others: 2-1/2 Turns Kit #22516487 Chevrolet/ GMC Diesel C1G6.2K7ZZ4X 11 Have Injection Pump Adjusted C1G1.6V2NEAX (CAL) C1G1.8V2NNA0 C2G1.8V5TDG9 C1G1.9T2XBN0 C2G2.5V5TPG5 C1G2.8V2NNA8 C1G2.8T2TRA0 C3G4.3V2AEA2 C1G4.4V2ACA6 (w/ closed loop fuel control) C3G5.0V4ARA8 C1G5.7V4ACA7 C1G5.7W4ACA1 C1G5.7V5NBM2 C1G5.7W5NBM7 none 1981 Chevette Diesel 11B9ZZ 2 Adjust Full Load Screw Buick Oldsmobile Pontiac Cadillac 14E2TM 13H2AC 13H2AEJ 12H2AD 12S4ABD 12S4AB 13Y4AR 13Y4ARJ 14E4NBD 14F4AE 14F4AEJ 12X2NN 16T5ADB 16T5ADBJ 16T5ARB none continued 63 ------- GENERAL MOTORS continued Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1968- 1980 Cadillac Buick Chevrolet GMC Isuzu (Luv) Opel All FED or CAL gasoline engines 13 Set Choke Coils 10 Adjust Choke Vacuum Break: Angle Gage: 2° over Spec Plug Gage: 0.015 in over Spec 3 Advance Timing 4° except those exempted below 4 Adjust Idle Mixture, Speed NOTE: Adjust idle speed ONLY if carburetor mixture screws are not covered with metal plugs. Write in "Procedure A" on Update Label. Pontial Oldsmobile All FED or CAL gasoline engines 13 Set Choke Coils 10 Adjust Choke Vacuum Break: Angle Gage: 2° over Spec Plug Gage: 0.015 in over spec 4 Adjust Idle Mixture, Speed NOTE: Adjust idle speed ONLY if carburetor mixture screws are not covered with metal plugs. Write in "Procedure B" on Update Label. 1978- 1979 Install Metering Valve Stop Screw Adjust Counterclockwise: 5.7L: 1-1/2 Turns 4.3L: AT: 2-7/8 Turns MT: 2-5/8 Turns Kit #22516487 or equivalent continued 64 ------- GENERAL MOTORS continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 1980 Buick 04E2MCR2 (CAL) 04E4UCD (Turbo) (CAL) Cadillac 06T5GY (FED) 06JORC2 (CAL) 1979 Cadillac 960V0 (FED,CAL) 960J0U (FED) 960JO (CAL) 960J0UC (CAL) none 1978 860JOU (FED) 860J0 CAL) 860Y0 (CAL) 1977 Cadillac 760JOU (FED) 760V0 (FED,CAL) 1976 Cadillac 60V0 (FED) 60JO (FED) 61V0 (CAL) 61JO (CAL) 65 ------- GENERAL MOTORS PROCEDURE 1: Install Altitude Harness Jumper. o Connect the altitude harness jumper wire from circuit //450E at the ALDL connector to pin #18 on the ECM connector. Refer to the chassis service manual for the location and identification of the jumper wire and the pin. PROCEDURE 2: Adjust Full-Load Screw (Owner Expense). NOTE: Perform this modification with the engine NOT running. o Remove the full-load adjusting screw lock wire and seal. o While holding the adjusting screw to prevent rotation, loosen the lock nut. o Rotate the screw 90° counterclockwise. o Retorque the lock not (8-12 n-m) while holding the screw to prevent rotation. o Install a new lock wire and seal. PROCEDURE 3: Adjust Timing. o Adjust the ignition timing as much as that specified as long as a road test at high altitude reveals no audible spark knock. Reference setting is the specification on the Emission Control Information Label. PROCEDURE 4: Adjust Idle. o Adjust the idle to the specifications on the Emission Control Information Label or to the specification given. o (HA) indicates adjustment to the equivalent certified high altitude specification. PROCEDURE 5: Adjust Primary Vacuum Break. o Adjust the primary vacuum break to the equivalent certified high altitude specification if required to improve cold start and driveability. continued 66 ------- GENERAL MOTORS continued PROCEDURE 6: Replace EGR Vacuum Control Assembly (Owner Expense). o Remove the existing EGR vacuum control assembly. o Install a new EGR vacuum control assembly of the part number listed. PROCEDURE 7: Remove EGR Vacuum Modulator Valve (Owner Expense). o Remove the EGR trim control vacuum modulator valve if the vehicle is so equipped. PROCEDURE 8: Set Pump Timing (Owner Expense). o Install a timing meter. o Set the pump timing to the specification listed. PROCEDURE 9a: Adjust Metering Valve Stop Screw (Owner Expense). o Install a magnetic tachometer probe. o Run the engine until it is at operating temperature, o Set the idle to specifications. o Turn the engine OFF. o Remove the air crossover assembly, o Install screen covers part number J-29657. o Put a shop towel in the full intake manifold valley area under the injection pump head to absorb any fuel leakage. o Put the transmission in PARK. o Turn the air conditioner OFF. o Start the engine. o Loosen the lock nut on the metering valve stop screw. o Slowly turn the stop screw clockwise until the idle speed drops about 10 rpm. o Turn the stop screw counterclockwise the given number of turns. continued 67 ------- GENERAL MOTORS continued PROCEDURE 9 a continued o Tighten the lock nut. o Check for fuel leaks around the stop screw, o Remove the towel, o Turn the engine off. o Remove the magnetic tachometer and the screen covers, o Reinstall all parts removed. PROCEDURE 9b: Adjust Metering Valve Stop Screw (Owner Expense). NOTE: The kit contains lock nut, seal, metering valve stop screw, and label. o Install a magnetic tachometer probe, o Run the engine until it is at running temperature, o Set the idle to specifications, o Turn the engine OFF. o Remove the air cleaner and the air crossover assemblies, o Install screen covers part number J-26996-2. o Put a shop towel in the fuel intake manifold valley area under the injection pump head to absorb fuel leakage. o Remove the housing pressure tap plug and seal on the rear of the injection pump. o Assemble the lock nut, seal (O-ring) and metering valve stop screw such that the bottom of the lock nut is at the midpoint of the screw (See Figure). o Install the assembly in the injection pump until the lock nut contacts the pump housing. o Tighten the lock nut. o Put the transmission in PARK. continued 68 ------- GENERAL MOTORS continued PROCEDURE 9b continued, o Turn the air conditioner OFF. o Start the engine, o Loosen the lock nut. o Slowly turn the metering valve stop screw clockwise until the idle speed drops about 10 rpm. o Turn the stop screw counterclockwise the given number of turns. o Tighten the lock nut. o Check for fuel leaks around the stop screw, o Remove the shop towel, o Turn the engine OFF. o Remove the timing meter and the screen covers from the intake manifold, o Reinstall all parts removed. PROCEDURE 10: Adjust Choke V-acuum Break. o Adjust the choke vacuum break to the value listed. PROCEDURE 11: Have Injection Pump Adjusted, o Remove the fuel injection pump. o Send the pump to an ADS (Association of Diesel Specialists) Service Center) for adjustment of the fuel flow rate. o Reinstall the pump when it is returned from the service center. PROCEDURE 12: Install Service PROM. o Install the service PROM in the ECM. Refer to the proper chassis service manual for the location of the ECM and the installation procedure. 69 ------- OCK NUT FLAT SURFACE METERING VALVE STOP SCREW GENERAL MOTORS: PROCEDURE 9b Metering Valve Stop Screw Adjustment 70 ------- ISUZU Year Model Engine Family Procedures Label Part No. 84 P'Up, Trooper ESZ119T2AAG1 1,2 8941468110 ¦ ESZ111D6JCD8 ESZ137K6JCD4 none 83 1 I-Mark, P'Up (except Diesel) 1,2 8941212890 i J DSZ119T2AAG0 3,2 DSZ111V2FGD5 4,2 82 CSZ111V2FDG4 4,2 I'Mark, P'up (except Diesel) 2,1 8942579070 LUV (except Diesel) 2,1 14057201 P'Up Diesel none 71 ------- ISUZU PROCEDURE 1: Advance Ignition Timing. o Advance ignition timing as much as 4° from specifications on Emission Control Information Label as long as a road test reveals no audible spark knock at high altitude. PROCEDURE 2: Adjust Idle Speed. o Adjust the idle speed to the specifications on the Emission Control Information Label. PROCEDURE 3: Connect Delay Valve. o Connect the delay valve to the vacuum line between the 3-way and air switching valve. PROCEDURE 4: Install Altitude Switch and Solenoid Valve Assembly. o Remove the air cleaner from the carburetor. o Remove the vacuum switch assembly. o Put the vacuum switch assembly back into place along with the altitude switch and the solenoid valve assembly. Use a common bolt. o Remove the 3 rubber caps from the altitude compensation air passage on the carburetor. o Insert the 3 small rubber hoses from the solenoid valve into three passage pipes and hold them with clips. o Put the air cleaner back on the carburetor. o Disconnect a large rubber hose from the air cleaner pipe. Connect this hose to one of the 3-way passages and hold it with a clip. o Connect the harness connector on the altitude switch and solenoid valve assembly to the body harness connector. 72 ------- MASERATI QUATTROPORTE 1983-1984 PROCEDURE: Reduce Idle CO Setting. o Reduce idle CO setting from 4.5% to 3.5%. 73 ------- MAZDA Year Model Engine Family High Altitude Kit Part Number Unless Otherwise Specified 83 Mazda B2000 DTK2.0T2AHH4 FED 8387-99-041 Courier E17Z-9D544-A Mazda B200Q DTK2.0T2AJJ5 CAL 8397-99-041 Courier E17Z-9D544-B Mazda, Courier DTK2.2K6JKK9 None 81 Courier FED BTK2.0T2AE9 E17Z-9D544-A CAL BTK2.0T2AG0 E17Z-9D544-B Courier FED BTK2.3T2AF3 E17Z-9D544-C CAL E17Z-9D544-D Chassis Cab E17Z-9D544-E Mazda B2000 FED BTK2.0T2AE9 8387-23-521 CAL BTK2.0T2AG0 8397-23-521 RX-7 FED BTD1.1V4GA7 None CAL BTK1.1V4GH3 GLC BTK1.5V2GB0 GLC Wagon BTK1.5V2GC1 626 BTK2.0V2GD6 70-80 Rotary engines None 80 Courier 2.0L FED OMAT D97Z-9D544-A CAL D97Z-9D544-B continued 74 ------- MAZDA continued Year Model Engine Family High Altitude Kit Part Number Unless Otherwise Specified 80 Courier 2.3L FED OWBT D77Z-9D544-H CAL D97Z-9D544-C Chassis Cab Mazda B2000 FED OMAT 8678-99-041 CAL 8682-99-041 Mazda GLC CAL Wagon w/AT OUCP 8318-99-041 Mazda GLC except CAL Wagon w/AT OUCP None 79 Courier 2.0L FED 9MAT D97Z-9D544-A CAL D97Z-9D544-B Courier 2.3L FED D77Z-9D544-H CAL 9WBT D97Z-9D544-C Chassis Cab Mazda 626 9NAP 8329-99-041 Mazda B2000 FED 9MAT 8678-99-041 CAL 8682-99-041 Mazda GLC FED 9UCP 8914-99-041 CAL MT 3922-99-041 AT 3961-99-041 78 Courier 1.8L FED 8FVBT D77Z-9D544-E CAL 8CVBT D77Z-9D544-F continued 75 ------- MAZDA continued Year Model Engine Family ' ~ T ~* High Altitude Kit Part Number Unless Otherwise Specified 78 Courier 2.3L FED 8FWBT D77Z-9D544-G CAL 8CVBT D77Z-9D544-H Mazda B1800 FED 8FVBT 3880-99-041 CAL 8CVBT 3882-99-041 Mazda GLC FED 8FTCP 3918-99-041 CAL MT . QPTfP 3922-99-041 AT 0\-» i^r 3961-99-041 77 Courier 1.8L FED FVBT D77Z-9D544-E CAL CVBT D77Z-9D544-F Courier 2.3L FED FWBT D77Z-9D544-G CAL CWBT D7 7Z-9D544-H Mazda B1800 FED FVBT 3880-99-041 CAL CVBT 3882-99-041 Mazda GLC FED FTCP 3918-99-041 CAL MT CTCP 3922-99-041 AT 3961-99-041 Mazda 808 1.3L FED FTCP. 3918-99-041 CAL CTCP 3922-99-041 Mazda 808 1.6L FED MT FNA 3608-99-041 AT 3621-99-041 CAL CNAP 3936-99-041 continued 76 ------- MAZDA continued Year Model Engine Family High Altitude Kit Part Number Unless Otherwise Specified 76 FED MT VBT D57Z-9D544-B Courier 1.8L CAL AT CVBT D67Z-9D544-B MT D67Z-9D544-A 77 ------- MAZDA All high altitude adjustments for Mazda and Courier involve replacing the primary and secondary main jets in the carburetor and adjusting the throttle positioner or similar device. Mazda provides for each vehicle a high altitude kit which contains new primary and secondary main jets and usually a new gasket for the carburetor. Part numbers for the high-altitude kits are given in the t ab le. The Procedure 1 given below is a comprehensive one; any one vehicle may not be equipped with all the items mentioned. Procedure 2 is assumed to involve many of the steps given in Procedure 1, but only this brief description of the procedure was given by the manufacturer. PROCEDURE 1: Install High-Altitude Kit. o Remove the air cleaner and duct assembly. o Remove the bolts attaching the accelerator shaft to the throttle lever. o Disconnect the fuel line and the fuel return line at the carburetor. o Disconnect the lead for the slow fuel cut valve (throttle solenoid) and the deceleration valve at the disconnects. o Disconnect the carburetor-to-distributor vacuum line at the carburetor. o Disconnect the hose from the carburetor to the vacuum amplifier. o Disconnect the vacuum hose for the purge control valve. o Disconnect the throttle return spring. o Disconnect the lead wire for the automatic choke. o Remove the servo diaphragm link for the throttle opener. o Using tool T72J-9510, remove the carburetor attaching nuts from the intake manifold studs. o Remove the carburetor. o Remove the locking plate. o Remove the plugs and the main jets from the carburetor. continued 78 ------- MAZDA continued PROCEDURE 1 continued o Install new primary and secondary main jets from the kit of the part number listed. o Reinstall the plugs. o Reinstall the locking plate. o Position the carburetor and a new gasket on the intake manifold and reinstall the attaching nuts. o Reconnect the throttle return spring. o Reconnect the accelerator shaft to the throttle lever and reinstall the attaching nuts. o Reconnect the slow fuel cut valve, the automatic choke lead and the deceleration valve at the disconnect. o Reconnect the carburetor-to-distributor vacuum line. o Reconnect the vacuum line for the purge control valve. o Reconnect the fuel line and the tuel return line to the carburetor. o Reinstall the air cleaner and the duct assembly. o Start the engine and check for fuel leaks. o Adjust the throttle positioner system, throttle opener, or dashpot to the rpm specified in the shop manual. PROCEDURE 2: Install High Altitude Kit, o Remove the carburetor, o Remove the dust cover. o Turn the idle adjust screw clockwise 1/4 turn, o Reinstall the dust cover. o Install the high altitude kit of the part number listed into the carburetor. o Reinstall the carburetor. 79 ------- MERCEDES All 1982, 1983, and 1984 models meet high altitude specifications. No modifications are required. 80 ------- MITSUBISHI Engine Family Procedure 50-state none CMT2.0T2BCA8 CMT2.6T2BCA0 All Others 1 PROCEDURE 1: o Unplug the two nipples on the carburetor. o Connect the HAC unit to these nipples with vacuum hose. o Replace the plug in the jet air passage with a shorter plug which will allow additional air to enter. o (Automatic Transmission Only) Replace the vacuum hose to the diaphragm chamber with a vacuum delay valve assembly. 81 ------- PEUGEOT Year Engine Family Procedures 1981 XN6 none XD2S none XD2C 1.2 PROCEDURE 1: Adjust Injection Pump Timing. o Adjust the injection pump timing to 13° + 1 BTDC. Use the adjustment procedure on pages F4032-F4034 of the workshop manual. PROCEDURE 2: Modify EGR System. o Delete the vacuum at the EGR metering device: Disconnect the wire n° 84. - Disconnect the metering device at the electrovalve. 82 ------- ROLLS ROYCE (BENTLEY) The following engines meet high altitude specifications. No modifications are required. Year Engine Family ' 84 ERR412 V6 FAAO i 83 DRR412 V6 FAAX ; 81 BRR412 V6 FA4 | 83 ------- SAAB All 1968-1984 models meet high altitude specifications. No modifications are required. 84 ------- SUBARU Year Engine Family Procedures 82-83 DFJ1.8T2AFD2 ? All Others None 81 All None 85 ------- TOYOTA oo ON YEAR MODEL ENC1NE TYPE ENGINE FAMILY HAC KIT PART # REPLACEMENT JET PART I IGNITION TIMING UPDATE LABEL 84 Truck 22R ETY2 4T2APF0 w/o HAC 04215 - 35080 /HAC Valve \ y25709 - 39010/ 5* BTDC 11282 - 35020 Truck 22R ETY2 4T2EBB0 w/o HAC 04214 - 35060 90999 - 41103 9* BTDC 11282 - 35030 ' All other 84 engines need no oodlflcation for high altitude use 83 Truck Cellca DTY2 4T2AFFX DTY2 4V2EBB9 w/o HAC 11282 - 13040 Truck 22R DTY2 4T2EBBX w/o HAC 04214 - 35050 90999 - 41120 9* BTDC 11282 - 15010 Truck Diesel DTY2 4K6JFF9 none none Injection tilling 0 044 inch plunger lift at TDC 11282 - 54030 All other 83 engines need no modification Cor high altitude use B2 Starlet 4K-C CTY1 3V2ACC7 90999 - 41103 16' BTDC 11282 - 13030 Corolla Tercel 3A-C CTY1 5V2ECC9 90999 - 41104 9* BTDC 11282 - 15010 Corolla 3T-C CTY1 8V2FCC8 5/KI 90999 - 41104 11* BTDC 11282 - 28010 4/NT AT 90999 - 41102 Truck Cellca 22R CTY2 4T2EBB9 w/o HAC CTY2 4V2ECCO 90999 - 41110 12* BTDC 11282 - 13020 Starlet CTYl 3V2AFF5 w/o HAC Install HAC valve Corolla CTYl 5V2AFF6 w/o HAC Corolla CTYl 8V2HFP1 w/o HAC Cellca Corona CTY2 4V2EFF9 w/o HAC Truck CTT2 4T2AFF9 w/o HAC Truck Diesel CTY2 2K6JFF8 Before 82-r-9 Install Injection noxile #23620 - 54030 Adjust opening pressure to 1,778 - 1920 psl with shins 0 0039 inch thicker than original Injection timing 0 046 Inch plunger lift at TDC 11282 - 54020 Truck Diesel CTY2 2K6JFF8 After 02-r-9 Injection lining 0 044 Inch plunger lift at TDC 11282 - 54010 All other 82 engines need no nodiflcation for high altitude use continued ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE ENGINE FAMILY HAC KIT PART // IGNITION TIMING 81 Starlet 4K-C BTY1.3V2AF8 w/HAC W/O HAC 04214 - 13010 04214 - 13020 8° BTDC 12° BTDC BTY1.3VAC5 04214 - 13030 12° BTDC Corolla Tercel 3A-C BTY1.5V2AF7 w/o HAC 5/MT 3/AT 04214 - 15010 9° BTDC 4/MT 04214 - 15020 BTY1.5V2EC1 04214 - 15030 9° BTDC Corolla 3T-C BTY1.8V2HF3 w/o HAC 5/MT 3/AT 04214 - 28010 11° BTDC BTY1.8V2FC7 4/MT 04214 - 28020 Corona/ Celica 22R BTY2.4V2EF6 w/o HAC BTY2.4V2EC3 04214 - 35010 12° BTDC Truck 22R BTY2.4T2AF1 2WD 04214 - 35020 12° BTDC w/o HAC 4WD 04214 - 35030 BTY2.4T2EM7 w/o HAC 04214 - 35040 12° BTDC All other 81 engines need no modication for high altitude use. continued ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE REPLACEMENT JET PART // IGNITION TIMING 80 Corolla Tercel 1A-C FED 5/MT 3/AT 90999 - 43100 9° BTDC 4/MT 90999 - 41096 CAL 90999 - 41102 Corolla 3T-C FED CAL 90999 - 41109 90999 - 41113 14° BTDC Celica Corona 20R FED 5/MT 3/AT 90999 - 41121 12° BTDC 4/MT 90999 - 41117 CAL 90999 - 41123 Truck 20R FED MT 90999 - 41119 12° BTDC AT 90999 - 41117 CAL 90999 - 41121 Land Cruiser 2F FED CAL 90999 - 41160 90999 - 41163 79 Corolla 3K-C 90999 - 41113 w/o HAC 16° BTDC w/HAC 8° BTDC (Sub-dia- phragm off) Corolla 2T-C FED 90999 - 41108 FED 14° BTDC CAL w/o HAC 18° BTDC CAL w/HAC 10° BTDC (Sub-dia- phragm off) Celica Corona 20R FED CAL MT 90999 - 41123 12° BTDC CAL AT 90999 - 41121 Cressida 4M FED 90999 - 41110 FED 14° BTDC CAL 12° BTDC j Truck 2 OR FED 90999 - 41119 12° BTDC i ( CAL 90999 - 41121 continued ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE REPLACEMENT JET PART # IGNITION TIMING 79 Land Cruiser FED 90999 - 41160 CAL 90999 - 41163 78 Corolla 3K-C 90999 - 41112 12° BTDC Corolla 2T-C FED 90999 - 41110 14° BTDC CAL 90999 - 41111 Corona 2 OR FED 90999 - 41115 12° BTDC CAL MT 90999 - 41123 AT 90999 - 41121 Celica 209 FED MT 90999 - 41117 12° BTDC AT 90999 - 41115 CAL MT 90999 - 41123 AT 90999 - 41121 Cressida 4M 90999 - 41110 14° BTDC Truck 2 OR FED MT 41115 12° BTDC AT 41113 CAL MT 41123 AT 41121 Land Cruiser 2F FED 90999 - 41123 11° BTDC CAL 90999 - 41122 77 Corolla 3K-C 90999 - 41113 12° BTDC Corolla 2T-C FED MT 90999 - 41106 FED 14° BTDC AT 90999 - 41104 CAL (sub off 14° BTDC diaphram ) CAL 90999 - 41111 Corona Celica Truck 2 OR FED MT AT 90999 - 41117 90999 - 41115 Corona Celica 12° BTDC CAL MT 90999 - 41123 Truck 12° BTDC AT 90999 - 41121 (sub diaphram off) Land Cruiser 2F 90999 - 41134 11° BTDC continued 89 ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE REPLACEMENT JET PART # IGNITION TIMING 76 Corolla 2T-C FED MT 90999 - 41105 14° BTDC AT 90999 - 41102 CAL 90999 - 41108 Corona 20R FED AT 90999 - 41117 12° BTDC Celica MT 90999 - 41119 Truck CAL AT MT 90999 - 41123 Corona 4M 90999 - 41104 FED 14° BTDC CAL 9° BTDC Land 2F FED 90999 - 41142 11° BTDC Cruiser CAL 90999 - 41122 75 Corolla 2T-C FED MT 90999 - 41105 Sinele Pt. 14° BTDC AT 90999 - 41102 Dual Main 16° BTDC CAL 90999 - 41108 Dual Sub 23-29° BTDC Corona 20F FED AT 90999 - 41117 12° BTDC Celica Truck CAL MT AT 90999 - 41119 (May-Aug 76: 90999 - 41123) MT 90995 - 41123 Corona 4M 90999 - 41104 FED 14° BTDC CAL 9° BTDC Land 2F FED 90999 - 41142 11° BTDC Cruiser CAL 90999 - 41118 74 Corolla 3K-C 90999 - 41180 9° BTDC Corolla 2T-C FED 90999 - 41106 FED 9° BTDC CAL 90999 - 41108 CAL 14° BTDC Corona Corona Truck 18R-C 90999 - 41114 11° BTDC Corona 4M FED 90999 - 41106 9° BTDC Corona CAL 90999 - 41104 continued 90 ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE REPLACEMENT JET PART # IGNITION TIMING 74 Land Cruiser i FED 90999 - 41118 11° BTDC CAL 90999 - 41116 73 Corolla 3K-C 90999 - 41108 9° BTDC Corolla Carina 2T-C before 4/73 90999 - 41105 9° BTDC after 4/73 90999 - 41106 Corona Corona Celica Truck 18R-C 90999 - 41114 11° BTDC Corona Crown 4M 90999 - 41106 9° BTDC Land Cruiser F 90999 - 41118 11° BTDC 72 Corolla 3K-C 90999 - 41108 9° BTDC Corolla Carina 2T-C 90999 - 41105 9° BTDC Corona Celica Truck 18RC 90999 - 41114 11° BTDC Corona 2M 90999 - 41116 11° BTDC Land Cruiser F 90999 - 41116 11° BTDC 71 Corolla 3K-C 90999 - 41106 1° ATDC Corolla 2T-C 90999 - 41113 9° BTDC Corona Celica Truck 8R-C after 12/70 90999 - 41124 Fed 4° BTDC Cal 14° BTDC Crown 2M 4° BTDC continued 91 ------- TOYOTA (continued) YEAR MODEL ENGINE TYPE REPLACEMENT JET PART # IGNITION TIMING 71 Crown 4M MT 90999 - 41098 90999 - 41106 90999 - 41103 4° BTDC AT 90999 - 41101 Land Cruiser F 11° BTDC 70 Corolla 3K-C 90999 - 41106 1° ATDC Corona Truck 3R-C 9° BTDC Corona 8R-C 4° BTDC Crown 2M 4° BTDC Land Cruiser F 11° BTDC 69 Corolla KC 1° ATDC Corona Truck 3R-C 9° BTDC Corona 8R-C AI - MT 4° BTDC > H 1 es 9° BTDC EM 9° BTDC Crown 2M 9° BTDC Land Cruiser F 4° BTDC 68 Corolla KC 1° ATDC Corona 3R-C 9° BTDC Crown 2M 9° BTDC Land Cruiser F 4° BTDC 92 ------- TOYOTA Most high altitude modifications for 1968-1984 light-duty Toyota vehicles and trucks involve some combination of the following: o Installation of a high altitude compensation (HAC) kit which usually consists mainly of a larger diameter primary main jet for the carburetor and gaskets for the air horn, main passage plug, and the main jet, o Adjustment of the ignition timing, and o Adjustment of idle rpm, fast idle rpm and throttle positioner rpm to low-altitude specifications. Specific installation instructions are given with each HAC kit. Additional instructions are given in the Emission Control Repair Manual. Part numbers for the HAC kit, and/or its components, and the specifications for the timing adjustments are given in the table. A set of general instructions, applicable in most cases, is given on the next page. 93 ------- TOYOTA continued GENERAL PROCEDURE for most kits: o Remove the air cleaner assembly, o Remove the carburetor assembly. o Remove the air horn assembly from the carburetor, o Remove the passage plug and the primary main jet. o Install a new primary main jet with a new gasket, o Reinstall the passage plug with a new gasket, o Reinstall the air horn subassembly with a new gasket, o Reinstall the modified carburetor assembly, o Reinstall the air cleaner assembly, o Warm up the engine to operating temperature. o Adjust the ignition timing at max 950 rpm with the distribution vacuum advance OFF. o Adjust the idle rpm. o Adjust the throttle positioner rpm. o Adjust the fast idle rpm with both the EGR system AND the choke opener system OFF. 94 ------- VOLKSWAGEN/AUDI Year Model Engine Family Idle rpm % CO Other Modifications 1982 Pickup CVW1.7T6APT3 925 + 75 1.2 +0.2 1981 VW BVW1.7TCAA7 BVW1.7VCFF6 BVW1.7V6FC8 no change no change Audi BAD1.7V6FF0 BAD2.2V6FF4 BAD2.2V6FC1 BAD2.2V6FX5 BAD2.2V6FY6 1980 Rabbit 900 + 50 1.0 +0.5 1977 Rabbit 925 + 75 1.5 +0.7 Activate High Compensation Jets 1975- 1976 Rabbit 850 + 50 1.0 +0.5 1975- 1976 Scirocco 1975 Dasher 19 7 A Dasher Audi Fox MT: 850 + 50 AT: 900 + 50 VW Wagon MT: 800 + 50 AT: 900 + 50 ' 1 . U T U.J 1973 Audi 80 950 0.8-1.0 Adjust Timing to TDC Set notches on Choke Cover & Adjuster Ring 5 mm Leaner from Large Tooth 1972- 1973 VW Wagon MT: 800 + 50 AT: 900 + 50 1.0 +0.5 95 continued ------- VOLKSGAGEN/AUDI continued Year Model Engine Family Idle rom 2 Co Other Modifications 1971- 1974 Convertible Sedan Ghia Thing MT: 900 + 50 AT: 800 + 50 2.0 +0.5 1970- 1974 Audi 100 925 + 75 0.8-1.0 Adjust Timing to 5° BTDC Set Notch on Housing 5 mm Leaner from Large Tooth 1970- 1972 Audi 90 950 0.8-1.0 Adjust Timing to 21° BTDC @ 3000 rpm Set Notch on Housing 5 mm Leaner from Large Tooth 1968- 1971 VW Wagon 800 + 50 2.0 + 0.5 1968- 1970 Convertible Sedan Ghia Thing 850 + 50 2.0 +0.5 96 ------- VOLVO Year Engine Family Procedure 83 DVV174V6FCG7 1,2 68-82 Carbureted 3 Fuel-inj ected 3 B28F (81-82) 3,1 Diesel 2 PROCEDURE 1: Disconnect Full Load Enrichment System. o Disconnect the ground connection (black wire) from the microswitch for full load indication. o Insulate the connector with electrical tape or the equivalent and secure it to the wiring harness. PROCEDURE 2: Adjust Injection Pump. o Advance the injection pump timing by 1.5° for each 1000 meters increase in altitude. This corresponds to an increased -value of 0.07 mm distributor plunger stroke @ TDC. o Turn the fueling screw counterclockwise 35° for each 1000 meters increase in altitude. This reduces fueling by 2.3 rnm^ per stroke per 1000 meters. PROCEDURE 3: Adjust Idles. o At altitude, adjust idle-CO and idle speed to low altitude specifications. o If a carbureted engine cannot meet the specifications, the fuel metering needle and/or the jet may need replacing. 97 ------- BLUEBIRD HEAVY DUTY TRUCK 1974-1984 427 c.i.d. engine PROCEDURE 1: Advance Ignition Timing. o Advance the ignition timing as much as 4° from specifications on the Emission Control Information Label as long as road tests at altitude reveal no audible spark knock at high altitude. PROCEDURE 2: Adjust Idle. o Adjust the idle speed to the specifications shown on the Emission Control Information Label. Attach supplemental Emission Control Information Label, PN 102235. 98 ------- RflPlfl CATERPILLAR HEAVY DUTY TRUCK Year Engine Family Procedure All DCT0636DAA5 ECT0636DAA4 DCT0636DCA9 ECT0636DCA8 Make adjustments according to the following charts. 99 ------- CATERPILLAR HEAVY DUTY TRUCKS FUEL SETTING INFORMATION 3208 210 HP DINA TRUCK ENGINE SETTINGS 32Y8309-UP Family DCT0636DAA5 Displacement 636 Cu. In. BARE high (A) A/F RATIO MAX. MANUOLU FULL ENGINE EPA OR EFFECTIVE IDLE FUEL CONTROL GOVERNOR TORQUE ALTI- TURBO PRESSURE TYPE LOAD HORSE- EPA/CARB SERIAL NUMBER RPM SETTING SETTING GROUP SPRING CONTROL TUDE CHARGER FULL LOAD OF RPM POWER CHIT. RANGE DARE ENG (mm) NUMBER NUMOER GROUP (FT. ) ASSLM. k Pa/In.Mg DSFC SERVICE 19 79 HAIlNGb : 32Y8309- 32Y357-16 19/9 RATINGS 2600 210 LPA 32Ytf3oy-35746 3030 3.18 None 9N3757 9LG506 6N509 2500-L None None .409 210 HP 2800 200 EPA • 1 II 3015 2. 80 i i 1 • 1 • i i 4000-L • 1 • • .404 ALT. DERATED 2800 194 FPA • • II 3000 2.62 i i t I 1 1 i • 5000-L 1 • I • . 395 ALT. DERATED 2600 1 « 5 LPA 28JO 2. b4 i i 1 1 ' 1 1 "" 25U0-L ' ' * "11 . JbO 1b5 IIP Intercity 2 800 200 EPA/CARB J2YB309-J5746 3020 2.90 None 9N5178 9L6SUB 6n50& 2500-L None None .406 LPA/CAKU. 1980 HAMUGS : J2yJ5747-J2yJ21V5 19U0 RATINGS 2BOO 210 LPA 32YJ5747-;2i75 30 10 3.25 None 9N375 I 9L6508 6N509 2500-L None None .414 EPA-TRUCK 2 a o o 200 LPA t i it 3015 2.87 i • 1 1 I 1 • • 4000-L • i • i .408 ALT. DERATED 2800 194 EPA * » it 3000 2.62 • • t 1 1 • • • 5000-L • i i i .395 ALT. DERATED 2b00 1 b5 LPA 2U80 2.64 i i 1 • 1 1 1 1 2500-L i i i t . 391 185 IIP Intercity 280U 200 EPA/CARU ii ii 3050 2.90 None 9 N 517 ii 9L650U i > 2500-L 11 ii .418 EPA/CARU. 19U1 RATINGS : J2Y72176-9270G 19U1 RATINGS 2800 210 LPA 32Y72176 3050 3.25 None 9N3757 9L6508 6N509-01 250U-L None None .414 TRUCK 2800 210 EPA 32Y20407-UP 3025 3.18 • i 1 • 1 1 i i 2500-L • i • i .391 TRUCK 2800 200 EPA » » 3015 2.U0 i • 1 1 1 1 ¦ i 4000-L i i • • .390 ALT. DERATED 2600 200 EPA/CARD * i 3025 2.90 • i 9N5178 1 1 t i 2500-L i i ¦ ¦ .398 EPA/CARB. 2800 194 EPA i i 3000 2.62 « « 9N3757 « 1 « * 5000-L t t • • .381 ALT. DERATED 2600 185 EPA < i 3005 2. 58 « i • 1 1 1 • i 5500-L • i • i .394 185 HP INTERCITY 1962,• 3 RATINGS : 32Y92707-UP, 51 Zl-UP 1982 1983 RATINGS 2600 210 LPA 32y<>2707-up J025 3.10 None "9NJ757 ytbbUU 6NSU9-01 2500-L None None .391 THULK 2800 200 EPA 1 1 3015 2. 80 • i • 1 • 1 i i 4000-L • * i ¦ .390 ALT. DERATED 2800 200 EPA/CARB 1 » 3025 2. 90 i i 9N5178 • 1 • i 2500-L • i i i .398 EPA/CARB. 2800 194 EPA 1 • 3000 2.62 • t 9N3757 1 1 i i 5000-L • i ¦ ¦ .381 ALT. DERATED 2600 185 EPA • 1 3005 2.50 t i i i « 1 • * 5500-L i » i i .394 185 HP INTERCITY SPECIFIC NOTES Governor Spring Color Code: 9L6508: 1 Yellow Stripe. Low idle is 650 RPM. Fuel injection tuning is 16° BTCl 0.127 Inch of pistcn travel. (A) Fuel setting can be measured with oc without fuel pressure. ~with EGR Variable timing advance is 5° for engines rated for EPA ratings Variable timing advance la 3s for engines'rated for EPA/CARD ratings. GENERAL NOTES Additional loads (fan, pumps, com- pressor, alternator, etc.) will cause the High Idle RPM to be 15-20 RPM Iocs than shown. If this difference is more than 50 RPM, contact the OEM for the correct setting. Manifold Pressures are measured with muffler and air cleanec Installed. If both items are removed, add 3 Inches to value 6hown L - Lug Condition ------- CATERPILLAR HEAVY DUTY TRUCKS FUEL SETTING INFORMATION 3208 175 HP DINA TRUCK ENGINE SETTINGS 40S1 -UP; 32Y1-UP Family DCT0636DAA5 Family DCT0636DCA9 Displacement 636 Cu. In. BARE IIIUII (A) A/F RATIO MAX. MAN 1 FOLD FULL ENGINE EPA OR EFFECTIVE IDLE FUEL CONTROL GOVtRNOR - TORQUE ALTI- TURBO PRESSURE TYPE LOAD HORSE- EPA/CARU SERIAL NUMBER RPM SETTING SEl'TING GROUP SPRING CONTROL TUDE CHARGER FULL LOAD OF RPM POWER CERT. RANGE BARE ENG (mm) NUMBER NUMBER GROUP (FT. ) ASSEM kPa/In.llg BSFC SERVICE 1 9b 1 ItAT I NGb )2V/2176-j2Y92>u6 19UI RATINGS 2600 1 bU LPA 2UOO 1.95 None 9N51J9 9L6508 6N509-01 7.5U0-L None . 4 UU 2600 165 tPA • < )¦ 2U25 2.18 i i • • • 1 II ¦ i • i .390 2600 185 EPA ¦ • •• 2855 2.64 i i 9N3757 t • « I 2,500-L i • .381 2800 160 FPA ii ii 2940 2. 00 • i 9N5139 1 1 II 7,500-L i i .400 2800 175 EPA • I ii 2985 2.30 • i 1 I • • » • 7,500-L • • .405 Alt. Derated 2800 1 75 EPA/CARB • I ii 2995 2. 30 • i 9N5178 1 1 EGR 7,500-L i • .399 1 9b 2 , 1 98 J HATlNi.b: 32Y92707-UP, 51Z1-UP i y b 2, 19BJ ratings 2b00 160 LP A 32Y927U7-UP 2U25 1.95 None 9N5139 9L650d 6N509-01 7,500-L None .408 2600 165 EPA • i 2815 2.18 1 I 1 • ii ii 7,500-L i i .390 2600 185 EPA ¦ i 2855 2.64 • 1 9N3757 • I •• 2,500-L ¦ i .301 2800 160 EPA • i 2940 2. 00 1 1 9N5139 ii •• 7,500-L • i .400 2800 175 EPA • i 2985 2.30 1 1 1 I • 1 ii 7,500-L • i .405 Alt. Derated 2800 1 75 EPA/CARB i i 2995 2. 30 1 • 9N5178 • ' EGR 7,500-L • ¦ .399 Governor Spring Color Code: 9L6508 - 1 Yellow Stripe. Low Idle is 650 RPM. Fuel injection timing is 16.0° BTCj 0.127 inch of piston travel. Variable Timing Advance is 3° BTC. (A) Puel setting can be measured with or without fuel pressure. Fans, pumps, alternator, etc., will cause the High Idle RPM to be 15-20 RPM less than shown. If this difference Is more than 50 RPM, contact the OEM for the correct setting. L » Lug Condition. ------- CHRYSLER HEAVY DUTY TRUCKS Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1983- 1984 FED 318 1 Adjust Timing to 12°BTDC. 2 Relieve Tension on Secondary Air Valve Spring. 3 Adjust Secondary Air Valve Opening to 1/2 Inch. FED 360 1 Adjust Timing to 8°BTDC. 2 Relieve Tension on Secondary Air Valve Spring. 3 Adjust Secondary Air Valve Opening to 1/2 Inch. 4 Replace Secondary Metering Jets: 120-5116 1982 FED 318 360 1 Adjust Timing: 318: 12°BTDC 360: 8°BTDC 2 Relieve Tension on Secondary Air Valve Spring. 3 Adjust Secondary Air Valve Opening to 1/2 Inch. 4 Replace Secondary Metering Jets: 4293720 5 Adjust Propane, Curb, & Fast Idles to Specifications. 1981 "U" or "T" in 8th 360-4V 6 Install Driveability Package: 4240180 position of VIN 1 Adjust Timing. 5 Adjust Curb & Hot Fast Idles continued 102 ------- CHRYSLER HDT continued Year Model Engine Family Applicable Procedures Replacement Part Number/ Specifications/Notes 1979- 1980 1 Adjust Timing. 5 Adjust Curb Idle, Idle Mixture, & Fast Idle. 7 (Carter TQ 4-bbl only) Turn Metering Rod Adjustment Screw 1 1/2 Turns Counter- clockwise . 8 (If plugs foul or if loading on cold start) Increase Vacuum Kick Setting 0.020 to 0.040 Inch From Original. 103 ------- 1970-80 CHRYSLER HEAVY DUTY TRUCKS BASTC TTMTNC SETTINGS - FEDERAL MODEL YEAR (TTM1NG IN DEGREES) ENGINE 1970 1971 1972 1973 1974 ,1975 1976 1977 1978 1979 1980 225-1 too 10B 100 100 7.58 100 100 108 10B 225-2 100 108 100 100 310-1 120 12B 100 12B 7.5B 80 8B 80 88 12B 318-3 120 128 12B 12B 12B 10D 10B 10B 318-3A 10B 3I8-3D 108 318-3C 10B 360-1 10B 10B 10B 100 108 10B 128 128 12B 360-3 10B 10B 10B 10B 10B 10B 10B 128 12B 361-2 120 12B 120 12B 361-3 120 120 12B 12B 12B 361-4 120 12B 12B 12B 12B 12B 128 128 383 Auto Trans 120 12B 303 Man Trans 100 10B 400 128 128 128 12B 128 12B 413-1 120 128 120 12B 413-2 120 120 12B 128 120 413-3 120 12B 12B 128 12B 120 128 12B 413-3A 108 440-1 128 128 12B 12B 12B 12B 128 4-10-3 12B 12B 12B 12D 12B 120 12B ------- 1970-80 CHRYSLER HEAVY DUTY TRUCKS BASIC TIMING SETTINGS - CALIFORNIA MODEL YEAR (TIMING IN DEGREES) ENGINE 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 225-1 10B 10B 10B 7.5B 7.5B 10B 10B 225-2 10B 10B 10B 318-1 12B 12B 10B 10B 7.5B 108 10B 10B 12B 318-3 12B 12B 12B 12B 12B 12B 12B 318-3A 10B 318-3B 10B 318-3C 10B 360-1 10B 10B 10B 12B 12B 10B 10B 12B 12B 360-3 10B 10B 10B 10B 10B 10B 10B 12B 12B 360-2 12B 12B 12B 361-3 12B 12B 12B 12B 12B 361-4 12B 12B 12B 12B 383 Auto Trans 12B 120 383 Nan Trans 10B 108 400 12B 12B 12B 413-1 12B 12B 12B 12B 413-2 12B 12B 128 12B 12B 413-3 12B 12B 12B 12B 440-1 12B 12B 128 12B 12B 120 120 440-3 ------- CHRYSLER HEAVY DUTY TRUCKS PROCEDURE 1: Adjust Timing. o Adjust timing to the given specifications. Specifications for 1970-1980 vehicles are given in the following tables. Use low-altitude specifica- tions for 1981 vehicles. PROCEDURE 2: Relieve Tension on Secondary Air Valve Spring. o Relieve the tension on the secondary air valve spring by one turn clockwise. PROCEDURE 3: Adjust the Secondary Air Valve Opening. o Adjust the Secondary Air Valve Opening to 1/2 inch. PROCEDURE A: Replace Secondary Metering Jets. o Remove the existing secondary metering jets and give them to the owner. o Install new jets of the part number listed. PROCEDURE 5: Adjust Idle. o Adjust the given idle speeds &/or mixtures to the original low-altitude specifications or to the given specifications. PROCEDURE 6: Install Driveability Package. o Install new carburetor, EGR amplifier, and EGR valve from the package. o Drain about one gallon of coolant from the radiator. o Cut the top radiator hose, from radiator end, 4 inches for vans and wagons and 3.5 inches for pick-ups and sport utilities. o Remove a 1-inch section from the hose coming from the engine where the cut was just made. o Place the two hose clamps over the open ends of the radiator hose. continued 106 ------- CHRYSLER continued PROCEDURE 6 continued— o Install the adaptor, PN 3751777, in the top radiator hose. Secure the adaptor using the hose clamps previously installed on the hose ends. o Use the sealer, PN 1070876, on the threads of the CCEVS and install the CCEVS in the adaptor, orienting the nipples toward the distributor. o Replace the coolant previously drained. o For vehicles Not equipped with a TIDC (Thermostatic Ignition Distributor Control) valve, remove the vacuum spark advance hose from the distributor to the generator to the carburetor. o For vehicles equipped with a TIDC valve, remove the vacuum hose harness and three lines that connect the TIDC valve to the distributor, manifold vacuum tree and carburetor. o Install the CCEVS vacuum hose harness moulded three-way connector on the CCEVS valve. - Connect the yellow striped hose to-the manifold vacuum tree. - Connect the red striped hose to the distributor. - Connect the solid black hose to the vacuum spark advance nipple on the left front of the carburetor base. - Tie the three hoses to the lower portion of the upper radiator hose using the strap supplied in the package. 107 ------- INTERNATIONAL HARVESTER HEAVY DUTY TRUCKS 1968 - 1974 Scout, Travelall 1979 - 1980 Pickup 900 - 1100 Pickup Metro 800A, 1100A Follow the procedures on the accompanying chart 108 ------- INTERNATIONAL HARVESTER HEAVY DUTY TRUCKS 1. PERFORM FOLLOWING ITEMS BEFORE TUNE UP b. c. d. e. f. g- h. i. J- k. 1. ra. n. Inspect all vacuum hoaea of emission system. Check air cleaner element. Check PCV valve Clean (lame arre9tor. Check heat riser valve for freeness. Check vapor storage caniEter filter. Inspect modulated air cleaner. Check drive belt tension. Check breaker points and condensor (Conv. Ign. ) . Lubricate breaker cam (Conv. Ign.). Inspect distributor cap and rotor. Torque carburetor mounting bolts. Torque manifold bolts. Check spark plugs. ENGINE 4-152, 4-196 BG-220, 241. 265 V-266. 304, 345. 392 6-232 6-258. V-400 YEAR 1968-72 79-80 1966 l%8-74 79-80 1969-72 1972-74 GAP .030" .035" .033" .030" .035" .033" .035" o. Check and record cylinder compression. 1 2 3 4 5 6 7 8 2. HOOK UP INSTRUMENTATION Scope. Timing light, Vacuum gauge. Tachometer and Dwell gauge Per Mfg. Recommendation 3. ENGINE WARM UP a. Set Choke at Fabt Idle Pou tion b. Run Engine for 5 Minutes 4. ECU FUNCTIONAL TEST CONDITIONS. High Idle Pos. a. Record RPM W/O EGIt (Temporarily Pinch or Plug Vacuum Hose) b. Record RPM W/EGR Functioning c. RPM Diffei ence NOTE. No RPM Drop - Repair EGR System per Service Procedure. 5. AIR PUMP FUNCTIONAL TEST a. Disconnect hobe(s) from air pump. b. Run engine at fast idle. c. Check for discharge of air from air pump. NOTE: No Air - Repair Air Injection System per Service Procedure. 6. IGNITION SYSI'LM 1 CS 1 S TEST SPEC a. Cranking Coil Output b. c. d. e. 20-23 KV Coil Output at 2500 Hl'M 20 KV Min! Spark Plug Var. Under Load 2 KV Max. Spark Plug Var. No Load 3-6 KV MjxT Spark Plug Firing Volts 6 1000 RPM 8-15 KV Dwell Var. 8 1000 RPM 3U Max Test ignition cable resistance only if a.b.c.d, or e is out of spec. Resistance 8,000 Ohm per ft. max. 7. CHECK DWELL ANGLE BREAKER POINT TYPE - 1968-1974 ENGINE 4-152, 4-196 BG-220, 241, 265 V-226. 304, 345. 392, 40u 6-232, 6-258 SPEC. 68-72° 28-35° 28-32° 31-34° COI tioi tin ill 8. IGNITION TIMING 1968 THRU 1979 CONDITION. Disconnect and Plug Dist. Vac. Advance Hose. Run engine at specified idle RPM. ENGINE SPEC 4-152, 4-196 BG-220. 241, 265 6-232, 6-258, V-i04 345. 392 V-266 V-400 4-196 V-304 V-345 OLD TDC 5" BTDC 1980 TDC 10° BTDC 7 1/2° BTDC NEW 2° BTDC 12° BTDC 12° BTDC 9. CURB IDLE ADJUSTMENT CONDITION. Normal Operating Temp ENGINE SPEC MANUAL AUTO ALL 700 700 10. ADJUST IDLE (CO) W/ANALYZER CONDITION Clamp off air injection hoses ENGINE SPEC'S. ALL 4-196 V-304 V-345 1968-74 1.0% 79 .3-1.5% . 1- .8% 1- .8% 80* 1.5-3.0% .4-1.0% .5-1.5% * Measured at air injection manifold 11. ADJUST IDLE (CO) W/O ANALYZER Idle Drop Method* ENGINE ALL 4-196 V-304 V-345 1968-74 40 RPM SPEC'S. 79 40 RPM 60 RPM 60 RPM 80 30 RPM 85 RPM inn ppm .IO ir I in :t!< ------- CUMMINS HEAVY DUTY TRUCKS Adjust the fuel manifold (rail) pressure according to the following table and procedure. CPL number, rated engine speed, and altitude at which the engine is used determine the correct rail pressure from the table. If the rated rail pressure is lower than that given in the table (as in the case of a derated engine) no adjustment is necessary. If the engine is older than those listed in the table, reduce the rail pressure about 3 percent for each 1000 feet above 500 feet. Engine Cubic Inert Year Maximum RsU Adjusted Raii Pressure (PSI) @ Altitude Family CPL Displacement Certified RPM Pressure (PSI)* 4000 loot 6000 foet 8000 foot 10.000 feat 091 0026 ass 1975-1982 2300 213 190 178 165 152 091 0026 655 1975-1982 2100 182 163 1S2 141 130 091 0026 655 1975-1982 1950 176 160 149 139 128 091 0026 855 1975-1982 1800 110 110 110 110 110 171 0126 903 1975-1978 2600 191 171 159 148 137 171 0126 903 1975 2400 165 164 153 142 131 171 0105 903 1975-1976 2500 123 123 123 123 123 171 0282 903 1977-1973 2600 192 172 160 149 137 171 0341 903 1978 2600 185 166 154 143 132 201 5004 378 1975-1978 3300 135 103 93 81 71 211 5003 504 1975-1978 3300 145 106 93 80 69 211 5003 504 1975-1978 3000 113 38 77 63 53 221 5005 555 1975-1982 3300 163 125 no 36 83 221 5005 555 1975-1982 3000 141 111 97 85 73 'Maximum luol mamloid prossure (rail) corresponds to ino comfiod EPA family maximum luol rate PROCEDURE: o Attach pressure gauge (PN 3375932) to the fuel pump valve outlet port. o Operate the engine until all systems reach operating temperature. Be sure all fuel passages are cleared of air. o Disconnect the vehicle throttle control linkage at the throttle lever. Move the lever clockwise against the throttle stop. o With engine running, open the throttle slightly by hand to obtain 200 to 300 rpm above normal engine idle speed. o Snap the throttle lever to the full open position (high idle) and accelerate the engine to maximum speed. continued 110 ------- CUMMINS HDT continued PROCEDURE continued o Observe and record the momentary maximum rail pressure. Repeat the procedure several times to verify the reading. (This reading is the "Snap Rail Pressure".) o On newer models, remove the ball from the end of the throttle shaft. Avoid damage to the adjusting screw. Turn the pressure adjusting screw clockwise to reduce the snap rail pressure to the value shown in the table. NOTE: Do not change the position of the throttle stop screws in the fuel pump body. (CPL number and rated rpm are shown on the engine dataplate.) o On older models, remove the throttle shaft from the fuel pump housing and change the shims in the fuel adjusting plunger to change the snap rail pressure. o Adjust the final rail pressure by changing the position of the rear throttle stop screw in the fuel pump body. Ill ------- FORD HEAVY DUTY TRUCKS Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 84 4.9L 9-77J-R12 1 New PCV Valve EV-77 (D8TZ-6A666-A) 9-78J-R00 2 Advance Timing 4° 9-77S-R10 9-78J-R11 3 (C6 AT only) Install Altitude Compensating Transmission Vacuum Diaphragm D8AZ-7A377-A Clip: D7FZ-7F006-A 4 Adjust Idle 82 4.9L 1 New PCV Valve EV-77(?) E,F Series 2 Advance Timing 4° 4 Adjust Idle E,F Series 5.8M 2 Advance Timing 4° 5.8W 1 New PCV Valve (?) 6.6M 5 Relocate Choke Rod - 4 Adjust Idle E,F,C,L Series B Series Bus 6.0L 2 Advance Timing 4° 7.0L 7.5L 1 New PCV Valve (?) 4 Adjust Idle 81 E,F Series 4.9L 1 New PCV Valve (?) 2 Advance Timing 4° 4 Adjust Idle continued 112 ------- FORD HDT continued Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 81 cont'd E,F Series 5.8M 2 Advance Timing 4° 5.8W 1 New PCV Valve (?) 6.6M 5 Relocate Choke Rod 4 Adjust Idle E,F,C,L Series B Series Bus 6.1L 2 Advance Timing 4° 7.0L 1 New PCV Valve (?) 7.5L 7.8L 4 Adjust Idle 8.8L 70-80 all 2 Advance Timing 4° 4 Adjust Idle & Fuel/Air Ratio - 113 ------- FORD HEAVY DUTY TRUCKS PROCEDURE 1: Replace PCV Valve. o Remove the existing PCV valve and give it to the customer, o Install a new PCV valve of the part number listed. PROCEDURE 2: Adjust Timing. o Setting given is an adjustment from low-altitude specifications. PROCEDURE 3: Replace Transmission Vacuum Diaphragm, o Raise vehicle. o Remove existing transmission vacuum diaphragm. o Install high-altitude transmission vacuum diaphragm of the part number listed. o Lower vehicle. PROCEDURE 4: Adjust Idle. o Adjust idle speed to low-altitude specifications. PROCEDURE 5: Relocate Choke Rod. o Remove the choke plate lever screw. o Rotate the lever on the rod and reposition it on the inboard (high- altitude) hole. o Reinstall the choke plate lever with the screw. 114 ------- GENERAL MOTORS HEAVY DUTY TRUCKS Year Model Engine Family Applicahle Procedures Replacement Part Number/ Specifications/Notes 82-84 All Gasoline 1 Advance Timing 4° 2 Adjust Idle Diesel 71N Series 3 or 4 Install Load Limiter or Replace Injectors Diesel 8-2 Fuel-Pinche Naturally aspirated Fuel- Pincher engines are to be used only at altitudes below 7500 ft. (49-state) or 5000 ft. (California). Above these altitudes, the turbo- charged Fuel Pincher must be used. 6.2L EGM06.2DAB1 DGM06.2DAB2 CGM06.2DAB3 5 Have Injection Pump Modified 4L-53T 6V-53T 6L-71T 6L-71TA 6V-71TA : 6V-72TA 8V-71TA 8V-72TA 6V-92TA 8V-92TA V8-8.2T none 81 All Gasoline 1 Advance Timing 4° 2 Adjust Idle 70-80 All Gasoline 6 Set Choke Coils 7 Reposition Choke Rod Lever 8 Set Vacuum Break(s) 1 [Cadillac, Chevrolet, 3MC only) Advance Timing 4° 2 Adjust Idle r-. 1 O r-- GMC DH 478 DH 637 9 Turn Droop Screw 115 ------- GENERAL MOTORS HEAVY DUTY TRUCKS ALTITUDE ADJUSTMENT INFORMATION MODEL YEARS 1970, 1971 AND 1972 ENCINE FAMILY IN IF.CTOR IN JF.CTOK flMINC INI EC, TOR I'AKT NO. PEAR TRAIN TIMING (a) FULL LO/ SPFI 0 RANCE LOAD LIMIT DEVICE LOCK NUT SETTING ABOVE PI.ATF INCHES NO. OF TURNS L-53N N40 1.460 5228763 Adv.Cear-Std.Cam 2800 Maximum 0.236 5-1/2 (3 & 4-53N) N45 1.460 5228773 Adv.Gear-Std.Cam 2800 Maximum 0.175 4-1/4 N50 1.460 5228783 Adv.Cear-Std.Cam 2300 Maximum 0.155 3-3/4 V-53N N40 1.460 5228763 Adv.Cear-Std.Cam 2800 Maximum 0.236 5-1/2 (6 & 8V-53N) N45 1.460 5228773 Adv.Cear-Std.Cam 2800 Maximum 0.175 4-1/4 N50 1.460 5228783 Adv.Cear-Std.Cam 2800 Maximum 0.155 3-3/4 L-71N (4V) 71NS 1.460 5228850 Standard 2100 Maximum (b) 0.155 3-1/2 (3. 4 & 6-71N) N55 1.460 5228785 Standard 2100 Maximum (b) 0.139 3-1/2 N60 1.460 5228760 Standard 2100 Maximum (b) 0.108 2-1/2 N65 1.484 5228900 Adv.Cear-Std.Cam 2100 Maximum (b) 0.082 2 N70 1.460 5228770 Adv.Cear-Std.Cam 2300 Maximum 0.104 2-1/2 V-71N (4V) 71N5 1.460 5228850 Standard 2100 Maximum (b) 0.155 3-1/2 [6. 6 & 12V-71N) N55 1.460 5228785 Standard 2100 Maximum (b) 0.139 3-1/2 N60 1.460 5228760 Standard 2100 Maximum (b) 0.108 2-1/2 N65 1.484 5228900 Adv.Gear-Std.Cam 2100 Maximum (b) 0.082 2 N70 1.460 5228770 Adv.Cear-Std .Cam 2300 Maximum 0.104 2-1/2 V-71N ( 2 V) 71N5 1.460 5228850 Standard 2100 Maximum 0.155 3-1/2 (6V-71N Coach) N55 1.460 5228785 Standard 2100 Maximum 0.139 3-1/2 N60 1.460 5228760 Standard 2100 Maximum 0.108 2-1/2 (a) Consult service manual when changing enm or gear timing. (b) 2300 RPM full load speed la permitted fur certain ei»er)>eniy vehicles. ------- GENERAL MOTORS HEAVY-DUTY TRUCKS ALTITUDE ADJUSTMENT INFORMATION MODEL YEAR 1973 (49 ¦ - STATE) I.OAI) 1. IMIf DEVICE 1 INII'( 10 K in ii noit CIAR TRAIN FUI L 1 OAD NUT SKIT INC ABOVK P ENCINE FAMILY IN ItCTOK M M UN. I'AIU' NO. I IHINC (.1) Sl'l.ll) RANGE INI III S NO. 01 Tl L-53N C40 1.460 5229340 Adv.Cear-Std.Cam 2 BOO Maximum 0.236 5-1/2 (3 & 4-53N) C45 1.460 5229345 Adv.Cear-Std.Cum 2800 Maximum 0.191 4-1/2 C50 J .460 5229350 Adv.Cea r-Sid.Cam 2800 Maximum 0.168 4 V-53N C40 1.460 5229340 Adu.Cear-Scd.Cam 2800 Maximum 0.236 5-1/2 (6 & 8V-53N) C45 1.460 5229345 Adv.Cear-Std.Cam 2800 Maximum 0.191 4-1/2 C50 1.460 5229350 Adv.Cear-Std.Cam 2800 Maximum 0.168 4 L-71N (4V) 71C5 1.484 5229352 Standard 2100 Maximum (b) 0.168 4 (3. 4 6-6-71N) C55 1.460 5229355 Standard 2100 Maximum (b) 0.150 3-1/2 C60 1.460 5229360 Standard 2100 Maximum (b) 0.117 3 C65 1.484 5229365 Adv.Cear-Std.Cam 2100 Maximum (b) 0.189 4-1/2 C70 1.484 5229370 Adv.Cear-Std.Cam 2300 Maximum 0.139 3-1/2 V-71N (4V) 71C5 1.484 5229352 Standard 2100 Maximum (b) 0.168 4 (6,84 12V-71N). C55 1.460 (c) 5229355 Standard 2100 Maximum (b) 0.150 3-1/2 C60 1.460 (c) 5229360 Standard 2100 Maximum (b) 0.117 3 C65 1.484 5229365 Adv.Cear-Std.Cam 2100 Maximum (b) 0.189 4-1/2 C70 1.484 5229370 Ad v.Cear-Std.Cam 2300 Maximum 0.139 3-1/2 V-71N (2V) 71C5 1.484 5229352 Standard 2100 Maximum 0.168 4 (6V-71N Coach) C55 1.470 5229355 Standard 2100 Maximum 0.150 3-1/2 C60 1.470 5229360 Standard 2100 Maximum 0.117 3 (a) Consult service manu.il when chniiKinK c.iin ur 1 lining. (b) 2300 RPM lull lond speed Is permit led for certain emcrKuniy vehicles. (c) 1,470 inch fur 8V-71N Coach en^lneb. ------- GENERAL MOTORS HEAVY DUTY TRUCKS ALTITUDE ADJUSTMENT INFORMATION MODEL YEARS 1974 THROUGH 1978 (49 - STATE) ENGINE FAMILY INJECTOR INJFCIOR IIMINC INII'CTOK PARI' NO. CHAR TRAII TIMINC (a) FULL LOAD SI'KI O RANGE 4L-53N 6V-53N C40 C45 C50 1.470 1.470 1.470 5229340 5229345 5229350 Adv.Cear-Std.Cam Adv.Cear-Std.Cam Ad v.Cear-Std.Cam 2800-2400 2800-2400 2800-2400 6L-71N 6V-71N 8V-71N 71C5 C55 C60 C65 C70 1.484 1.460 1.460 1.484 1.484 5229352 5229355 5229360 5229365 5229370 Standard Standard Standard Adv.Gear-Std.Cam Adv.Cear-Std.Cam 2100-1800 (b) 2100-1800 (b) 2100-1800 (b) 2100-1900 (b) 2300-1900 12V-71N 71C5 C55 C60 C65 1.484 1.460 1.460 1 .484 5229352 5229355 5229360 5229365 Standard Standard Standard Adv.Cear-Std.Cam 2100-1800 2100-1800 2100-1800 2100-1900 6V-71N (2V) 8V-71N (4V) Coach 71C5 C55 C60 1.484 1.470 1.470 5229352 5229355 5229360 Standard Standard Standard 2100-1800 2100-1800 2100-1800 6V-92 8V-92 9270 9275 9280 9285 1.460 1.460 1.460 1.460 5229170 5229380 5229180 5229400 Standard Standard Standard Standard 2100-1950 2100-1950 2100-1950 2100-2100 LOAD LIMIT DEVICE LOCK NUT SETTING ABOVE PLAfF INCHES NO. OF TURNS 0.236 5-1/2 0.191 4-1/2 0.168 4 0.168 4 0.150 3-1/2 0.117 3 0.189 4-1/2 0.139 3-1/2 0.168 4 0.150 3-1/2 0.117 3 0.189 4-1/2 0.168 4 0.150 3-1/2 0.117 3 0.270 6-1/2 0.230 5-1/2 0.200 5 0.160 4 (a) Consult service manual when changing cam or gear timing. (b) 2300 RPM full load speed Is permitted fur certain emergency vehicles. ------- GENERAL MOTORS HEAVY DUTY TRUCKS ALTITUDE ADJUSTMENT INFORMATION MODEL YEARS 1975 THROUGH 1979 (CALIFORNIA) ENGINE FAMILY IN I h CI OR IN ll ( roi< I I M I N«. IN I EC NIK I'AKr nii. CIAR IRA IN TIMINI. (.1) FULL I.OAD SI'HD RANCE LOAD LIMIT DEVICE LOCK NUT SI-TI1NC ABOVE 1*1 A11- INI.Ill b NO. or I URNS MODEL YEARS 1975-1976 6L-71N 71B5 B55 B60 B65 1.500 1.508 1.508 1. 4B4 5229550 5229555 5229560 5229565 Standard Standard Standard Adv.Cear-Std.Cam 2300-2300 2100-2100 (b) 2100-2100 (b) 2100-2100 (b) 0.231 0.186 0.163 0.142 5-1/2 4-1/2 4 3-1/2 8V-71N 71B5 B55 B60 B65 1.500 1.500 1.500 1.484 5229550 5229555 5229560 5229565 Standard Standard Standard Adv.Cear-SLd.Cam 2300-2300 2100-1950 (b) 2100-2100 (b) 2100-2100 (b) 0.231 0.186 0.163 0.142 5-1/2 4-1/2 4 3-1/2 6V-71N Coach 7B5E B55E B60E 1.500 1 .500 1.500 5229580 5229575 5229570 Standard Standard Standard 2100-2100 2100-2000 2100-2100 0.215 0.161 0.150 5 4 3-1/2 8V-71N Coach 71B5 B55 B60 1.500 1.500 1 .500 5229550 5229555 5229560 Standard Standard Standard 2100-2000 2100-1800 2100-2100 0.231 0.186 0.163 5-1/2 4-1/2 4 MODEL YEARS 1977-1979 6L-71N 71B5 B55 B60 1.500 1.508 1.508 5229550 5229555 5229560 Standard Standard Standard 2100-1800 (b) 2100-1800 (b) 2100-1800 (b) 0.231 0.186 0.163 5-1/2 4-1/2 4 (a) Consult service manual when cImiirIiik cam or f.car timing. (b) 2300 RPM full lu.nl speed Is permitted for tcrlaiii eineri'.eiicy vehicles. ------- GENERAL MOTORS HEAVY DUTY TRUCKS ALTITUDE ADJUSTMENT INFORMATION MODEL YEARS 1979 THROUGH 1984 LOAD LIMIT DEVICE LOCK IN)ECTOR INJECTOR GEAR TRAIN FULL LOAD NUT SKITING ABOVE HI ATI- ENGINE FAMILY INJECTOR IIMIN(. I'AHf NO. .TIMING (.1) SI'KI l> RANGE INCHES NO. OF TURNS 6L-71N 7E50 7E55 7E60 7E65 71B5 B55 B60 1.484 1.496 484 484 500 1.508 1.508 5229785 5229790 5229795 5229800 5229550 5229555 5229560 Standard Standard Standard Std.Cear-Adv.Cam Standard Standard Standard 2100- 2100- 2100- 2100- 2100- 2100- 2100- 1800 (b) 1800 (b) 1800 (b) 1900 (b) 1800 (b) 1800 (b) 1800 (b) 0.200 0.160 0.120 0.190 0.231 0.186 0.163 5 4 3 4-1/2 5-1/2 4-1/2 4 8V-71N 7E50 7E55 7E60 7E65 1.496 1.496 1.500 1.496 52297B5 5229790 5229795 5229800 Standard Standard Standard Adv.Cear-Std.Cam 2100-1800 (b) 2100-1800 (b) 2100-1800 (b) 2100-1900 (b) 0.200 0.160 0.120 0.190 5 4 3 4-1/2 6V-71N Coach 7E50 7E55 7E60 1.508 1.496 1.500 5229785 5229790 5229795 Standard Standard Standard 2100-1800 2100-1800 2100-1800 0.200 0.160 0.120 8V-71N Coach 8.2 Liter 7E50 7E55 7E60 1.496 1.496 1.500 52297B5 5229790 5229795 Standard Standard Standard MODEL YEAR 1980 2100-1800 2100-1800 2100-1800 0.200 0.160 0.120 Naturally aspirated 49-state 8.2 Fuel Squeezer engines can operate without modification up to 7,500 feet elevation and engines certified for use In California can operate up to 5,000 feet elevation. Above these altitudes, turbocharger 8.2 Fuel Squeezer engines should be uBed. (a) Consult service manual when changing cam or gear timing. (b) 2300 KPM full load speud Is permitted for certain emergency vehicles. ------- GENERAL MOTORS HEAVY DUTY TRUCKS PROCEDURE 1: Adjust Timing. o Settings given assume low-altitude specifications as the base condition. Given specification is maximum adjustment; use only if no detonation results. PROCEDURE 2: Adjust Idle. o Adjust idle mixture and speed to low-altitude specifications or to given alternative specifications. If the carburetor mixture screws are covered by metal plugs, do not adjust mixture. PROCEDURE 3: Install Load Limiter. o Follow the instructions Steps 1-6 in Section 14.14 of the service manual. o Set the load limit screw lock nut as in Step 7 using the attached table. The limiter can be readjusted to either improve performance or further reduce smoke. o Complete Steps 8 and 9 of the above instructions. o Caution the owner that the power output of the engine has been restricted. PROCEDURE 4: Replace Injectors. o Remove inlectors. o Install injectors of the next smaller size as shown on the attached table. o Adjust cam and gear timing, if required, as shown on the chart. PROCEDURE 5: Have Injection Pump Modified. o Remove the injection pump. Be sure to note the relationship of the timing marks on the pump and front housing. The pump must be reinstalled into this exact position. continued 121 ------- GENERAL MOTORS HDT continued PROCEDURE 5 continued o Send the pump to an ADS Service Center for the high-altitude adjustment. o Reinstall the pump into its original timing setting. If the original relationship was not retained, retime the pump. PROCEDURE 6: Set Choke Coils. NOTE: Disregard if choke is sealed or already set at the lean limit, o Set choke coils one notch leaner than specifications. PROCEDURE 7: Reposition Choke Rod. o Remove the choke plate lever screw, o Reposition the rod to the altitude hole, o Reinstall the screw. PROCEDURE 8: Set Vacuum Break(s). o Set vacuum break(s), if so equipped, to the following specifications: Angle Gage: 2° more (leaner) than specified. - Plug Gage: 0.015 inch more (leaner) than specified. PROCEDURE 9: Turn Droop Screw. o Unscrew the four bolts on the top cover of the fuel injection pump and remove it. o Turn the droop screw up to one full turn clockwise (in.), o Reinstall the cover. 122 ------- HINO HEAVY DUTY TRUCKS 1984 High altitude adjustment on all 1984 HINO engines involves re- moving the injection pump, adjusting the injection volume and timing to the following specifications, then reinstalling the pump. PROCEDURE: o Remove the splashboard (EM100E only). o Remove the engine room cover (EK100E only). o Remove the air intake pipe (EM100E only). o Remove the oil level gauge guide support, o Disconnect the lever link, o Disconnect the fuel pipe, o Disconnect the oil pipe, o Disconnect the high pressure pipe. o Remove the injection pump setting bolt. Use special tool 90819-1707 (EM100E) or 09819-3004 (H07C-B+C). o Remove the injection pump assembly. o Set up the pump on the pump tester at the following conditions: Test Condition Diesel fuel feed pressure 2.0 kg/cm^ High pressure pipe i>2 x ^6 x 600 mm Turning direction Right hand seen from drive side Diesel fuel temperature 40 - 45° C Calibration nozzle 12SD12 (BOSHCH NO.) Nozzle opening pressure 175 kg/cm^ 123 ------- HINO HDT continued PROCEDURE continued o Adjust the full load stopper so that the injection volume agrees with that in the following table: Calibration Standard Engine Model Max. Altitude (feet) Pump Speed (rpm) Injection Volume (cc/200 stroke) Injection Timing EM100E 4,000 - 5,000 1,350 18.1 ± 0.6 15° BTDC H07C-B 4,000 - 5,500 1,500 13.7 ± 0.4 17° BTDC H07C-C 4,000 - 5,500 1,500 14.1 ± 0.4 11° BTDC o Set the injection timing according to the table, o Install the injection pump assembly, o Reconnect the high pressure pipe, o Reconnect the oil pipe, o Reconnect the fuel pipe, o Reconnect the lever link. o Reinstall the oil lever gauge guide support, o Reinstall the air intake pipe (EM100E only). o Reinstall the engine room cover (EM100E only). o Reinstall the splashboard (EM100E only). 124 ------- INTERNATIONAL HARVESTER HEAVY DUTY TRUCKS Non-turbocharged Diesels: PROCEDURE 1: (All non-turbocharged diesels). o Inspect that fuel is free of water, ice, clouding, and of correct grade, o Inspect fuel filter(s) and replace if necessary. o Inspect for and correct any external leakage of fuel, oil, air, or coolant. o Check and adjust accelerator linkage with engine off. Throttle level should contact hi-idle stop when pedal is fully depressed. o Check and adjust shut-off cable with engine off to full run position. o Check and adjust low-idle rpm, high-idle rpm and no-load rpm (with engine warm) to the specification on the label on the rocker arm cover. o Check air cleaner restriction and replace element if necessary. PROCEDURE 2: (If engine performance has been poor or if there is excessive exhaust smoke). o Check and adjust timing to specifications on label. o Check injection nozzles and correct any deficiencies. o Check and correct any deficiencies in inlet vacuum and outlet transfer pump fuel pressures. o Check and adjust intake and exhaust valve tappet clearances. o Check crankca'se pressures at full load and rated rpm. Correct any deficiencies. o Check exhaust back pressures at full load and rated rpm. Correct any deficiencies. PROCEDURE 3a: (9.PL and D-190 Engines Only). o Remove the seal wire from the maximum fuel adjusting nut. o Loosen the locknut and turn the adjusting stud clockwise 1/2 turn (180°). continued 125 ------- INTERNATIONAL HARVESTER HDT continued PROCEDURE 3a continued o While holding the stud in its new position with a wrench, tighten the locknut. o Install a new seal and seal wire. PROCEDURE 3b: (DV-550 Engines Only). o Remove seal wire. o Remove torque capsule cover and gasket, o Remove end nut and lock bracket, o Loosen max fuel adjustment locknut. o Turn max fuel adjusting nut clockwise 1/2 turn (180°). o While holding the adjustment nut in its new position with a wrench, tighten the locknut. o Reinstall the lock bracket and end nut, tighten the end nut. o Reinstall the torque capsule cover and gasket. o Install a new seal wire and seal. PROCEDURE 3c: (DV-550 Engines Only). o Remove the lead seal and seal cap from max fuel stop screw, o Loosen locknut. o Turn max fuel stop screw out 1/2 turn (180° counterclockwise). o While holding the screw in its new position with a suitable rod or alien wrench, tighten the locknut. o Reinstall the locknut. o Install a new seal and seal cap. continued 126 ------- INTERNATIONAL HARVESTER HDT continued PROCEDURE 3d: (6.9LD Engines Only), o Remove the injection pump. o Have the pump recalibrated by an authorized ADS service center, IH service center, or Stanadyne Corporation facilities. o Reinstall the injection pump. PROCEDURE 4: (If engine is still under warranty). o Check high-altitude modifications, o Install new governor seals. Turbocharged Diesels: No modification required. Gasoline Powered: See chart. 127 ------- INTERNATIONAL HARVESTER HEAVY DOTY TRUCKS PROCEDURES l. A. li. c. u. L I. G. II. 1 J K. L. M. I'l HI OliM IO| l/MINC 111 MS M10IU. I1INI--UP I nspee C all vacuum liobcb of cmissiun by it cm. Check an cleaner element Cheek 11V valve Clc.ui fl.uiic aricstor. v.i|Hir storage canister filter (Calif, engines). Inspect modiilateJ air cleaner. Cheek drive I)l 11 tenbion. Uii.ck bleaker |M)intb and condensor (Cunv. Ign.). lubricate breikcr cam ((onv Ign ). Iiij|h11. dibtnluilur cap and lotot. roii|iic taiburetor mnuiling Inilts. 1 oi<|iio iicii111 o111 holts I hick spark plugs Ill^lHC Year Gap 4 I'll, 1970-71 0 030" 4-19D 1975-7B 0 015" 6 232/258 All 0 035" III) 3113 All 0 030" V- 3(11/315/392 Al 1 0.03U-0 U3S" 1IV IDI/4 l(> Al 1 0 0 30" l(l> 4110/ 15(1/501 All 0 030" V-40I/478/5I9 All 0 030" V-537 All 0 030" (Jicck .in.l ili oill iy]inder compression. 12 3 4 5 6 7 2. I link iip insikiimi.n'iai ion Scope, 11111111;:; light, Vacuum t;.nlye, 1 aclioiiieler, and lhsLll g iui;c Per Mfg Itecomiiciiilitlun l.'JU'll IV.VJC-I III' A bet ilioke at fist idle [Mbitinn 11. Itiui engine lui live niiimlc.> 4. ICR FUNCTIONAL 11 Sf CONDI HONS: lligli Iille I'os. A. Record RIM W/0 I Ul (leinpoiai ily Pinch or Plug Vacuum I lose) B. Record R1W IV/1 Git I unctloiilng C. IdII Diffeienee NOIX. No R1W Diop - Repair LCR System per Service Proce- dure . AIR IUMP nJN(TIONAl IL«?r A. Disconnect hosc(s) fioin air |iuiiip. B. Run engine Jt fust idle. C. Check foi discluuye of air from air pump. NOTE: No Air - Repair Air Injection System per Service Procedure. 6. 1GNIII0N SYSI1M II SIS ll.Si A. 1). C. 1). L. K C. Cranking Co11 Output 20-23 KV Coil Output .it 2500 RIM 20 kV Mm. Spark Plug Var. Under lxud 2 KV Mix Spaik Plug Var. No Load 3-6 KV Mix Spaik Plug linng Volts i 1000 RIN 6-15 KV Dwell Var. t 1000 Itl-M 3° Mix. lest ii;iiition cable resistance only if A, II, C, D, oi E is out of spec. Resistance 8,000 Olun |ici ft. max. 7. C1I1CK I)W1 11. ANGII Illll-AklH 11)171 IV I'L Ijih I no 4-l'J(i I1D-40(i/l50/501 0-232/258, HI)-308 V-301/315/392, V-401/478/S49 IW11 Dci;nos (.8 72° 31 31° 31-31° 28-32° Meetronic Ignition IXvell Check is Nut Normally Needed. I (INI 1 ION TIMING CONDITION Discoiuieet and Plug Hibt Vac Advance llose Run engine at speciticd idle KIT-I. 1 jit»liie Model Yeai(b) Old New 4-190 All nx- 2° 1.1 DC 6-232/25B 1970-73 iuc 2° 111 IK' 6-258 19/4 5° 111 DC 7l) UIDt HD-308,RD-40b/450/501 All S" 111 DC 7° Ull* V-30I/3I5V392* All MIL* 2°' III IIC *V-345 Non-Governed 1979 d Later 5° 111 DC 7° HIU "V-392 Non-Governed 19/S S" HI DC 7° I.IU V-401/S49, V-537 All 7" UIDT 9° 111 DC V-478 1070-71 111" HI DC 12° llll* V-478 1972-74 7° HIDC 9° llll* V-478 1975 t, Liter 12° Ull* 14° llll* HV-404 All 9" HIDC 11° llll* MV-416 All 5" HII*. 7° llll* lJ. CURD IDI i: AlllUS*!! U »I CONDI1ION Normal Opeiatmg Temp. 5 Iraiib. 1 n Ncutlal. Ijii'lne MhIc 1 Yi ir(b) Rltl 4-196 1970-71 700 4-196 1975 SMI 111)- 308, RD - 406/4 50/ 501 ,V 478/549 All 500 6-232 Al 1 700 6-258 1972-73 700 6-258 197-1 600 V-401 Al 1 600 MV-404/416, V-537 All 5M) V-30IV3ISV392* 1970-78 700 *V-304/315/392 (loadstar) 1970-71 550 V-345/392 1979 f, latei 650 10. AIUUSI' 11)1 J (CO) W/ANA1.YZI R CONDI I ION Clamp ofl jir injection hobeb Ijiijiiie Urn lei Ycar(->) Idle (0 All (i-Cylindcr Ijigmes All 2 S 3 O4. All 4-Cylindcr U V-8 Ijigines Al 1 1 0 1 s: 11. AIUUSI IDIL (CO) W/f) ANAHZI It Idle Ihop Method Ijigine All •1 - I 'JO V 31)1 V- 315 V- 315 V-392 MV-404/44H MV- HI 1/4lo V- 5 37 Hide I Yi.ir(s) 1970 71 1975 I, I iter 1077 t, 1 ii. i l')/7 I, I Hi r l'J77 t, l.iler Al I 1975-76 1*177 I, Liter l*">7s r, i it. i Speed 111 op JO" I 10 30 Ull hi) Non-Uivenii. d 110 (Oli'lllCd 40 25 50 25 i c ?M" f I tip ta Lgh ifu mi: 1. " pe =5trr oni ------- ISUZU HEAVY DUTY TRUCKS Engines with an averiod compensator on the rear of the injection pump require no modification for high-altitude operation. Use the following procedure for all others: PROCEDURE: o Remove the seal which binds the full load set bolt and locknut to the governor housing. o Loosen the locknut. o Turn the full load set bolt 1/4 turn clockwise (90°) for a turbocharged engine or 1/2 turn clockwise (180°) for a naturally aspirated engine. o While holding the bolt in place, fully tighten the locknut. o Pass wire (PN 5157292480) and seal (PN 5157292490) or equivalent'through the full load set bolt, locknut, and governor housing. Seal. 129 ------- IVECO HEAVY DUTY TRUCKS PROCEDURE: o Remove the fuel injection pump from the engine. o Install the pump on the test rig. o Adjust rack travel to reduce fuel injection delivery 1% for every 500 feet of altitude at rated speed. Be sure that the reduction in delivery is of the same order at max torque speed as at rated speed. If necessary, set the torque control spring pre-load to obtain the required delivery. o Reduce the GVW rate by 1/2 of the percent rate of fuel reduction. o Reinstall the injection pump. no ------- MITSUBISHI HEAVY DUTY TRUCKS Year Engine Family 1977-1980 6DR5 1981 BMM0243DAA3 1983 DMM0243DAA2 PROCEDURE: o Remove the injection pump. o Position the pump on a test bench with the following specifications: - Injection Nozzle: ND-DN12SD12A - Nozzle Opening Pressure: 175 kg/cm^ (2,487 psi) - High Pressure Pipe: ^2.0 x ^6.0 x 600 mm («50.079 x ^0.236 x 23.6 in.) - Fuel Feed Pressure: 2.0 kg/cm^ (28.4 psi) - Testing Fluid: No. 2-D Diesel Fuel - Testing Temperature: 40 ± 5°C (104 ± 9°F) o Adjust fuel delivery to 33 ± 1 mm^/stroke at 1100 rpm. o Reinstall the injection pump. 131 ------- PERKINS HEAVY DUTY TRUCKS No modifications are necessary for high-altitude operation of turbo- charged diesel engines. The following procedure is for naturally aspirated engines only. It should be performed by an authorized fuel pump specialist or by a Perkins distributor. PROCEDURE: o Reduce the fuel delivery rate according to the following table: Altitude m(ft.) Maximum Fuel Delivery Reduction 0 - 600 ( 0 - 2000) No change 600 - 1200 ( 2000 - 4000) 6% 1200 - 1800 ( 4000 - 6000) 12% 1800 - 2400 ( 6000 - 8000) 18% 2400 - 3000 ( 8000 - 10000) 24% 3000 - 3600 (10000 - 12000) 30% 132 ------- CUSHMAN CYCLE 1978 - 1983 Install Carburetor Modification Kit, PN 886771. Instructions are included in the kit. 133 ------- HARLEY DAVIDSON CYCLE Install the high altitude kit listed below by following the instructions included with it. Model Kit Number FLH-1200 27094-78 FX 27095-78 FXE 27095-78 FXS-1200 27095-78 XLH 27096-79 XLCH 27096-79 XLCR-1000 27096-79 FLH-80 27093-78 134 ------- LAVERDA CYCLE 1983 1000 RGS 1981 - 1982 Jota, Mirage PROCEDURE: o Turn off the engine, o Turn off both fuel tank petcocks. o Put a drain pan under the carburetor assembly, o Remove the float bowl hex nuts on one carburetor, o Remove the main jet. o Install main jet PN 62-500-322. o Remove the idle jet. o Install idle jet PN 62-500-331 o Reinstall the float bowl. o Repeat the above steps on the remaining two carburetors, o Open the fuel tank petcocks and check for leaks, o Start the engine and check for leaks. o Adjust idle CO and rpm, if necessary, to low altitude specifications. 135 ------- TRIUMPH CYCLE Replace the main jets in the carburetor with the following: / 1978, 1979: Part number 99-0446 1981, 1982, 1983: Part number 99-7599 ' 136 ------- |