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
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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
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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
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Page
HEAVY DUTY TRUCKS continued
Mitsubishi 131
Perkins 132
CYCLES
Cushman 133
Harley Davidson 134
Laverda 135
Triumph 136
iv
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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
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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
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R240CM
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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
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RIMCH
°*
roioc
(A| MOSOMMO
^^-^Olttl M00 4M11I
RENAULT 10
MANUAL
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mitt
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teaaotooAO
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|A) If 01 OMOM
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o*
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RENAULT It
AUTOMATIC
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02101
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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
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RISK
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n
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MS tO
mbm
SI OARA 1
SS OARA tl
S3 OARA IS
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-
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*
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•10 R
RiniiiR 0
Riaao
n*n
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«•»» (A) 11 01 010 ISO
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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
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