EM-20 ENGINE MECHANICAL - Engine Tune-up

ADJUSTMENT OF VALVE CLEARANCE

HINT: Adjust the valve clearance while the engine is cold.

(2L-T)
REMOVE AIR CLEANER

(w/ Intake Pipe)

REMOVE INTAKE PIPE

REMOVE CYLINDER HEAD COVER

(See step 16 on page EM-38)
SET NO. 1 CYLINDER TO TDCICOMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its
groove with the timing pointer.
(b) Check that the valve lifters on the No. 1 cylinder are
loose and valve lifters on the No. 4 cylinder are tight.
If not, turn the crankshaft one revolution (360") and align
the mark as above.

ADJUST VALVE CLEARANCE

No. 1 No. 3
EX EX (a) Check only the valves indicated in the illustration.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the valve clearance measurements which
are out of specification. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.20 - 0.30 mm (0.008 - 0.012 in.)
Exhaust 0.40 - 0.50 mm (0.016 - 0.020 in.)
(b) Turn the crankshaft one revolution (360°), and align
No. 2 No. 4 the mark as above (See procedure step 4).
EX EX
(c) Check only the valves indicated in the illustration.
Measure the valve clearance.
(See procedure step (a))

(d) Remove the adjusting shim.

Turn the crankshaft to position the cam lobe of
the camshaft on the adjusting valve upward.
Using SST, press down the valve lifter.
SST 09248-64010
HINT: Before pressing down the valve lifter, position the
notch on the exhaust manifold side.

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 ENGINE MECHANICAL - Engine Tune-up EM-21

Remove the adjusting shim with small screwdriver *

and magnetic finger.

(e) Determine the replacement adjusting shim size by

using following the formula or charts:
0 Using a micrometer, measure the thickness of the
shim which was removed.
Calculate the thickness of the new shim so the
valve clearance comes within specified value.
T . . . . . . Thickness of used shim
A . . . . . . Measured valve clearance
N. . . . . . Thickness of new shim
Intake side: N = T + (A - 0.25 mm (0.010 in.))
Exhaust side: N = T + (A - 0.45 mm (0.018 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated values.
HINT: Shims are available in seventeen sizes in incre-
ments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984
in.) to 3.300 mm (0.1299 in.).

(f) Install a new adjusting shim.

Place a new adjusting shim on the valve lifter.
RemoveSST.
SST 09248-64010
(g) Recheck the valve clearance.

6. REINSTALL CYLINDER HEAD COVER

(See step 4 on page EM-43)
7. (wl Intake Pipe)
REINSTALL INTAKE PIPE

8. (2L-T)
REINSTALL AIR CLEANER

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 EM-22 ENGINE MECHANICAL - Engine Tune-up

Adjusting Shim Selection Using Chart

INTAKE

New shim thickness rnrn (in.)

I Shim
No. / Thickness 1 Shim
1 Thickness I

Intake valve clearance (Cold):

0.20 - 0.30 mm (0.008 - 0.012 in.)
EXAMPLE: The 2.80.0 rnrn (0.1 102 in.) shim i s installed
and the measured clearance is 0.350 rnrn (0.0138 in.).
Replace the 2.800 rnrn (0.1102 in.) shim with a No. 21
shim.

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 ENGINE MECHANICAL - Engine Tune-up EM-23

Adjusting Shim Selection Using Chart

EXHAUST

Exhaust valve clearance:

0.40 - 0.50 rnm (0.016 - 0.020 in.)
EXAMPLE: The 2.800 mm (0.1 102 in.) shim i s installed
and the measured clearance is 0.350 mm (0.0138 in.).
Replace the 2.800 mm (0.1 102 in.) shim with a No. 11
shim.

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 EM-24 ENGINE MECHANICAL - Encline Tune-up

INSPECTION AND ADJUSTMENT OF INJECTION

TIMING (2L-T Austria)
CHECK INJECTION TIMING
Using a mirror, check that the mark on the belt case and
the center mark on the pump flange are correctly aligned
with the amount of overlap as shown.

Flange
R1167

ADJUST INJECTION TIMING

(a) Loosen the following bolts and nuts:
(1) Two bolts holding injection pump to injection
pump stay.
(2) Two nuts holding injection pump to timing belt
case.
HINT: Do not loosen the union nuts of injection pump
more than 114 of a turn.

(b) Slightly tilt the injection pump body and align the
belt case mark with the center mark on the pump
flange to the correct overlap dimension.

(c) Tighten the following bolts and nuts:

(1) Two nuts holding injection pump to timing belt
case.
Torque: 210 kg-cm (15 ft-lb, 21 N-m)
(2) Two bolts holding injection pump to injection
pump stay.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)

START ENGINE AND CHECK FOR LEAKS

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 ENGINE MECHANICAL - Engine Tune-up EM-25

ADJUSTMENT OF INJECTION TIMING

(Others)
1. INSTALL SST AND DIAL INDICATOR
(a) Remove the plug bolt and gasket from the distribu-
tive head plug of the injection pump.
(b) Install SST (plunger stroke measuring tool) and a dial
indicator to the plug bolt hole of distributive head
plug.
SST 09275-54010

SET NO. 1 OR NO. 4 CYLINDER TO 25" OR MORE

BTDCICOMPRESSION
Turn the crankshaft pulley clockwise so the pulley groove
is 25" or more from the timing pointer.

(2L-T)
RELEASE ACSD ADVANCE
(a) Using a screwdriver, turn the cold starting lever
counterclockwise approx. 20".
(b) Put a metal plate (thickness of 8.5 - 10 mm (0.335
- 0.394 in.)) between the cold starting lever and
thermo wax plunger.

ADJUST INJECTION TIMING

(a) Set the dial indicator a t 0 mm ( 0 in.).
(b) Recheck to see that the dial indicator remains a t 0
mm (0 in.) while slightly rotating the crankshaft
pulley clockwise or counterclockwise.

(c) Slowly rotate the crankshaft pulley clockwise until

pulley groove is aligned with the timing pointer.
(d) Measure the plunger stroke.
Plunger stroke:
2L-T 0.54 - 0.66 mm (0.0213 - 0.0260 in.)
3L -
0.84 0.96 mm (0.0331 - 0.0378 in.)

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 EM-26 ENGINE MECHANICAL - Engine Tune-up

(el Loosen the following bolts and nuts:

(1) Four union nuts of injection pipes a t injection
pump side.
(2) Two bolts holding injection pump to injection
pump stay.
(3) Two nuts holding injection pump to timing belt
case.
HINT: Do not loosen the union nuts of injection pump
more than 114 of a turn.

(f) Adjust plunger stroke by slightly tilting the injection

pump body.
If the stroke is less than specified, tilt the pump toward
the engine.
I f the stroke i s greater than specified, tilt the pump away
from the engine.

(g) Tighten the following bolts and nuts:

(1) Two nuts holding injection pump to timing belt
case.
Torque: 210 kg-cm (15 ft-lb, 21 N-m)
8 Recheck the plunger stroke.
(2) Two bolts holding injection pump to injection
pump stay.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)
(3) Four union nuts of injection pipes.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)

(2L-T)
REMOVE METAL PLATE

REMOVE SST AND DIAL INDICATOR

(a) Remove SST and the dial indicator.
SST 09275-54010
(b) Install a new gasket and the plug bolt of the distribu-
tive head plug.
Torque: 170 kg-cm (12 ft-lb, 17 N-m)

START ENGINE AND CHECK FOR LEAKS

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 ENGlNE MECHANICAL - Engine T u n e U ~ EM-27

ADJUSTMENT OF IDLE SPEED AND MAXIMUM *

SPEED
1. INITIAL CONDITIONS
(a) Engine a t normal operating temperature
(b) Air cleaner installed
(c) All accessories switched OFF
(d) All vacuum lines properly connected
(e) Valve clearance set correctly
(f) Injection timing set correctly
(g) Transmission in neutral range

2. CONNECT TACHOMETER

3. ADJUST IDLE SPEED

(a) Check that the adjusting lever touches the idle speed
adjusting screw when the accelerator pedal is released.
f not, adjust the accelerator linkage.

b) Start the engine.

(c) Check the idle speed.
Idle speed: 2L-T 700 - 800 rpm
3L 650 - 750 rpm
(d) Adjust the idle speed.
Disconnect the accelerator linkage.
Loosen the lock nut of the idle speed adjusting
screw.
Adjust the idle speed by turning the IDLE SPEED
ADJUSTING SCREW.
Idle speed : 2 L-T 750 rpm
3L 700 rpm
Securely tighten the lock nut, and recheck the idle
speed.
Reconnect the accelerator linkage.
After adjustment, adjust the accelerator linkage.

4. ADJUST MAXIMUM SPEED

(a) Check that the adjusting lever touches the maximum
speed adjusting screw when the accelerator pedal i s
depressed all the way.
I f not, adjust the accelerator linkage.
(b) Start the engine.
(c) Depress the accelerator pedal all the way.

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 EM-28 ENGINE MECHANICAL - Engine Tune-up

(d) Check the maximum speed.

Maximum speed:
2 L-T 4,700 - 4,900 rpm
3L (Hong Kong, Singapore and Malaysia)
4,300- 4,500 rprn
3L (Others) 4,500 - 4,700 rprn
(e) Adjust the maximum speed.
Disconnect the accelerator linkage.
Cut out the seal wire of the maximum speed ad-
justing screw.
(2L-T and w/ HAC)
Using SST, loosen the lock nut of the maximum
speed adjusting screw.
SST 09275-54020
(W/O HAC)
Loosen the lock nut of the maximum speed adjust-
ing screw.

Adjust the maximum speed by turning the MAXI-

MUM SPEED ADJUSTING SCREW.
Maximum speed:
2 L-T 4,800 rpm
3L (Hong Kong, Singapore and Malaysia)
4,400 rprn
3 L (Others) 4,600 rprn
HINT: Adjust a t idle speed. Then, raise engine speed
and recheck the maximum speed.
(2L-T and w/ HAC)
Using SST, securely tighten the lock nut.
SST 09275-54020
(W/O HAC)
Securely tighten the lock nut.
Recheck the maximum speed.
Reconnect the accelerator linkage.
After adjustment, adjust the accelerator linkage.
Seal the maximum speed adjusting screw with a
new seal wire.

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 ENGINE MECHANICAL - Engine Tune-up

ADJUSTMENT OF AIR CONDITIONER IDLE-UP

SETTING SPEED
INITIAL CONDITIONS
(a) Engine a t normal operating temperature
(b) Air cleaner installed
(c) All vacuum lines properly connected
(d) Valve clearance set correctly
(e) Injection timing set correctly
(f) Transmission in neutral range
(g) Idle speed set correctly

CONNECT TACHOMETER

ADJUST AIR CONDITIONER IDLE-UP SETTING

SPEED
(a) Start the engine.
(b) AICswitchesON.

-/
(c) Disconnect the vacuum hose from the idle-up actua-
Vacuum EM8169 tor.
(d) Apply vacuum to the idle-up actuator.
(e) Race the engine to 2,500 rpm for a few seconds,
release the throttle and check the idle-up setting
speed.
A/C idle-up setting speed : 950 rprn

(f) Adjust the idle-up setting speed by turning the IDLE-

Type A
Idle-Up Setting UP SETTING SPEED ADJUSTING SCREW.
Speed Adjusting (g) Race the engine to 2,500 rpm for a few seconds, re-
lease the throttle and recheck the AIC idle-up setting
speed.
(h) Reconnect the vacuum hose to the idle-up actuator.

FMR7M

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 EM-30 ENGINE MECHANICAL - Intake Venturi System (LN 2L-T only)

INTAKE VENTURI SYSTEM

(LN 2L-T only)
ON-VEHICLE INSPECTION
NOTICE: Always stop the engine when installing or re-
moving the vacuum gauges, or removing the vacuum hoses.

(Austria)
PREPARATION
Using two 3-way connectors, connect two vacuum gauges
to hoses between the actuator and VSV.

CHECK THROTTLE VALVE (LOW ALTITUDE AREA)

HINT: Perform this check a t an altitude below 800 m
(2,600 ft) and a t an atmospheric pressure above 700
mm Hg (94.5 kg/cm2).
Start the engine and check that vacuum operates on
diaphragm chamber B so that the rods are pulled up.
Check that when the accelerator pedal is depressed,
atmospheric air operates on both diaphragm cham-
bers so that the rods return.

Check that when the starter switch is turned OFF

(engine stopped) from idling condition, vacuum
operates on both diaphragm chambers so that the
rods are pulled up.
Check that after the starter switch i s turned OFF, the
rods gradually return.

CHECK THROTTLE VALVE (HIGH ALTITUDE AREA)

HINT: Perform this check a t an altitude above 800 m
(2,600 ft) and a t an atmospheric pressure below 690
mm Hg (93.2 kg/cm2).
Check that during idling or with the starter switch OFF
(engine stopped), vacuum i s not operating on either
diaphragm chamber.

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