Parts and Repair Procedures

1. With the car in a stall with ready access to an emissions analyzer, timing light, and tachometer, raise the hood and install fender covers.

2. With the timing light, check ignition timing - engine fully warmed up, transmission in Neutral, broke set, all accessories OFF and engine at normal curb idle speed (750 +/- 100 rpm). Adjust if necessary to 8 degrees BTDC. Recheck idle rpm and adjust to 750 rpm.

FIGURE 1:

3. Attach Authorized Modification Label to the underside of the hood in the location shown in Fig. 1.

4. Adjust the sub-EGR valve touch point as follows:

a) Slowly open the throttle and observe the engine speed at which the sub-EGR valve linkage begins to move. This is the "touch point".

FIGURE 2:

b) By turning the adjusting screw (Fig. 2), adjust the touch point to the following speed:

M/T ............ 2300 rpm A/T............. 2500 rpm

NOTE: Turn screw clockwise to decrease touch rpm, counterclockwise to increase.

5. Apply a dab of white paint or nail polish to the threads of the Sub-EGR Adjusting Screw so that further adjustment cannot be made without detection (Fig. 2).

FIGURE 3:

6. Check to see if the Mixture Adjusting Screw (MAS) seal has been removed. Fig. 3. If it has, perform an exhaust gas analysis. Adjust the MAS to bring CO to 0.5%. Recheck and adjust idle speed to 750 rpm. Install a new MAS seal.

7. Remove test equipment and shut off the engine.

8. Remove all four spark plugs.

9. Check for cracked or chipped insulators, carbon fouling, and damaged gaskets. Clean the plugs if they are serviceable. Check all electrode gaps and set to .039"-.043".

10. Reinstall or replace the spark plugs.

NOTE: If new, be sure plugs are gapped to .039"-.043".

11. Remove the air cleaner from the carburetor.

FIGURE 4:

12. Clean the air cleaner element with compressed air. Fig. 4.

FIGURE 5:

13. Clean the outside of the carburetor. Look carefully for marks of tampering or misadjustment. Check the choke valve for smooth operation. Inspect the Secondary Main Air Jet for any dirt. Fig. 5.

14. Using carburetor choke spray cleaner, clean the choke shaft and the Secondary Main Air Jet.

15. If the car has an automatic transmission, you may have to install an orifice in the secondary throttle vacuum line. Some cars already have this orifice - any car built after the VIN shown below has one.

CORDIA with P/S:
JA3BF444*DZ800967 w/o P/S:
JA3BF444*DZ800990

TREDIA with P/S:
JA3BF464*DZ801013 w/o P/S:
JA3BF464*DZ801119

FIGURE 6:

In addition, all Cordias and Tredias that have had the Performance Optimizing Program modifications should already have orifices installed.

Install the office at the point shown in Fig. 6.

FIGURE 7:

16. Inspect the choke cover attaching screws shown in Fig. 7 for evidence of tampering. If no tampering is found, go to Step 19.




17. If tampering is found, remove the carburetor from the car. Remove the choke cover and verify the position of the choke linkage shown in the illustrations on Page 8. Adjust if necessary as described.

18. Use Screw Kit MD606977 to reinstall the choke cover.

19. Clean and inspect the heads of the screws securing the float bowl cover. If you see tool marks indicating that the cover has been removed and reinstalled, go to the next step. If not, go to Step 22.

20. Remove the float bowl cover. Check the sized the main and pilot jets. Replace any that are not the same as the specifications in the table shown below.

TABLE OF JET SIZES

Part Name Size Part Number

Primary Main Jet #108.8 MD606198

Secondary Main Jet #175 MD600844

Primary Pilot Jet #56.3 MD608291

Secondary Pilot Jet #52.5 MD617154


21. Reinstall the float bowl cover.

FIGURE 8:

22. Replace the Primary Main Air Jet with a new one. See Fig. 8 for location. Loosen the jet with a 4 mm screwdriver.

NOTE: The red plastic nozzle extension from a WD-40 can is a handy tool for removing the let from the carburetor. Use the proper jet from the table below.

PRIMARY MAIN AIR JET TABLE
Old New

Cars with Manual T/M #70 - #60 (MD600116)

Cars with Auto-T/M #70 - #65 (MD606848)

FIGURE 9:

23. Remove the exhaust manifold heat protector. Check the ID number molded into the top of the exhaust manifold. Fig. 9. Take action as shown in the table below. If the manifold is cracked, replace it.



EXHAUST MANIFOLD ID TABLE

FIGURE 10:

24. Reinstall the carburetor and adjust the accelerator cable as described below. See Fig. 10.

a) Make sure the engine is at curb idle and that the choke is fully open.
b) Check accelerator cable free play. It should be 0-2 mm.
c) If not, loosen the adjusting nut and reposition the cable to obtain the desired free play of 0-2 mm.

25. Remove fender covers and prepare the vehicle for delivery to the customer.