ENGINE TUNE- UP

I. INTRODUCTION The engine tune-up has become increasingly important to the modern automotive engine with its vastly improved power and performance. With the higher compression ratios, improved electrical systems and other advances in design, today's engines have become more sensitive to usage and operating conditions, all of which have a decided effect on power and performance. In order to extract the full measure of performance and economy from your engine, it is essential that it be properly tuned at regular intervals. A regular tune-up will keep your car's engine running smoothly and will prevent the annoying breakdowns and poor performance associated with an un tuned engine. A complete tune-up should be performed at least every 12,000 miles (19,200 km) or 12 months, whichever comes first.

II. TOOLS AND MATERIALS

Service Manual Spark Plug Socket and Ratchet Dwell Meter Oil and Oil Filter Air Filter Power Timing Light Hydrometer Screwdrivers Allen Wrench Feeler Gauge

III. AUTOMOBILE ENGINE

IV. TUNE- UP
BATTERY 1. CLEAN THE BATTERY POSTS AND CLAMPS 2. CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If insufficient, refill with distilled (or purified) water. Check the specific gravity of each cell. Standard specific gravity at 20C (68F): 1.25 1.27 for 55D 23R type 1.27 1.29 for 80D 26R type If not within specifications, charge the battery. HINT: Check the indicator as shown in the illustration. 3. CHECK HYDROMETER Green Dot visible: Battery is adequately charged. Dark (Green Dot not visible): Battery must be charged. Clear or Light Yellow: Replace battery. HINT: There is no need to add water during the entire service life of the battery. HIGHTENSION CORDS INSPECTION 1. DISCONNECT HIGHTENSION CORDS FROMSPARK PLUGS Disconnect the high tension cords at the rubber boot. Do not pull on the curds. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. REMOVE DISTRIBUTOR CAP WITH HIGHTENSION CORDS 3. INSPECT HIGHTENSION CORD TERMINALS Check the terminals for corrosion, breaks or distortion. Replace cords as required. 4. INSPECT HIGHTENSION CORD RESISTANCE Using an ohmmeter, measure the resistance without disconnecting the distributor cap. Maximum resistance: 25 Kilo ohms per cord If the resistance is greater than maximum, check the terminals. If any defect has been found, replace the high tension cord and/or distributor cap. 5. REINSTALL DISTRIBUTOR CAP AND HIGHTENSION CORDS 6. RECONNECT HIGHTENSION CORDS TO SPARK PLUGS SPARK PLUGS 1. DISCONNECT HIGHTENSION CORDS FROM SPARK PLUGS Disconnect the high tension cords at the rubber boot. Do not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. REMOVE SPARK PLUGS Using a spark plug wrench, remove the spark plugs. 3. CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush, clean the spark plug. 4. VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear, thread damage and insulator damage. If abnormal, replace the spark plug. 5. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) 6. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the six spark plugs. 7. RECONNECT HIGHTENSION CORDS TO SPARK PLUGS

DRIVE BELT 1. Check for: Cracks, deterioration, stretching or wear Adherence, oil or grease. Improper belt to pulley contact 2. Replace belt 3. Adjust belt ENGINE OIL 1. Check oil level The oil level should be between the L and F marks. If low, check for leakage and add oil up to the F mark. 2. Check oil quality Deterioration Entry of water Discoloration or thinning 3. Replace oil filter Remove oil filter with SST. Install a new filter and tighten it firmly Start engine and check for oil leakage Stop engine and recheck the oil level 4. Replace oil COOLING SYSTEM 1. Check coolant level - If low, fill reservoir to Full Line Check coolant quality Check for: Coolant cleanliness Rust or scale deposits around the radiator cap and filler neck. Entry of oil 2. Check cooling system parts. Check for: Damaged or deteriorated radiator and water hoses. Loose hose clamps Damaged or corroded radiator core. Leakage from water pump, radiator core or loose water drain cock. Faulty operation of radiator cap. - inspect the spring tension and seating condition of radiator cap vacuum valves. If the valve opens at a pressure below specification or is otherwise defective, replace the radiator cap. Valve opening pressure: STD 0.75- 1.05 kg/cm2 (10.7- 14.9 psi) Limit 0.6 kg/cm2 (8.5 psi) AIR CLEANER A. Oil Bath Type Air Cleaner 1. Clean Element Remove the air cleaner cap and element. Wash the element and case with kerosene and dry them thoroughly. 2. Install Air cleaner Refill the case up to the indicated level with clean engine oil. Saturate the element with clean engine oil.

 Install the cap and element. Tighten the air cleaner on the air cleaner support. B. Paper Element Type Air Cleaner 1. Clean Element Remove the air cleaner. Remove the element and blow compressed air from the inside. Replace the element with a new one if torn or excessively dirty. 2. Visual Check Check for: Damaged, worn or deteriorated gaskets. , Damaged or worn seal washer. 3. Install Air Cleaner Install the gaskets. Finger tighten the front and rear stays. After installing the element tighten the air cleaner cap with clips. Tighten the wing nut and both stays. CARBURETOR AUTOMATIC CHOKE 1. Check the valve operation by pushing down the valve with your finger and releasing it. The valve should return quickly and smoothly. 2. Warm- up the engine. 3. Shortly after, check the choke valve begins to open and the choke housing is heated. 4. Check the engine starting and running condition. If necessary, adjust the automatic choke setting by turning the coil housing Note: If mixture is too rich--- turn clockwise. If too lean--- turn counterclockwise. IDLE SPEED ADJUSTMENTS 1. Check the following items beforehand. Air Cleaner installed Normal operating coolant temperature Choke fully open All accessories switched off All vacuum lines connected Ignition timing set correctly Transmission in N range Fuel level should be about even with the correct level in the sight glass. 2. Break the idle limiter cap on the idle speed adjusting screw, if installed. 3. Adjust the idle speed by turning the idle speed screw. 4. Install a new limiter cap on the idle speed adjusting screw, if one was installed. Note: For the idle mixture adjustment, the idle mixture adjusting screw is adjusted and plugges with s steel plug by the manufacturer. DISTRIBUTOR Check Distributor cap Check the distributor cap and check the cap and rotor for: 1. Cracks, damage, corrosion, burning or dirty cord hole. 2. Burnt electrode terminal. 3. Weak center piece spring action. Adjust Gap

1. Adjust the air gap. (Breaker points less type) Air gap: 0.2- 0.4 mm (0.008- 0.016 in. ) 2. Adjust the rubbing block gap and damping spring gap. (Breaker points type) Rubbing block gap: 0.45 mm (0.0177 in.) Damping spring gap: 0.1- 0.4 mm (0.004- 0.016 in.) Check vacuum advancer operation Apply vacuum to the diaphragm and check that the vacuum advancer moves in accordance with the vacuum. Ignition timing adjustment 1. Check Dwell angle (Breaker points type) Using a dwell angle tester, check the dwell angle at idle speed before adjusting the ignition timing. Dwell angle: 52o If the angle does not meet the specification, adjust the rubbing block gap as follows. More than 53o ----------Decrease the gap Less than 51o--------------------- Increase the gap 2. Check Ignition timing Connect a tachometer and timing light. Warm-up the engine Disconnect the vacuum hoses from the distributor and plug the ends of them. Check ignition timing with the engine idling. Ignition timing: 21R, 21R-C(Sweden) 8o BTDC/ Max. 600rpm(M/T) 21R- C(Australia) 5o BTDC/ Max. 600rpm(M/T) 5o BTDC/ Max. 650rpm(A/T) 22R 8o BTDC/ Max. 950rpm(M/T) If necessary, loosen the distributor set bolt and turn the distributor to align the timing marks. Recheck the ignition timing after tightening the distributor. COMPRESSION PRESSURE 1. Warm- up the engine. 2. Remove all spark plugs. 3. Disconnect the high tension cord from the ignition coil to cutoff the secondary circuit. 4. Insert a compression gauge into the spark plug hole and fully open the throttle valve. While cranking the engine, measure the compression pressure. Compression pressure: STD Limit 21R 21R & 21R-C More than 11.0 kg/cm2(157 psi) 9.0 kg/cm2(128 psi) 21R-C 22R 2 More than 11.5 kg/cm (164 psi) 10.0 kg/cm2(142psi) 22R Difference between each cylinder: 1.0 g/cm2(14 psi) 2 More than 12.0 kg/cm (171 psi)