Operations After Installing Engine

TRANSMISSION LINKAGE ADJUSTMENTS

Linkage Adjustment, Manual Trans.:

Manual Transmission:

1. Adjust reversing lock clamp:
- Engage 1st gear.
- Adjust clearance between clamp and gear lever. The clearance must be 0.5-1.5 mm (0.020-0.059 in), measured with a feeler gauge.
- Tighten fastening screws.
2. Also check clearance in 2nd gear.
3. Install rubber gaiter (boot).

Linkage Adjustment, Automatic Trans.:

Automatic Transmissions:

1. Check-adjust gear selector.
step 1. Check that clearance from position D to stop = position 2 to stop.
step 2. Adjust gear selector rod length if necessary.
- Rough adjustment, use adjuster at rear of selector rod.
- Fine adjustment, use sleeve (max. visible thread = 35 mm (1.4 in).

NOTE: Extending rod decreases position D clearance and increases position 2 clearance.

2. After adjustment, move selector lever to position 1 and then to P. Repeat the check according to step 1.

ENGINE CHECKS & ADJUSTMENTS:

Engine Fluid Levels:

1. Fill engine with oil and coolant.
- Engine oil volume 3.85 liters (4.1 US qts) (incl. oil filter).
- The cooling system holds 9.5 liters (10.0 US qts) (manual transmission) and 9.3 liters (9.8 US qts) (automatic transmission). Set heater control to MAX when adding coolant.

2. Vehicles with automatic transmission, check oil level, top up if necessary.

NOTE: The engine must be running and the gear selector must be in position N or P.

Check For Fluid Leakage:

3. Run engine to operating temperature:
- Check for oil and coolant leakages.
- Refill coolant as required.

Throttle Control Linkage Adjustments:

Throttle Control Linkage:

1. Remove link rod from throttle control pulley.
2. Loosen throttle control switch:
- Loosen screw (inhex 3 mm).
- Turn switch clockwise

Throttle Valve Adjustment:

3. Adjust throttle valve:
- Loosen adjustment screw lock nut (8 mm wrench).
- Loosen adjustment screw until throttle valve completely closes.
- Tighten screw until it just touches throttle valve lever.
- Tighten screw additionally 1/4 turn.
- Tighten lock nut.
4. Check that throttle valve moves easily and does not bind.

Throttle Valve Switch Adjustment:

5. Adjust throttle valve switch:
- Turn switch counter-clockwise to stop, but not so far that throttle valve begins to move.
- Tighten screws.
6. Check adjustment. A "click" (idle switch opens) should be heard immediately when throttle valve moves.

Throttle Cable Adjustment:

7. Check throttle control pulley.
- Pulley should move easily without binding.
8. Adjust throttle cable:
- Cable should be stretched but should not influence pulley position. Pulley should touch idle stop.
- Depress accelerator pedal to floor and check that throttle control pulley touches full throttle stop.

Kick-Down Cable Adjustment (Automatic Trans):

9. Check/adjust kick-down cable (automatic transmission):
- Stretch the kickdown cable while leaving the throttle closed.
- Release the cable from the stretched position and let it snap back to rest, while listening for a metallic clunk from the transmission.
- Using the sheath adjustment tighten the cable until the clunk ceases.
- Slacken the adjustment until clunk just returns.

Throttle Control Link Rod Adjustment:

10. Connect and adjust link rod:
- Position a 1 mm (0.040 in) thick feeler gauge between throttle control pulley and idle stop.
- Adjust link rod so clearance between throttle valve lever and adjustment screw is 0.1 mm (0.004 in).

Final Engine Checks

Check & Adjust Timing & CO:

1. Check/adjust:
- ignition timing
- idle speed and CO.

2. After driving approx. 1000 km (600 miles):
- Tension timing belt.
- If valve system has been repaired, valve clearance should be checked/adjusted.