Repair Procedures

1. Open the hood and install fender covers on both fenders.



2. Look for a vacuum regulator valve on the bracket on the bulkhead at the rear of the engine compartment. If the vehicle does not have the vacuum regulator valve, follow the next procedure.
NOTE: ANY VEHICLE WITH THE VACUUM REGULATOR VALVE DOES NOT NEED TO BE REPAIRED.



3. Disconnect the intake air temperature sensor connector, vacuum hoses, and remove the air cleaner assembly.

CAUTION: The following steps should be performed on a cool engine.



ENLARGING THE SECONDARY AIR NIPPLE HOLE

4. Disassemble the secondary air filter case from the air cleaner assembly and remove the secondary air filter from the case.



CAUTION: WEAR PROTECTIVE EYE SHIELDS WHEN PERFORMING THE TWO FOLLOWING OPERATIONS.

5. Enlarge the secondary air nipple hole to 3/4" by drilling. Do not allow the hole to extend to the outer diameter of the nipple. Remove the burr around the hole with a knife when drilling is completed.

CAUTION: Do not drill over 5 mm. (0.2 in.) deep.



6. Clean the secondary air filter case by using compressed air, assemble the secondary air filter into the case and reassemble the case to the air cleaner assembly.



REPLACING THE PRIMARY MAIN AIR JET

7. The primary main air jet supplies air down the primary emulsion tube and must be replaced with one of a larger size. The new jet can be identified by the number 70.



8. Using a clean shop towel, cover both bore openings of the carburetor.



9. Unscrew the primary main air jet using a small blade-type screwdriver. With a pair of needle-nose pliers or tweezers, remove the jet from the carburetor air horn.

CAUTION:
TAKE EXTREME CARE NOT TO DROP THE JET INTO THE CARBURETOR.



10. Install the new primary main air jet into the carburetor air horn, again making sure that you do not drop the jet into the carburetor. Don't forget to remove the shop towels when completed.



INSTALLATION OF CARBURETOR CHOKE SHIM CAP


11. Disengage the high altitude compensator from the clip on the firewall and move it away from the carburetor.




12. Disconnect the upper coolant hose from the carburetor choke wax element housing, and carefully move it away from the carburetor to prevent damaging the hose or spilling coolant.



13. Remove the throttle return spring bracket.



14. Using the Fast Idle Release Driver, spread the choke fast idle pinion lever away from the choke wax element housing. This will create a space between the wax element plunger and the choke adjust contact screw.



15. With the Fast Idle Release Driver still in place, install the plastic choke shim cap onto the tip of the choke adjust contact screw using the handle.
NOTE: To allow easier installation twist the choke shim cap on the installation handle to give an angle of approximately 10 degrees.









16. While holding the shim cap in place with the installation handle, remove the Fast Idle Release Driver.


17. Make sure the choke shim cap has not moved out of position and is securely on the end of the choke adjusting screw.
NOTE: THE CHOKE ADJUSTING SHIM IS NOT AVILABLE SEPERATELY. IF THE SHIM IS DAMAGED OR LOST A NEW PARTS KIT IS NECESSARY.


18. Break off the installation handle from the shim cap. Make sure the choke shim cap has not dropped down.



19. Reinstall the throttle return spring bracket, the high attitude compensator and the upper coolant hose.



CLEANING THE SUB-EGR VALVE


20. Disconnect the two vacuum hoses to the vacuum switching valve from the carburetor. Move the vacuum switching valve away from the carburetor.



21. Disconnect the sub-EGR valve linkage by pressing in on the retaining pin and spring and pulling upward on the linkage.



22. While holding up the Sub-EGR valve linkage, remove the rubber boot from the carburetor and gently pull the Sub-EGR valve from the bore in the carburetor.

CAUTION: DO NOT DAMAGE THE BOOT WHEN REMOVING IT



23. Clean the valve with carburetor cleaner. You may want to use a piece of very fine emery cloth to remove any carbon deposits. Clean the valve by twisting it on the emery cloth.

CAUTION: DO NOT CLEAN THE VALVE WITH A WIRE BRUSH OR WHEEL, AS THIS WOULD SCRATCH THE VALVE. SCRATCHES WILL ALLOW CARBON TO BUILD UP ON THE VALVE QUICKLY.



24. Spray carburetor cleaner into the Sub-EGR valve bore in the carburetor



25. Install the rubber boot onto the Sub-EGR valve. Reinstall the valve in the carburetor and reconnect the linkage.




26. While lightly operating the idle-up lever, install the rubber boot completely to the circumference groove of the Sub-EGR valve bore. Then make sure the boot has been installed correctly in place by operating the idle-up lever fully.



27. Reconnect the vacuum hoses to the carburetor.



28. Spray carburetor cleaner into the choke linkage and around the secondary main air jet.



29. Reconnect the intake air temperature sensor and vacuum hoses, and reinstall the air cleaner assembly.



RESETTING THE IGNITION TIMING

30. Make sure the engine is at operating temperature and the curb idle speed is correct.

Manual Transaxle 700 rpm
Automatic Transaxle 750 rpm



31. Connect a timing light. Loosen the distributor mounting nut and set the ignition timing to 7 Degrees BTDC.



32. Before closing the hood, you'll need to place a punch mark over the 1st digit of the serial number on the bulkhead identification plate. This will show that the campaign procedures have been completed.



33. On the authorized modifications label, you will need to write in the following information:

CHANGE AUTHORITY: "EMR-90-004"
DEALER CODE: Your 5 digit dealer code
REPAIR DATE: The date of the repair Month/Day/Year



34. Next apply the authorized modification label to the underside of the hood, close to the emissions label. This label will show the new ignition timing specification. Wipe the hood surface clean before applying the new label.


35. After completing these procedures, make sure that all fuel and coolant connections are not leaking. Check that all fasteners are tightened to the proper torque. Remove the fender covers