18R-G ENGINE TUNE-UP

Page
18R-G ENGINE TUNE-UP
ENGINE OIL
COOLING SYSTEM
DRIVE BEL’
AIR CLEANER
BATTERY ................................................................,.3-7
SPARK
HIGH TENSION CORD ......................................... ..3-a
DISTRIBUTOR
NO. 2 CHAIN TENSIONER ..................................... 3-11
VALVE TIMING....................... ...............................................J-11
VALVE CLEARANCE
CARBURETOR......................................................... 3-22
THROTTLE LINK I INITIAL IDLE SPEED)................,..,.3 24
BEST IDLE
CO CONCENTRATION ............................................,. 3-28
ENGINE CONDITION
COM PRESSION
3-2 18R-G ENGIN E TUNE-UP — 18R G £ngine Tune up Item

18R-G ENGINE TUNE-UP IYEM

ENGINE OIL Oil levgl ch8ck ”Fum” line

Oil r•pi•nisxmenț API ›erxi«a SE cia if icetion
Oil capacity Total 4.7 liter 5.0 US qt. 4.1 tmp.qt.
Crankcaae 4.Z liter 4.4 US qt. 3.8 Imp.qt.
Quality check
Oil filter replecewnt SST [09228 10]
2 Cooling SYSTEM Cœlant Iesel cheek “FaII” line

Coolant capacity lw/haater) 9.1 liter 9.6 US qt. 8.0 Impst.

DRIVE BE LT Ten$ÎQn Fan - Alterrotor 8 - 12 m/ 0.31 - 0.47 in

Ctankshaft J6 - 19 mm 0.63 — 0.75 in

AIR CLEAN ER
BATTERY J.2S — 1.27 at 20 C 68”F

SPARK PLUG Vitual check

f'lug gap 0.9 - 1.0 mm 0.035 — 0.D3S in

HjGH TENSIOM COI3D Hesirtance
DtSTRI8UTOR Distrib utor cep
Point 94p 0.4ô mm
Dwe\T angle

at Enq\ne stog 5ᵉ BTDC

Coolant 60’C baIo•
Cool+ct 60°C ebo•e
Governor opereiioiæl
Vecuum operational
NO.2 CHAIN TENSIONER
10 VA LVE TIMING
11
20º BTDC (Referenœ only)
S° BTDC/1000 rprr
0.5 — 1.0 mm at 3 — 5 k4
SSï 105248-27010)
0.26 — 0.32 mm 0.0J0 — 0.013 in
OU - 0.37 mm 0.012 — 0.Org in
 18R-G ENG I NE TUNE-UP — \8R G Engine June up Item 3»3

ITEM REMARK

12 CARBURETOR Float lerel g5T [Og240 27010]

16 - 18 mm 0.63 - 0.71 in
ACCELERATION PUMP Fuel di+eherging time 0.8 — 1.1 tacond
fuel injection direction
Starter wire gO° fat royalty disc)
Thrott Ie delve full opon
WARM UP ENGINE
13 THROTT LE LINK 1000 - 50 rem
(INITIAL IDLE SPEED) Wnifeld vacuum 330 mm Hg
Vacuum difference below 10 mm H9 0.39 in I-it
14 BEST IDLE ADJUSTMENT
Scraw owt 1h tu rn
1000 +. 50 rpm
Manifold vacuum abose 330 rim Hg 13.00 in 7-tg
1s CO CONCGNTRATION 0.5-0.9 @
16
17 COMPRESSION PRESSURE Standard 13.0 kg/cm' 184.6 psi
Limit 10.0 kg/cm 2 142.0 psi
Difference of prassura
between cyIir›dets Lass than 1.0 kg/cm' 14.2 pri
18R-G ENGINE TUNE-UP — Engine Oi\

ENGINE OIL
LEVGL CHECK and REPLENISHMENT
Oil level should be up to the F line on the level
gaoge. II low. add oil up to the F I ine.
Ue API arvioe SE ctassificaiion engi»e oil.

OUALITY CHECK
PUI I out the oil level gBuge md examir+e the oil
adhering on the graJueta:I pen, The oil should
not be d‹scoIored or Gin.

OIL FILTER REPLACEMENT

I Remove the oil filter by using SST
f00228 340\0] .
2. For installation, t?gh\eo firmly the gif
fiIter by hand,

After star ting che engine. check for oil leak

and recheck ‹he oil level
Fig. 3-5 COOLING SYSTEM
COOLANT LEVEL CHECK nd
REPLENISHMENT
If c‹x•Iwt is low, fill reservoir Bank up to ”Full"
line.

COOLANT QUALITY CHECK

There should not be any excessive deposit of
rust c< scales around the radiator cap or radiaQr
filler hole, arid the cgolaat should also be free
from oil. Replace the coolat if exassively
dirty,

INSPECTION of COOLING SY3TEM

PARTS
There should be no defecs such as listed below
1. Damage, deterioration, or loose rlamps in
rwJiator hoses, water hoses
2. Leakage due to cor rgsicin or damage in
r«Iiator core.
3. Leakage due to loose wajer drain cock.
4. Leakage from water pump.

5. Faulty operation of rad ia‹or c .

Inspecc ‹be r@iator cap pressure regulating aud
vacuum valves for spring tension md seating
condition. I f the valve oeens at a pressure leve[
beta the specified value or is otherwise de
festive, rgplae the radiator cap,
Veka openix0 presume limit
3—6 18R.G ENGiNG TUNE-UP — Drive Belt, Air Clegner

DRIVE BELT
VISUAL CHECK
Tt›ere should bB no defects such as Tistqd below:
1. Cracked. deter iorated, svetched. or when
belt.
2. Adherence of oil or grease.

3. Improper of bolt Bgsinst the

GOOD put ley.

Fig. 11 TENStON CHECK and ADJUSTMENT

When the belt is pressed dcsvn with t 0 kg (72 Ib)
forœ, the belt diould deflect the specified

AIR CLEANER
ELGMGNT CLEANING
i. lu removing ne air cleaner or elemen t. and
after removal. use cae not to droe dirt
and dust do•am into the carburetor.
2. In cleening the element, blow air from the
inner side,
3. lu case lhe element ix tom or escessively
dirtY, replace with ng une.
18R-G ENGINE TUNE-UP — Battery, k Plug 3—7

BATT ERY
vlSUAL CHECK
II very dirty. remove and clean before check ing.
There would be no defects such as listgd beta:
1. Rusted batiery mounting hardware.
2. Oamqje or leakage in bat very.
3. Lcose connection, rusting, decerioration or
corrosion of battery Terminals.

SPECIFIC GRAVITY MEASUREMENT

Hold the hydromeler so that the float will no1
contact against the cylinder call andreed tone
graduation.
Spec?ic gravity 1.D-].27
M 20°C(68’F}

ELECTROLYTE LEVEL CHECK and

REPLENISHMENT
The electrolyte level should be up to 1he upper
level. I f low. add distilled water for purified

SPARK PLUG
VISUAL CHEC K
Cendi tion is g£fctd if none of che following
defects are present
\. Cracks or damages in the threads or
inwlator.
2. Wear on the electrodes.
3. Damaged or deteriorated gaskets.
4. Burnt condition of electrode arid unde
sirable carbon deposit.
 18R-G ENGIN E TUNE-UP — High Tension Cord

CLEANING
1, Do no t use spar k p Iug c leaner Ionger than
necessary.
2, Blow off cleaning comeor nd and carbon
on the threads thoroughly with air.
0, Clean off Oin from the or ter Sur face of
insulator and threats.

GAP ADJUSTMENT
Check the plc g gap with plug gap gauge. I f not
to specified value, adjust by bending the qrou nd
Router[ electrode.
f•lug gap

HIGH TENSIOFI CORD

W e ‘pulirig out the st›erk plug cord from d›e
plug. always grip the end & plug cord.

Fig. 3•20
 18R-G ENGINE TUN£-UP — Distributor

Fig. 3-2J DISTRIBUTOR

— CAP INSPECTION
Clean the di$nibutof cap and insper{ the oqp
0 irty, Corrosion, BuYnirI•g and rotor for:
i, Crac ks. damage. dirty cord hole, cor rosion,
burning,
2. Gunter g iece spring acliori.
3, Burnt elect rode ier m inal.

POINT GAP ADJUSTMENT

I, I \ the points are excessively burn1 or
pitted , replace the breaker poin js.
2. Adjusl point gap,
Ppint qsp 0.dfi mm IO.018 in)

DWELL ANGLE
Check if dwell angle is within the specified Value.
Dwell angle b0--64”

Within 3s fat Idling to 2000 elm)

IGNITION TIMING
INSPECTION
Sei the engine revolution at idle speed, the
octane seisctor must be set at standard pos' tion.
Ipitior+ sizing
at Enpne Stop 6”BTDC
TOC Coolant 6o’C balow 20°BTDC fRefere•i-

Coolant 60”C above 5’BTDC/l000rpm

3-10 18R-G ENGINE TUNE-UP —

ADJUSTS\4ENT
Align rfie \itning mar ks Ly t ur ning disiribu tor
body.
Ignition tim ing
Coobnt abow ¥0”C

20”B3'DC (Raferenm onty)

GOVERNOR OPERATIONAL
INSPECTION
1. Rgtor should return quick Iy when turned
clockwise bv fiar›d ar›d released.
2. Rotor should not be ex ce$sively loose.

3. Start the engine and disconneci the vacu

um FO$e from the disk ibuior. The timing
mark should vary in accordance with the
opening end closing of ihrottle valve.

VACUUM ADVANCE OPERATIONAL

INSPECTION
Connect the distributor vacuum hose.
The octane selector shguld vary in accordance
with the opening and closing of throtile valve.

Ociince 5eiecie
 ‘J8R G GNGIN E TUNE-UP — No.2 Chein Tensioner. Valve Timing 3—11

NO.2 CHAIN TENSIONER

CHECK THE BACK STROKE
Press d ow n the pt unger wi th 3— Skg 16. 6— 11.OIb)
force arid measure the st roke.
Sttoke 0.5—1.Omm (0.02--0,04in l

Fig. 3 ADJUSTMENT
1. Loom the lock nut.
2. Press the plunger with 3 Skg (6.6 11.0
Ibs) force and screw in the adjust nut un‹iI
it rests on the plunger,
3. Unscrew 1he adjust nut 1 /3 2/3 t‹ rns arxj
in+Jre iT with lock nui.
4. Check the srroke to see that ii is within the
speci fied value.

VALVE TIMING
INSPECTION
1. Remove the engine cylinder head cover.
2. Set No. I cylinder to TDC/compression.
A\ TDC compression position, timing
check slits in the flange of comshafts are
positioned upward.

3, Check the positions of camshaft No. 1 and

No. 2.
Use SST 109248 27010) .
3—12 18R-G ENGINE TUNE-UP - Valve Timir›8
FT 343
4, Valve Timing permissible error
* 2’ Camshaft rotation angle.
fi 0.5mm IO.020inl
Camshaf flange outer per imetgr.

ADJUSTMENT
1. Resec No. \ cylinder TDC/comprassion.

2. Loom rha cgmWft motJntirfg bow.

3. Shift lfiie wade.

 18R-G ENGINE TUNE -UP — Velve Timing 3—13

fl , I f v'ziII gg easier to pull ct/t he p'ir if the

c:r4mgh@f t is turns sligTntly in the forward
¢!ir eat iu r su as tu p ronidn p Iay.

Fig. 3-38
5. When valve I inning is advanced.
(! I Al ign with pin Mr+Ie in coi/nterctock

(2) Turn the camshaft so ‹has its slit well

be I ined up with Thn •di=s gauge and
rtinsert 1he nin.

6, When vg{v$ timing is retar‹Jed

\1) Align with hole pin in clock wise
dlraction,
\2) Turn the camshaft so that its slid will
be lined up with the adjust gauge and
rginser‹ the pin.

Fig. 3-40
pin with the washer and tighten
3-14 jBR-G ENGINE TUNE-UP — val e Timia

Fig, 3-41
8, FloraTe the crankshaft in the normgl
direction until No. \ cylinder TDC/

Fog. 3-42
9. Fecheck ihe Nu. 1 comshaJ t velve timing
with SST t0924&270 TO] .
Camshaft slii and SST protrusion should
match up.

F+y. 3o3
10. Flecheck the No. 2 camfdqaf t valve timing
with SST (0g248 27010] .
Camshafi slit and SST protrusion should
match up.

17 . Tighten the camshaft moun\ing boli.

Yoixjua 7.0-Big+n !fi0.6-57.Bh-tb)
 18R-G ENGINE TUNE-UP — Valve Clearance 3— 15

VALVE CLEARANCE
(THE ENGINE SHOULD BE IN
COLD CONDITION)
INSPECTION
1. Make sure of ihe following.

) Camshaft bearing cap. \ .2-1.8kg-m

{8.7 13.0ft-lbl
l2l Valve timing . Use SST [0024&
270JO] .

Fig. 3-46

A '”
Set No. \ cylinder to 7DC/compression.
In this condition, timing check slits in the
flange of camshaf ts are positioned upward.

fi. Meast re only valve clearance indicated by

arrows and record the results.

In‹M‹e O.z6-g.3z = ‹o.o‹oo.013 int

Exhaust 0.31-0.37 mm \O.012 0.01S inl
3—18 18R-G ENGINE TUNG-UP — Valve Clearanœ

5. Check remaining values indicated by arrows

and record the results.

ADJUSTM ENT
in case eny of the measured valves are noi
within the specified valves,
1. Set No. 1 cylinder to 7 DC /cgmpression.

Fig. 344
2. Pleoa glighing marks between No. 2 Chain
and gears and between The respective gears
and pin holes for correct reassemblv.

3. Remove par‹s as follows.

11I No, 2 chain damper.
(2 [ No. 2 chs in tensioner ,
3) Camshaft timing gear.

Fie. 3-52
\4l Camshaft No. \ bearing cap.
DSI Gradully boom No, 2 tg Flo, 5
begring cap nut5 in 2 io 3 stages in
the sequence a$ shown,
(6) C emshaft.
 18R-G ENGINE TUNE-UP — Valve Clearance 3—17

4. Remote valve lifter when ya]ve clearanœ is

not within $pecified valve.

B. KeeQ valves and adjusting in order.

6. Selec‹ a new pad that will give the specified

valve clearanœ as follows.
11 ) Measure the pad tha‹ was off with a
micrometer.

\2) Calculate thickness

Ile de valve clgergnce
Marv Pad WiÆngss specili«I valve.
- T1 + (A Q. WMm) Tt ..... 7hicknas of pad used
A ...... Valve clearance measured
Exhæict Side
£¥aw Pad Tht<knass
- T1 d• A --Ô.M MM}
3-18 IBR-G ENGINE TUNE-UP — Velve Clearance

Fig. 3•b8
(3l Selec‹ a pad vvich a rhickness as cloæ
a possible to the valve ralcolated.
Pads are ava‹IabIe in 41 size, in
increments of 0.05 mm IO.ŒI2 int ,
truin 1.00 mm (0.Org in [ io 3.00 mm
10.118 int.

7. Install pad ar›d yalve lifter

Fig, 3•58
8. Install ‹he camshaft
. (\ I Rotate the crankshaft about 90° the
rever5e direc t ion.
— but?on -
Lower piston to prevent intarferance of

(2) Position st it uf «grnsha4 t upwgrd as

 (3[ Instal I the No. 2 to No, 5 cemshafj
bearing caps.
Face the arrow man toward front.
]4) GrddualTy tighten bear ing cap nuts in
3 to 4 stage in The sequence aS

Totgue 1.7-2.3 k0-m (12.3-16.6

\5) Then tighten No. 1 bearing «ap tg

1.2-\ .8kg m f8.7• 13.0ft-lbI,

Fig. 3-6J
9. Recheck iniake side valve clearance.
11I E xheust side valve lifter No. 2 and No.
4 shoud protrude the same amount
(approx. ? mm)

Fig. 3&2
(21 Measure intake side valve clearance.
II ot*t5ide 1he specified valve, Choose
another pad.

Fig. 3-63
TO. Recheck exhaust side vslve clearance.
( 7 [ Intake side valve I ifter No. 3 and
NQ. ig @ouI'£;l protrude The same
amount.
f2T Measure exhaust side clearance.
I f outside the specified value, choose
another ped.
3—20 18R-G ENT INE TUNE•UP — Valve Clearance

11. I natalI the Nc. 2 chain and can shaf t gears.

11 ) Posi riur the No. I and to. 2
cainshaf I st it vertically upward wi \h
SS 1 109248 270t0I .
(2) e\ tTne No. 1 «yl inner to TDC/
« rnpressic›r .

AI ign chain and gaar yvith marki ng

made before disassembly.
14) AIign camshaft and gear pin hole to
oositiun before disassembly and
insert pin,

Hold the pin with the washer ,

Turn tfi+e «ranksf+aft 5\igh thy in

normal direction, until there is no
slack in he pins, tears, and
carnshat s. ar›d then i ighten ‹he bol ts
to specified torques.
Torsua 7.we.0ke m lS0.6-S7.8tt IbF
 18R-G ENGINE TUNE-UP — Valve Clearance 3—21

Fig. 3-68
(7I Adjust the No. 2 chain tensioner. Back
stroke 0.5-1.Omm (0.02- 0.04in)
at 3-5kg (6.6-111b)

Fig. 3-69 12. Recheck valve timing.

( 1 ) Rotate the crankshaft two turn in
normal direction until No. 1 cyIinder
TDC /comperssion.

Fig. 3-70 (3) Recheck valve tim ing with SST

(09248-27010] .
3-22 18R-G GNGINE TUNE-UP — C4rburmor

CARBURATOR
CARBURATOR ADJUSTMENT PROCEDURES

Check he I owing items boeoh

Spark PluR Check acceerafion pump

High Tenion Cord } , F ue discharging time. ---
Dwejl Angje J?. Fuel ?jecr d#ecroo.
lgni tion Titning
Valve Timing
Volvo Clearance Check and adjust Check end z<Iit st starter
tuel level wire.

Best idle 1hrottle link

6¡ustmant.

L -- --- -- - Checke ngine »ondi1ion Check and adju$t

CO
GOOO 0.x

FINISH

Fig. 3-71 FLOAT LEVEL

1. Start 1fie engine and ilde.

2. Take out one of 1Fe main iet holders in

assembled form.

3, Insert SST [09240- 27010) in the hole

from which he main jet holder was
removed.
4. Check the gasoline Ie•et inside the gaupe to
w if with in trite I imi\.
Standard level 16- t8mm 10.65-0.71in)
 18R-G ENGING TUN£-UP — Car6urmor 3-23

Fig. 3•73 ADJUSTMENT

7. Adj ust by t r r n‹ng ‹he f loa ‹ level ad just ing

One @Fo

Fig. 5•74
2. Recheck the float level.
Condition where the fuel pump i5
operating and apply itsg fuel pressur e.

ACCELERATION PUMP
INSPECTION
1. Remove tone carbur etor.
2. Check 1he f+ el in The fIoa‹ chamber.

3. Check the \ueT dischargir+g time

0.&1.1 second
3-24 IBRD ENGINE TUNE-UP — Carburetor. Throttle Link

4. Check the feel injection direction.

STARTER WIRE

THROTTLE LINK
{INITIAL IDLE SPEED)
INSPECTION
Check the following items beforehand,
\, Coolant temperature 80”C 7 \80”F)
2. Accessory perts All switched off.

Fog. 3-76
3. Mount the tachometer gnd the dual
vacuum gauga ‹o the vaCuum take-off
connection on ihe No. 1 and No. 4 image
manifolds

@ O@
 ENG FNE TUNE-UP — Throttle Link 3-2s

4. Check the idle speed and the diffarer›ce

IMITIAL \ Q LE SPEED between front and rear manifold vacuum,
Idle speed 1000 2 g0tTim
MAN‹FOLD v CUUM

10xM{D
FRONT AMO BEAR balow l0naxiHg TO.3BnHg)

ADJUSTMENT
Check the fgI)owing items beforehand.
1 Coolant temperature 80”C (\ 80° F)
2, Acce5sgry perT5 All switched off,

Fig. 3•8t
3. Mount the tachometer and tha duel
vacuum gauge to the vacuum takeoff
connection on the No. 1 and No. 4 intake
mani folds.

4.
3-26 18R-G ENGING TUNE-UP — Carburetor. Throttle Link

5. Loosen the rear idle speed adjusting screw

until it is wee from the lever.

6. Ser to l800rpin by \urni‹ g the frcnt idle

speed adjusting screw.
Engine speed 1800 rpizi
Check the engine speed after raising tFe
engine soeed.

Fig. 3-85
7. Seb to front rear vacuum di f Terence to
within 1ommHg [0.39inHg) by Turning the
mmi-I9 synchronizing screw.
Ftont a++d rear vecuum difference
below 1ommHg (0.39inHg)
Check the vauuri difference after raising
he engine speed.

8. Lousen the frunT idle speed adjusting screw

and lower the engine speed to 950 -
1.050 rpm.
Engine speed 1000 SO rpm
Check ‹he engine speed after raising the
engine speed.
 1BR-G ENGINE TUNE-UP — east tdle Adjustmgn\ 3-77

9. Screw in the slightly the rear idle jpeed

ad¡usti g s¢rew and raise ‹he engine speed.
then adjust the engine speed to 950 -
1050 rpm.
Engiw 000 S ppm
Cheek the engine speed afcer raising ‹he
engine speed.
10. PeaÜjus1 fron1 rear vacuum di flerenœ.
Below 10mmHg (OWinHg)

BEST I DLE ADA/STMENT

1. Screw out all of the idle mixture adjusting
screws 11 turn from tully closed position.
- Nota —
Mraw in tjY until fully closed. aking
care not to injuce the cacburetw idle port
of the sczgw point.

Fig. 3-BS
2. Sat to the mas imum vacuum reading by
t urning aach idTe m ix ture adjusa ing screw.

Repeat adfusonent 2 or 3 timæ to obtain

maximum Vacutam Setting.

Menifogd vaeuum Aboea 3B0mmfig

Fig. 3W
3, Readjust tha fglTgwing Z or 3 limes.
( t 7 IdIe speed edjusting Screw

(2) Synchronizing lldle to

Belew l0mixiHg (0.39inHg)

(3I IdIe mixiure adlusting screw
Manîfofd vevuum
Abe• zaa»mHg Ils.œinHg›
3-28 18R-G ENGINE TUNE•UP -

CO CONCENTRATION
& ” Measure the CO cor›centretion
11 I Before measuring, race ihe engine at
about 2,000 rgm for 30 - 60
seconds.

\2) Measure within 1 io 3 minutes aYtar

r8ci g the engine to allow ihe
ooricentretion to stabilize.

2. Adjusi the CO concentration.

When the concentration is high:
1) 4 idle mixture adiusting screws 1/16
lurn.
72) Measure ihe CO conce4ntretion a0ain.
(3) If still high, 4 idle mixture adjusting
screws another \ /\ e turn.
(4) Check ihe engine speecl.

Fig.8.4
3. Check rpm of each cylinder when if
misfires.

All four cytlrxtart dteutd its sent

11) Men one plug misfires, r8isg rpm

md clean.
T2l When dBcrggse in rpm is not uniform,
adjust with the idle mixture adjusting
 18R-G ENGINE TUNE-UP — Engine Condition. Compression Pressure 3—?8

ENGINE CONDITION
]. Check if the engire returns to idle sped
when both suddenly and slowly
accderaced.

?. Opening throtile valve gradually should

couse engir+8 4o speed up smoothly in
reletion ‹o amount of valve opening.

COMPRESSION PRESSURE
1. Warm up the engine.
2. Remow all spgrk plugs.
3. Disconnect the high tension cord from
ignition coil to cut-off the secondary
circuit.

Fig. 3W
4. I user t a compression 9au9e into ihe spark
plug hole, open ihe throt ile valve fully, and
measure the compression pressure while
crank ing the engir+e with starter motor.
Compraafon Preesuta (at 200 rixnf
STD 13.0hg/<m* \184.6psif
Limit 10.&gYcm' f142.jail
Diffacence of ptaz›uca between
cylinders Lees than 1.@‹g/cm' 714.2patf
MENtO