Federal Models High Altitude Conversion (25-02-83)

L.D.V. Colt, Challenger/Sapporo High Altitude Kit PN MD069088

1. Modify thermo valve "A" hose harness as outlined:
   1. Remove connector "I" from thermo valve "A" and cut all three hoses off of connector "1". Reinstall upper vacuum hose "E" on thermo valve nipple "E" See, Figure 1, Views A and B .
   2. Cap nipple "A" on thermo valve "A" with supplied Rubber Cap PN MD026761. See Fig 1 , View B .
   3. Cut vacuum hose "B" 2-23/64" from end of hose at connector "1" and install supplied Vacuum Hose Terminal (Tee) PN MD001865. See Fig 1 , Views A and B.
   4. Connect vacuum hose "A" hose terminal (tee) nipple "B" Figure 1, Views B and C.
2. Revise basic timing as outlined:

   1.4L and 1.6L Colt

   1. Reset basic timing to 10° BTDC.
   2. Reset curb idle speed to vehicle emission control information specification.

   Challenger/Sapporo 2.6L

   1. A. Reset basic timing to 12° BTDC
   2. B. Reset curb idle speed to vehicle emission control information label specification.
3. Vehicle emission control update label installation:
   1. Clean area where update label is to be installed. See Fig 2 for Colt model and Figure 3 for Challenger/Sapporo models .
   2. Affix update label to the specified locations indicated in Figures 2 and 3.
   3. The label is constructed such that if installed properly, it cannot be removed without destroying or defacing the label.

L.D.T. With 2.0L 2.6L Engines

Select appropriate kit from parts list.

1. Replacing primary main air jet:
   1. Remove air cleaner assembly.
   2. Replace the primary main air jet with the one specified below:
      PRIMARY MAIN AIR JET
      
      

      Engine	Jet Size
      2.0L	#80 (Kit MD069089)
      2.6L W/5-Speed	#95 (Kit MD069090)
      2.6L W/Auto.	#100 (Kit MD069091)

      See Fig 4 for location of primary main jet and type of screwdriver to be used to remove and install 1 he air jet. An expandable tip screwdriver is recommended to prevent the air bleed from being dropped into carburetor bore.

2. Revise basic timing as outlined:
   REVISED TIMING SPECIFICATIONS
   
   

   Engine	Revised Timing Spec.
   2.0L	10° BTDC
   2.6L	12° BTDC

   1. Reset curb idle speed to vehicle emission control information label specifications.
   2. Adjust basic timing and curb idle speed.
3. Vehicle emission control update label installation:
   1. Clean area where update label is to be installed. See Fig 5 .
   2. Affix update label to the specified location indicated in Figure 5.
   3. The update label is constructed such that if installed properly it cannot be removed without destroying or defacing the label.

L.D.T. Colt/Ram 50 Trucks With 2.3L Turbo Diesel Engine use Kit MD 064454)

1. Fuel flow rate adjustment:
   1. Loosen nut and insert the adjusting shim (l) between the nut and washer. Do not remove the nut or screw. See Fig 6 .
   2. Turn the adjusting screw inward to the stop and, while holding the screw, tighten the nut to a torque of 4.3 to 6.5 foot pounds.
   IMPORTANT: MAKE SURE THE NUT AND THE LOCKING SLEEVE ARE TIGHT AGAINST ONE ANOTHER AS THE ENGINE WILL NOT RUN PROPERLY OTHERWISE.
2. Fuel injection timing adjustment:
   1. Change fuel injection timing from 2° ATDC for low altitude to TDC for high altitude.
   2. Perform the following preparatory steps:
      1. Loosen the nuts (two places) and bolts (two places) securing the injection pump. Do not remove the nuts and bolts.
      2. Loosen (but do not remove) the nuts securing the injection pipes (4 in all) on the injection pump side. When loosening the nuts, hold the delivery valve holder with a spanner to prevent it from rotating with the nut.
   3. Adjust the injection timing as follows:
      1. Remove the plug from the rear of the injection pump. See Fig 7 . Attach the prestroke measuring adapter and a dial indicator. Do not over tighten gauge to adapter as readings will be erratic. See Figure 8.
         CAUTION: BEFORE INSTALLATION OF ADAPTER, MAKE SURE THAT THE PUSH ROD IS PROTRUDING BY 10 MM (0.4 IN.). SEE Fig 8 . * PROTRUSION OF PUSH ROD CAN BE ADJUSTED WITH AN INNER NUT.
      2. Turn the crank pulley to such a position that the notch on the pulley is at approximately 30° before the top dead center. See Figure 9 . Then, set the dial indicator to zero. Slightly turn the crank pulley clockwise and counterclockwise to make sure that the dial indicator does not deviate from the zero position. If it does, readjust the pulley position so that the notch on the pulley is at 30° before the top dead center.
      3. Turn the crankshaft in the normal direction (clock-(wise) to bring the notch to specification and check that the dial indicator reads 1 +/- 0.03 mm (0.0394 +/-0.0011 in.). See Fig 10 .
      4. If the dial indicator does not indicate the specified value, tilt the injection pump body to the right or left until the dial indicator reads 1 +/- (0.03mm) (0.0394 +/- 0.0011 in.). See Fig 11 . Then, temporarily tighten the bolts securing the injection pump.
      5. Repeat Steps 2 through 4 to check that the adjustment has been made correctly.
      6. Remove the prestroke measuring adapter, fit the plug, and tighten both the plug and the four injection pipe nuts.
3. Idle Speed Adjustment:

   Check the following before attempting to adjust the idle speed:

   1. The engine has been warmed up sufficiently to heat the coolant to 80 to 90°C (180 to 190°F).
   2. The injection timing is as specified.
   3. The fast idle is released.
   4. The injection nozzle operate normally.

   Adjust the idle speed as follows:

   1. Loosen the lock nut of the idle adjustment screw and turn the screw clockwise or counterclockwise to obtain an idle speed of 750 +/- 50 rpm. After adjustment, tighten the lock nut. See Figure 12.
      CAUTION: DO NOT DISTURB OTHER SCREWS.

4. Labeling
   1. Apply Fuel Injection label to fuel injection pump over the current label as shown in Fig. Fig 6 .
   2. Apply Vehicle Emission Control Information Update label in engine compartment as shown in Fig. Fig 13 .