Caution Dys
TESTING AND ADJUSTING SPECIFICATIONS 1 976 to 1980 Models Diagram for warm-up regulator Part No. 063 133 403 Bosch No. 0438. 140.011 System pressure Test value Adjust value Pressure Pressure accumulator accumulator 20 cc 40 cc 25 - 4 Testing and Adjusting Specifications TESTING AND ADJUSTING SPECIFICATIONS 1 981 1982 Models with Oxygen Sensor Control pressure cold at ambient temperature Diagram for warm-up regulator Part No. 477 133 403 Bosch No. 0438. 140. 088 System pressure Test value...
Checking Fuel Delivery Rate For Control Pressure Circuit
3. Disconnect left hose from special tool P 378 at feed line to control pressure regulator and hold in a measuring glass capacity at least 500 cc . 4. Turn on ignition. Turn valve to position 2 and let fuel pumps s run exactly 1 minute by pulling off two-pin plug on mixture control unit. The fuel pump s in cars from 1979 models can be run by supplying battery voltage to multiple-pin plug terminal 7 red white with a piece of wire. The ignition need not be turned on. 3. Disconnect left hose from...
Installing Drive Belt
Crankshaft position engine installed TDC mark on flywheel and clutch housing must align with each other. Printed in Germany - VII, 1980 Installing Drive Belt 15-5 Mark on camshaft sprocket and indicator on cylinder head cover must align with each other. Turn tensioning roller in direction of arrow. It must be just barely possible to twist the drive belt 90 when holding belt at a point midway between the camshaft and crankshaft sprocket with thumb and index finger. Crankshaft position engine...
Unit For Oxygen Sensor
An elapsed mileage switch for the oxygen sensor is installed on the left engine carrier. After a distance of 30,000 miles it will turn the oxygen sensor indicator light ON. Each time the oxygen sensor is replaced, the elapsed mileage switch must be reset to zero. Loosen three screws on control unit. Pull off plugs and remove control unit. 2. Press in reset button of elapsed mileage switch against the stop with a piece of approx. 3 mm dia. wire. This will reset the counter to zero and restore...
Checking Frequency Valve For Oxygen Sensor Control
2. Connect ohmmeter on frequency valve. 2. Connect ohmmeter on frequency valve. 2. Loosen coupling nut arrow on frequency valve, while counterholding on hexagon of fuel feed line. 1. Loosen fuel return line on solenoid and bracket for frequency valve. 3. Replace frequency valve if necessary.
Removing And Installing Crankshaft Oil Seal
Remove pulley end oil seal with 10-221 or screwdriver Install pulley end oil seal. Press in to stop. Removing and Installing Crankshaft Oil Seal 13-9 UNDERSIZE CRANKSHAFTS FOR REPAIRS Dimensions in mm Crankshaft main Crankshaft connecting Size Diameter Out of round Diameter Out of round
Replacing Check Valve
Important Conform with safety regulations when Important Make sure fuel hose is positioned correct- working on fuel system ly and cannot rub prior to tightening 3. Remove hose clamp and check for leaks. Install guard again. 1. Clamp fuel feed hose with standard hose clamp and detach pressure side hose on fuel pump by loosening hollow union bolt or coupling nut. 2. Loosen check valve, while counterholding on hexagon of fuel pump with a narrow machined open-end wrench. 1. Screw in new check valve...
Caution Noh
Always make CO adjustments from lean to rich. For example, if the mixture is too rich, first turn the CO adjusting screw counter-clock-wise further than necessary and then clockwise to specified setting. b Never press down on adjusting wrench during adjustments engine will stall . Turn the CO adjusting screw only slightly, since the smallest turn will change the CO level considerably. 7. Turn clockwise for richer mixtures, counterclockwise for leaner mixtures. See page 25 - 4 b for CO...
Checking Warm Up Regulator Warm Engine
1. Disconnect wire connectors at warm-up regulator. 2. Disconnect electrical connector at air flow sensor. Turn on ignition. 3. Check power supply with voltmeter at disconnected plug. Voltage min. 11.5 V. Printed in Germany Removing and Installing Warm-Up 25 - 21 Regulator - Checking Warm-Up Regulator 4. Check heating coil, resistance of heating coil approx. 20 Ohm. If heating coil has open circuit, replace warm-up regulator.
Checking Crankshaft Bearing Play
The Plastigage method is a simple way of checking bearing play - even with crankshaft installed in car. Plastigage is available in three different sizes for measuring ranges from 0.025 to 0.23 mm 0.0001 - 0.009 in. PG-1 green 0.025 to 0.075 mm 0.001-0.003 in. PR-1 red 0.05 to 0.15 mm 0.002-0.006 in. PB-1 blue 0.10 to 0.23 mm 0.004-0.009 in. The end play is measured on bearing 3 thrust bearing with a feeler gage. Play of new bearings 0.10 to 0.19 mm Wear limit 0.25 mm 2. Clean bearing shell and...
Removing And Installing Oxygen Sensor
1. Lift car. 4. Unscrew oxygen sensor. 2. Pull off rubber cap from oxygen sensor plug and plug. 1. Coat threads of oxygen sensor with Bosch paste VW 140 16 Ft. Be careful that paste does not enter slot of sensor. 2. Tighten sensor to specified torque. Reference value 50 to 60 Nm 36 to 43 ft lb . 3. Pull off plug from oxygen sensor.
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2. Check distributor cap, distributor rotor, ignition lines and spark plugs Warning ignition off . Resistance of spark plug wire including connector approximately 6 k Ohm Resistance of distributor rotor approx. 5 k Ohm 3. Check ignition timing Timing good 5. Check ballast resistors and ignition coil Ignition off, wires disconnected at resistors and ignition coil Ballast resistor 0.4 Ohm 0.35 to 0.45 Ohm Ballast resistor 0.6 Ohm 0.55 to 0.65 Ohm Ignition coil primary between terminals 1 and 15...
Removing And Installing Distributor
3. When installing the distributor rotor make sure that it faces the cylinder 1 mark on the distributor housing. 2. Remove distributor cap, disconnect vacuum hose and wires, unscrew distributor hexagon nuts and remove distributor. 3. When installing the distributor rotor make sure that it faces the cylinder 1 mark on the distributor housing.
Removing And Installing Voltage Regulator
2. Pull hose off connector on alternator guard. 4. Remove guard after unscrewing the three hexagon head screws. 6. Be careful of ground strap when installing guard. 6. Be careful of ground strap when installing guard. 2. Pull hose off connector on alternator guard. 4. Remove guard after unscrewing the three hexagon head screws.
Removing And Installing Fuel Tank
4. Remove luggage compartment lining, 2. Remove final muffler and transmission. 5. Remove cover in luggage compartment, 3. Drain fuel clamp return hose with standard hose clamp. Detach suction hose at fuel pump and drain fuel into an appropriate container. 6. Disconnect wires at tank sending unit, Removing and Installing Fuel Level Transmitter 20-7 Removing and Installing Fuel Tank 9. Detach fuel hoses and remove fuel tank from below. 1. When installing, slide the protruding hoses into the tank...
Removing And Installing Cylinder Head
The cylinder head can be taken off without removing the engine. The engine block has 2 centering bushings to facilitate installation of head. REMOVING AND INSTALLING CYLINDER HEAD from 19 80 Model Polygon socket head bolts for cylinder head. See figure for tightening sequence, Opposite sequence for loosening. warm 120 Nm 86 ft lb cold 100 Nm 72 ft lb If the cylinder head was removed, the cylinder head bolts must be retorqued after about 1000 miles 1600 km. Warm up engine. Using loosening...
Adjusting Valve Clearance
2. Turn crankshaft until the cam lobes of the cylinder to be adjusted point upward. 3. Check valve clearance, if necessary correct with complete turns of the adjusting screw one turn of the adjusting screw will change valve clearance by 0.05 mm .
Specs For Ignition Coil On 924s
Observe the following safety measures to avoid damage The high voltage lead must be fitted with a shield-while working on TCI-H ignition systems. ing sleeve of at least 2 k-ohms. 1. Only connect and disconnect testers and leads with ignition turned off. 2. Spring retainers of removed distributor and dust caps must not hang in sensor system while cranking engine. 3. Never connect a capacitor on the ignition coil. 4. Specified ignition coil must not be replaced with a conventional ignition coil....
Checking Operation Of Deceleration Valve
1. Detach hose between valve and intake manifold at valve and insert plug in open hose end. 2. Start engine. Bring engine briefly to about 350 rpm. Shut throttle valve quickly. 3. Check with finger for suction at hose connection. Replace valve if suction cannot be felt. Checking Cold Start Valve for Leaks Removing and installing deceleration valve Checking operation of deceleration valve
Removing And Installing Mixture Control Unit
1. Disconnect battery. Always use new seals for fuel connections. 2. Remove rubber boot from air sensor. 3. Clean fuel distributor thoroughly in area of fuel connections. 4. Detach wire plugs, injection lines, control pressure line, fuel return line and fuel feed line. 5. Loosen 6 Allen head bolts and remove mixture control unit. Removing and Installing Mixture Control Unit
Basic Adjustment Of Mixture Control Unit Initial Start
This test requires that the sensor plate be adjusted correctly rest position . 1. Unscrew one injection line on fuel distributor. 2. Bridge electrical safety circuit. 3. Turn mixture control screw slowly, without applying pressure on adjusting wrench P 377, until fuel just begins to leave the open outlet arrow of the fuel distributor. From this position turn mixture control screw counterclockwise one half turn. 4. Connect injection line again. Run engine to operating temperature approx. 80 C...
Checking Cold Start Valve For Leaks
2. Disconnect electrical connector at air flow sensor pump running . 3. Wipe jet of start valve dry. This jet must not leak at all within a minute's time. Replace a malfunctioning or leaky start valve. CHECKING OPERATION OF HOT START VALVE Reduction of Control Pressure During Hot Start Warm engine. Coolant temperature 60 C 140 F or more. 1. Connect pressure tester and set switching valve at position 2. 2. Operate starter to open hot start valve and drop control pressure. Specification 0. 5 to...
Checking Valve Guides
When reworking valves seats valve guides must be checked for wear. This is particularly true for engines with high mileage. If wear is excessive, cylinder head must be replaced, until such time when repair procedures are published. 2. Place new valve in guide. End of valve stem must be flush with guide. Intake valve guide max. 0.8 mm Exhaust valve guide max. 1.0 mm REMOVING AND INSTALLING VALVE STEM SEAL Cylinder Head Installed 1. Remove camshaft and tappets. 3. Move piston of each cylinder to...
Basic Adjustment Of Mixture Control Screw After Replacement Of Pivot Lever
This test requires that the sensor plate be adjusted correctly rest position . 2. Bleed fuel system , Remove injectors and hold over a container, operate sensor plate by hand several times . 3. Using adjusting wrench P 377 first turn mixture control screw counterclockwise by 1 - 2 turns. Never apply any pressure on the adjusting wrench during adjustments, since this would change the injection rate. 6. Run engine to operating temperature 80 to 90 C 180-190 F oil temperature, and adjust idle...
Caution
Lift engine carefully to avoid damaging propeller shaft, clutch or body. 31. Attach chain US 1105 to lift points on engine. Using universal floor crane, lift engine slightly to tension chain. 28. Detach front exhaust pipe at exhaust manifold and connecting flange at primary muffler. 32. Disconnect electrical connectors, detach hose and loosen clutch bell housing.bolts. 30. Disconnect universal joint at steering rack arrow . Remove cross member and discon nect stabilizer at frame on both sides....
Replacing Valve Guides
During repairs, installed valve guides must have the same codes as those replaced. 3. Select suitable replacement repair guide from following table. Cylinder heads with cracks between valve seats or between a valve seat and spark plug threads can still be used without risk of a shorter service life, if the cracks are not wider than 0. 5 mm max. or if only the first spark plug threads are damaged. Code for Production and Repair Guides 1. Clean and inspect cylinder head. Heads, in which the valve...
Machining Valve Seats
Valve seats showing traces of wear or burnt spots can be machined until reaching wear limit depth b. If depth b is exceeded the cylinder head must be replaced, since valve clearance could no longer be adjusted to specifications. Valve seat inserts cannot be replaced with normal worshop facilities. If a valve seat has been machined, the valve adjusting screw must be replaced with adjusting screw 046 109 453 C previously with white marking, now with no marking . a - 36.5, 38.5 mm dia. a -...
Removing And Installing Engine
6. Detach windshield washer hose at T-adaptor, 7. Disconnect electrical connector of engine compartment light. 4. Set heater control lever to warm position fully open and remove pressure cap. 5. Drain coolant at plug on radiator, and loosen and remove coolant hoses. 9. Remove coolant expansion tank with carrier and hoses. 10. Take windshield washer tank off and place it behind right-hand headlight. 11. Take alternator cooling hose off. 12. Disconnect starter wire arrow at positive pole,...
Removing And Installing Needle Bearing
Needle bearing can be replaced without removal of engine. Clutch must be removed first. See Repair Manual - Group 30. Pull out needle bearing with Special Tool 10-202. 13-12 Removing and Installing Flywheel Replacing Starter Ring Gear Pull out bearing sleeve with US 1088. Pull out bearing sleeve with M 12 x 65 hexagon head bolt. Drive in needle bearing up to stop with Special Tool 9124. For version II drive in seal up to stop with Special Tool 9123. Use about 3 grams of lithium grease NLGI...
Checking Oil Pressure And Oil Pressure Switch
1. Remove oil pressure switch and install tester. 2. Install tester in cylinder head in place of the oil pressure switch connect test lamp to oil pressure switch terminal Wk and ignition coil terminal 15. Turn ignition on test lamp should light. If not, replace the switch. 3. Start engine test lamp must go out. Stop engine. Lamp must light again at a pressure between 0.3 and 0.6 bar 4.3 and 8.5 psi . 4. Start engine. The oil pressure must be at least 2 bar 28 psi at 2000 rpm and oil temperature...
Tolerances And Wear Limits
80- 93 C or 85 - 102O C 176 - 200 F or 185 - 216 F 0.9-1.15 bar 12. 8-16.4 psi 0. 06 - 0.1 bar 0.9 - 1.4 psi 0. 03 - 0. 07 mm 0. 001 - 0. 002 in. 0 - 0.13 mm 0 - 0. 005 in. 2. 2 - 3. 2 bar 31. 3 - 42. 6 psi 0. 3 - 0. 6 bar 4. 3-8.5 psi V alve Timing Camshaft bore Camshaft Camshaft Camshaft 26. 00 - 26. 021 mm 1. 0236 - 1. 0245 in. 25.94 - 25.96 mm 1. 0213 - 1. 0181 in. 0. 05 - 0. 16 mm 0. 002 - 0. 006 in. measured at center brg. brgs 1 5 on V-blocks 38. 5 - 38. 525 mm 1.515 - 1.517 in. 38.45 -...