912E Factory Service Manual

912E Factory Service Manual
Workshop Manual
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STUTTGART-ZUFFENHAUSEN
912 E REPAIR MANUAL
This repair manual describes all important operations for which special instructions are required to
assure proper completion, This manual is essential for the shop foremen and mechanics, who need
this information to keep the vehicles in safe operating condition. The basic safety rules, of course,
also apply to repairs on vehicles without exception.
The 912 E Repair Manual only describes repair operations which differ from those for 911 models»
Refer to the 911 Repair Manual for all other information,
The information is grouped according to repair numbers, which are identical to the first two digits
of the repair time and warranty code,
The repair group index and alphabetical index are quick guides to find information in the manual,
Descriptions of design and operation can be found in service training course reference material,
This repair manual will be kept up to date with workshop bulletins; the information of these
bulletins will be made part of the manual from time to time. We recommend that the Workshop
Bulletins be filed in the special folder provided for this purpose,
"REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL
4
912 E
Please file the supplements according to the repair groups and make appropriate entries in the table below,
Supplement No. Filing Date Signature
QI
III
IV
. VI
VII
VIII
IX
XI
XII
XIII
XIV
GENERAL Technical Date Page 0,1
REPAIR GROUP
Engine -crankcase 10
Engíne-Crankshaft, and moving parts 13
Engine -Cylinder Head, Valve drive 15
Engine -Lubrication 17
Engine -Cooling 19
ENGINE Fuel Supply system 20
Fuel system, Fuel Injection 24
Exhaust System 26
- Starter, Power Supply 27
Ignition System 28
TE
Clutch, Control 30
| Mech. gear-shift system-actuat., hous. 34
TRANSMI 5 SION Mech. oar -shift system - Gears, Shafts 35
; Differential 39
Front Wheel Suspension 40
Rear Wheel Suspension 42 =
CHASSIS Wheels, Tires, measuring vehicle 44
Brakes, - Hydraulic - system 47
Steering 48
Body -Front Section 50
Body -Center Section 51
7 Body -Rear Section 53
Lids 55
Doors 57 —
BODY Sliding Roof 60
Bumpers 63
Glasses 64
Exterior equipment 66
Interior equipment 68
HEATING, VENTILATION, Heater 80
AIR CONDITIONING Air Conditioner 87. —- )
Instruments, Radio 90 0
Windshield Wipers and Washer 92
ELECTRICS Exterior Lights 94 ©
Interior Lights 96
wiring 91
Contents
Anti-backfire Valve, Checking Operation
Auxiliary Air Regulator, Removing and Installing; Removing and
Installing Thermo Time Switch
Axle Alignment Data
Belt Tension, Checking and Adjusting; Removing and Installing
Fan and Fan Housing
Brake Disks, Checking and Machining
Camshaft, Checking and Installing
Centrifugal Advance Curve
Clutch Disk, Checking; Installing Clutch
Clutch Disk, Removing and Installing
Clutch - Exploded View
Clutch Play, Adjusting
Clutch, Removing and Installing; Checking Clutch
Cold Start Valve, Checking; Checking Cold Start Valve for Leaks,
Temperature Sensor II
Cooling System - Exploded View
Connecting Rods, Checking and Installing
Connecting Rods, Reconditioning
Control Unit, Removing and Installing; Removing and Installing
Cold Start Valve
"Crankcase and Flywheel - Exploded View
Crankshaft and Connecting Rods, Installation Notes
Crankshaft End Play, Adjusting
Crankshaft, Disassembling and Assembling
Crankshaft, Reconditioning
Crankshaft Seal, Removing and Installing
Current Flow Diagram
Cylinder and Pistons = Exploded View
Cylinder Head and Valves = Exploded View
Cylinder Head and Valves, Installation Notes
Cylinder to Piston Play, Checking; Piston and Cylinder Installation Notes
Distributor, Installing
Distributor Drive Shaft, Removing and Installing
Engine Carrier, Removing and Installing
Engine, Removing and Installing
Equipment Charts - Fuel System/Fuel Injection
Equipment Charts = Ignition
Exhaust System - Exploded View
Page
24 - 9
24 - 4
44 - 01
19-5
47 - 1
15 - 16
28 - 5
30 - 4
30 - 1
30 - 2
30 - 5
30 - 3
24 - 8
19 - 1
13 - 23
13 - 24
24 - 3
13 - 8
13 - 19
13 - 12
13 - 21
13 - 22
13 - 13
97 - 1
13 - 2
15 - 2
15 = 5
13 - 6
28 - 7
28 - 8
10 - 8
10 -1
24 - 01
28 - 1
26-2
contents
Exhaust System - Installation Notes; Checking Reactor for Leaks,
Checking EGR Operation, Removing and Installing EGR Valve
Flywheel, Checking: Checking and Assembling Crankcase
Fuel Filter, Removing and Installing
Fuel Pressure, Checking
Fuel Pump Delivery Rate, Checking; Fuel Pump Test Specifications
Fuel Pump, Removing and Installing
Idle, Adjusting
Ignition Timing, Adjusting
Ignition Timing Control, Checking in Vehicle
Input Shaft Oil Seal, Removing and Installing
Intake Air Sensor and Air Cleaner, Removing and Installing
Intake Air Sensor, Checking; Checking Throttle Valve Switch,
Checking Auxiliary Air Regulator, Checking Thermo Time Switch
Oil Circuit ~ Exploded View
Oil Pressure and Oil Pressure Switch, Checking
Oil Pump Housing and Cover, Oil Filter and Oil Pressure Switch,
- Removing and Installing; Checking Oil Cooler
Piston, Checking: Checking Cylinder to Piston Play
Piston Marks; Checking Piston
Preassembled Crankshaft and Camshaft - Exploded View
Relays and Fuses, Location
Technical Data - Brakes, Hydraulics
Technical Data - Front Wheel Suspension
Technical Data - Manual Transmission
Technical Data - Rear Wheel Suspension, Propeller Shaft
Technical Data - Steering
Technical Data - Wheels, Tires, Axle Alignment
Temperature Sensor II, Removing and Installing, Removing and
Installing Pressure Regulator
Thermostat, Checking; Ad justing Control Flaps
Thermo Time Switch, Removing and Installing
Thermo Time Switch, Checking
Throttle Housing, Removing and Installing
Throttle Valve Switch, Removing and Installing
Transmission Case, Disassembling and Assembling
Vacuum Advance Curve
Valve Clearance, Adjusting
Valve Guides, Checking; Replacing Valve Guides
Valve Guides, Replacing
Valve Seats, Refacing
Valves. Racanditinnina. Dafantsn r-1... A
Page
26 - 4
13 - 11
20 - 4
24 - 6
20-3 -
20 - 1
24 - 10
28 - 3
28 - 4
35 - 1
24 - 1
24 =
17 - 2
17 = 7
17 - 6
13 - 5
13 - 4
13 - 14
90 - 1
47 - 01
40 - 01
30 - 01
42 - 01
48 - 01
42 - 02
24 - 5
19 - 6
24 - 4
24 = 7
24 - 2
24 - 2
34 - 3
28 - 6
15 - 10
15 - 8
15 - 9
15 - 7
General
“mil
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УСТ | №
a. a
E 086
TF Ly r y pis
TECHNICAL DATA
(Refer to the different repair groups for adjustment data and wear limits.)
Engine
Bore mm/ in. 94/3.70
Stroke mm/in. 71/2,80
Displacement ст /Ш, > 1971/120,3
Compression ratio | 7.6: 1
Horse power SAE Net kW/HP 64/86 at engine speed of
4900 rpm
Technical Data. General 0 1
Printed in Germany
General
Torque SAE Net
Horse power per liter SAE Net
Max. engine speed
Max, cruising speed
Cutoff speed of speed limiter in
control unit
Engine weight with muffler (dry)
Engine Design
Crankcase
Crankshaft
Crankshaft bearings
Connecting rods
Connecting rods bearings
Piston pin bushing
Pistons
Piston pins
Piston rings
Cylinders
Cylinder head
Valve seat inserts
Valve guides
Valve arrangement per cylinder
Exhaust Valves
Valve springs
Valve drive
Camshaft (021.109.101 K)
Camshaft bearings
Camshaft drive
Nm/ft 1b 133/98 at engine speed of
4000 rpm
kW /HP 32.5/43.6
rpm 5800
rpm 5000
+
rpm 5800 - 100
kg/1b 155/342
Light alloy, two piece
Forged
4 plain bearings
Forged steel
Tri-metal plain bearing shells
Press fit steel bushing with lead/brass
bearing surface
Cast light alloy with steel insert
Floating type, locked by circlips
2 compression rings, 1 oil scraper ring
Special gray cast single cylinders
One per 2 cylinders, light alloy
Shrunk fit, annealed sinterred steel
Press fit, intake: special brass
exhaust: thermohedul
1 intake, 1 exhaust, parallel overhead
Sodium filled reinforced seat
1 coil spring per valve
1 camshaft, followers, push rods and
rocker arms
Gray cast, 3 plain bearings
Steel shells with white metal bearing surface
Bevel gears
0.2 Technical Data, General
Printed in Germanv
General
SE - 7
Timing with 1 mm valve clearance:
Intake opens BTDC
Intake closes ABDC
Exhaust opens BBDC
Exhaust closes ATDC
Ignition
Ignition coil
Speed limiter
Ignition timing .
Firing order
Ignition control
Dwell angle
Spark plugs
Electrode gap
Cooling
Engine
Fan drive
Crankshaft/fan ratio
Air delivery rate
Engine Lubrication
Lubrication
Oil cooling
Oil filter
Oil pressure gauge
Max. oil temperature
Oil consumption
Emission Control
Heater
gt/600mi.
O
12
42
43
4
о оо
Battery ignition
12 volt
5800 - 100 rpm
27 BTDC at 3500 rpm
(vacuum hose disconnected)
1-4 -3-2 \
Centrifugal and vacuum
44 - 50
M 14 x 1,25 x 19, heat range 175
0,7 mm (0.028 in,)
Air cooled
Fan on crankshaft
1:1
800 1/sec at 4600 rpm of crankshaft
Forced feed by gear pump
Oil cooler in fan air stream
Full flow
Indicator lamp
Up to red field
0,5to 1.0
Air injection, thermoreactor and EGR
Warm air heater dependent on engine
temperature with electric blower, Heating
can be adjusted continuously with control
lever,
Printed in Germanv
Tankhninalt Mata Marana 1 non.
General
Fuel system
Fuel delivery
Fuel octane
Electrical System
Battery voltage
Battery capacity
Battery capacity (optional extra)
Alternator output
Ignition
Ignition coil
Firing order
Ignition control
Dimensions
Length
width
Height
Wheelbase
Track, front
Track, rear
Ground clearance -
-
Approach angle, front limited
by apron
Departure angle, rear limited
by apron
Weights
Curb weight
Max. total weight
Max. axle load, front
Max, axle load, rear
Payload
Max, roof load incl, luggage
carrier
RON
Ah
Ah
AFC fuel injection into intake manifold
Electric roller cell pump
91 (reg. grade fuels)
12
44
66
980, 70 A, 14 V (Bosch)
Battery ignition
12 V Bosch
1-4-3-2
Centrifugal and vacuum
(DIN Curb Weight)
min/ in,
mmy/in.
mm/ in,
mm/in.
mmy/in.
mm/in,
mm/in.
mm/in,
(DIN 70020)
kg/1b
kg/1b
kg/1b
kg/1b
kg/1b
kg/1b
4291/168,94
1610/63.39
1340/52,76
2271/89,41
1360/53,54
1330/52.36
180/7.10
140/5.51
(unioaded)
(with max. payload)
16° (with max, payload)
17° (with max. payload)
1160/2558
1400/3087
600/1323
819/1797
240/529
35/77
0.4 - Technical Data. General
Те бы ой бы оно он
General
Filling Capacities
Engine as measured with oil dipstick
according to Owner's Manual
"Oil change with replacement of
filter
Oil change without filter.
replacement
Transmission with differential
Fuel tank
Brake fluid tank
. Windshield washer
Performance
- Top speed
Acceleration from 0 to 100 kph
(0 to 62 mph)
Kilometer from standing start
Weight per HP
Climbing ability in % 5 speed
transmission
Premium HD oil according to API Classification SD or SE
of viscosity SAE 30 for summer, SAE 20 for winter, SAE 20
W 20 for year round temperatures between -15 С to O0 C,
(+5 F to + 32 F) or SAE 10 W for year round temperatures
below -15 C (+ 5 F).
ltr/gt
ltr/gt
ltr/gt
ltr/gal.
ltr/gt
ltr/gt
kph/ mph
sec
sec
kg/1b
approx 3.5/3.7
approx 3.0/3.2
approx 3.0/3.2 gear lube acc.
to MIL-L 2105 B SAE 90
80, 21.1, of which 81/ 2.1 gal,
in reserve
approx 0,2/0,21
approx 8,0/8,5
178/110.6
13.5 (DIN curb weight and 1/2
payload)
34.0
12/26
ist gear 50%
2nd gear 27%
3rd gear 17%
4th gear 11%
5th gear 7%
Printed in Germanv
Technical Data. General 0.5
General 10
TOLERANCES AND WEAR LIMITS
| The term "wear limits" indicates parts which are near or have already reached the dimensions given should
not be reinstalled during an overhaul. When determining the wear limit of pistons and cylinders, the oil
eonsumption of the pertinent engine must be taken into account,
‘Note: The values are in mm if not otherwise specified.
Upon Install, Wear Limit
(New)
Cooling System
{Thermostat .…. + « + « . + + + . . Opening temp. 85 - 90°C/185-194°F
jFan/pulley .. + +++»... Imbalance max, 5 cmg
Oil Circuit `
1-0il pressure (SAE 30 oils only)
at 70 °c/158 F oil temp.
at 25600 rpm . .. + +». . Pressure approx 64 psi (4,5 atm) 28psi (2 atm)
2-Oil check valve spring |
compressed length:
3%.0mm............Load 15 - 19 Ib (6.8-8.8 kg)
“18-Oil pressure control valve spring compressed length:
16.8mm. +. voce... „Load 9,6 1b (4.35 kg)
4-Oil pressure switch
opensat....eosoocooo. Pressure 2,1-6,4psi (0,15-0,45atm)
Cylinder Head and Valves
1-Cylinder seat depth in cylinder 5.4 - 6,6
2-Combustion chamber volume 58.7-60,2 cm
3-a) Rocker arm . . » . . » . . : Inside dia. 20,0-20,02 20,04
b) Rocker shaft .. .. .. .. . Diameter 19.95-19.97 19.93
4-Valve springs -
compr, length 30 . ...... .Load 160-1841b (72.5-83.5kg)
d-Valve seats | |
a) Intake. о ео овес ооо. Width 1.8 - 2.2
b) Exhaust . ....e.ooo o Width 2.0 - 2,5
e) Intake. ..eÑoocosooo. Seat angle 45°
d) Exhaust , .......... Seat angle 45,
. €) Outer correction angle . . . 15
f) Inner correction angle . . … 75°
6-Valve guide
Intake ...Q.oooooooeoo Inside dia, 8,00 - 8,02 8.06
Exhaust .....”emo o... Inside dia, 9,00 - 9,02 9,06
7-Valve stem
Intake .. .. ++. +».0e0.., Diameter 7,94 - 7.95 7,90
Exhaust , . « + + + +» +. , Diameter 8.91 - 8.92 8.87
8-Valve guide/valve stem Ÿ
Intake + exhaust . . . . . . . . Side clearance Мах. 0.30 1.2
9-Valve head
> Intake. .....oearo... Diameter 42.0
Exhaust, . . . +. .+...... Diameter ; 36.0
10-Valve clearance (cold) |
Intake . о о о + + +00... Adjustment 0.15
Exhaust . . + — + + + + + + © Adjustment | 0.20
Printed in Germany Tolerances and Wear Limits 10 - 01
10 - General
a = Upon Install, Wear Limit
(New)
11-Compression pressure
(with open throttle and engine at operating
temperature, all spark plugs removed, practically
no blowby with gauge in spark plug seat, engine
cranked by starter motor). . . . . . Pressure | 121 - 156 psi - 92 psi
RE RE | (8.5-11.0 atm) (6.5 atm)
Pressure difference between cylinders ma, 21psi
. (1.5 atm)
Cylinders and Pistons
2 oversizes, each with 0,5 mm greater diameter
1-Cylinder +. ....eooocoooooo y Qutof-round ma, 0,01
2-Cylinder/piston . ....o.oooooo Clearance 0.02 - 0.05 0,20
3-a) Upper piston ring ....... « «Side clearance 0,04 - 0,07 | 0.12
b) Lower piston ring . + . + + . + . . Side clearance 0,04 - 0,07 0,10
4-0il scraper Ting . + о о о ооо . . . Side clearance 0,02 -0,05 0.10
5-a) Upper ring. ..o.cocsoo. End gap 0.35 - 0,55 0.90
b)Lowerring ............ Endgap 0.35 - 0.55 0,90
6-Oil scraper ring .. +. « « + + + « » End gap 0,25 - 0,40 0.95
7-Piston weight ....oooccooro
8-Weight difference between pistons of 1
Re engine . ...eceacacroee Max. 4 g Max, 10 g
In the event of repairs |
)
Crankcase
1-Main bearing bore
a) Bearings 1-3-,....e..o0ooo. Diameter | 70.00-70.02 70.03
b) Bearing4.......000000, Dimete 50,00-50,04. 50,04
2-Flywheel end seal bore ........ Diameter 95.00- 95,05
3-Fan end seal bore .. . + + + « « + » Diameter 62,00-62,05
4-Camshaft brg, bore, , , . . . . .. Diameter 27.50-27.52
5-0il.pump housing bore , . , . . . . Diameter 70.00-70.03
6-Cam follower bore . . . . . + . .-. Diameter 24,00-24,02 24.05
Camshaft
1-Bearings 1-3 , ...Ñ.oocoooo.. Diameter 24.99-25.00
2-Center bearing runout
(Bearings 1 and 3 on V-blocks), . , Runout Max, 0,02 0.04
3-Camshaft/camshaft bearing
(including preload exerted by housing)
...................w so. Radial play 0,02-0,05 0.12
Thrust bearing . .......... Endplay 0,04-0,13 0.16
4-Camshaft gear. . . . + «4+... Backlash 0,00-0,05 |
5-Cam follower . . vo vo «+o » » « Diameter 0,04-0,13 0,16
6~Housing bore /cam follower . , . . . Radial play 0,02-0,06 | 0,12
7-Push rod. +... 0 oe » o « » « « Runout . Max. 0.3
10-02 : Tolerances and Wear Limits a Printed in Germany
10
General
_ + Upon Install, Wear Limit
| (New)
Crankshaft and Connecting Rods
3 undersizes, each 0,25 mm smaller in diameter
1-a) Bearings 1-3 . . + » + + + + + » . , Diameter 59,97-59,99
b) Bearing 4 . + + + + + + + + + + » » Diameter 39,98-40,00 -
c) Connecting rod brg . ., . . . . . . Diameter 49,98-49,99
2-Crankshaft runout at bearings 2 and 4
(1 and 3 on V-blocks) . .. e e... Runout 0,02
Ir 0000000 0000000 wos 2 lmbalance Max, 12 cmg \
4-Main bearing journal , . ...eoo Out-of-round 0,03
5-Connecting rod bearing journal , . . , Out-of-round 0,03
6 -Crankshaft/ main bearing (including preload exerted
by housing)
a) Bearings 1-3 + + + ¢« + +» +». . Radial play 0.05-0,10 0,18
b) Steel bearing 2 . . « » + + +» » « . Radial play 0,03-0,09 0,17
ce) Bearing4..,.,.erééecorceooo Radial play 0,05-0,10 0,19
7-Crankshaft/main bearing 1...... End play 0.07-0,13 0.15
8-Crankpin/ connecting rod .". . . . . Radial play 0.02-0,07 0.15
5 ; End play 0,10-0,40 0,70
9-Connecting rod weight . .,...e.
10-Weight difference between connecting rods -
| of one engine. ..o ccoreoeo. Max. 6 g
11-Piston pin. . ¢ 4 ¢ « » + + + + +». Diameter 23.99-24,00
12-Connecting rod bushing . . . . . . , Diameter 24.01-24,02
13-Piston pin/connecting rod bushing
oo . + # # # + # # » +» e + # # # #8 Radial play 0,02-0,03 0,04
14-Flywheel (measured in center of clutch
“ friction surface) + + . ¢ o +. + + . Lateral runout Max, 0,4
Imbalance Max, 20 cmg
Oil seal contact flange . . ..... Outside dia, 74,9-75,1 74,4
Machining flywheel teeth. , , . . max, 2,0
Clutch
1-Total pressure .. . . + o « s « Pressure 1100-1232 1b
(500-560 kg)
2-Total clutch, . + + + » + + + « . Imbalance Max, 15 cmg
3-Clutch pressure plate. . ., . , . « +» « Runout 0,10
4-Clutch disc . . . + + + + « « + + » » » Lateral runout Max, 0.5 |
(measured at 210 mm dia.) |
Drinmtad Ten 78 YA mas
8 10 . General
TIGHTENING TORQUES FOR ENGINE
a Discription Thread Nm (mkp)
1 - Drive shaft screws M8x1,5 42 (4.2)
2 « Transmission carrier to body M 12 x 1.5 80 (8.0)
3 - Engine carrier to body M 10 49 (4.9)
4 - Engine to transmission M 10 47 (4.7)
5 - Spark plugs M 14 x 1,25 34.3 (3.9)
6 - Small pulley nut M 14 x 1,5 58,8 (6.0)
7 = Fan bolts | M8 19.6 (2.0)
8 = Oil pump nuts M 8 19,6 (2.0)
9 - Oil drain plug M 12 x 1.5 21.6 (2.2)
10 a screen cover locking nut M8 12.7 (1.3) |
11 - Rocker arm shaft nuts M 7 13.7 (1.4)
12 - Cylinder head nuts M 10 31.4 3.2)"
13 = Engine carrier bolts (crankcase) M 8 29.4 (3.0)
14 = Fan hub boli ` _ M8 31,4 (3.2)
15 - Flywheel bolts M 12 x 1.5 107,9 (11.0)
16 - Crankcase half bolts and nuts M 8 19,6 (2.0)
17 - Nuts for crankcase halves M 10 x 1.25 32.4 (3.3)
18 - Connecting rod nuts M9x1 32.4 (3.3)?
19 - Mid grip nuts for reactor M 8 22,0 (2.2)
20 - Clutch bolts M 8 23.9 (2,9)
1)
2)
Tighten in sequence,
Replace, lubricate bearing surface,
10 - 04 : Tightening Torques .
Printed in GCarmanvu
Engine, Crankcase
10
TRF oh
- A >
La В * во К E
L Ea E
= . a
`
No. Description Special Tool Remarks
1 Engine holder VW 612/4
6
for floor VW 612/3 or US 612/5
jack with transmission arm
Printed in Germany Removing and Tnstalling Engine 10 = 1
Engine, Crankcase 10
REMOVING AND INSTALLING ENGINE
The engine/transmission assembly is lowered as Caution
a unit to remove. If compressor hoses are to be disconnected,
refrigerant must be discharged from air condi-
tioner system before loosening hoses.
‘Removing
1, Jack up car.
2. Disconnect battery ground cable,
3. Take off relay plate cover, pull off 14-point
plug, pull off front plug on double relay,
separate plug at resistor (if car has air
conditioning, detach plug to compressor).
6. Disconnect both heater hoses at heater blower,
. 4, If car has air conditioning, take compressor
off of console by loosening and removing
the two rear bolts, Loosen the front bolt
slightly, push out the compressor to the left
and leave it connected to hoses in the car,
Drinrad in Mermanu . Damavina and Tnetallinao Encina 10 » Y
r
10 ~ Engine, Crankcase
+
7. Detach fuel feed hose at fuel filter, 10, Disconnect return spring, detach operating
| | cable on throttle housing and mounting
bracket and slide it down through the engine
guard.
12. Loosen plug at control unit, pull back spring
on engine), a . clip and pull it out of socket at the same
$ time.
Engine, Cran kcase 10 -
13. Loosen screws on cover for rear tunnel and 20, Loosen and detach clutch cable at
remove cover, Co transmission.
14, Pull boot off of body and slide it forward
over the selector rod,
Wg —
роет 30
= ais 18e А
15. Loosen socket head set screw of shift rod
coupling and pull coupling off of inner shift
rod on transmission, ВЕ
21. Loosen drive shaft screws at differential
flanges,
16, Disconnect electronic speedometer sensor wire > F5 [
in tunnel and remove rubber grommet with —
wire plug toward the outside,
22, Place floor jack with appropriate holder
underneath the engine/ transmission assembly
tit i i ,
© 17, Loosen and disconnect heater hoses at heat at its center of gravity, with slight preload
exchangers, -
18, Disconnect ground strap between transmission
and body.
19, Disconnect wire at starter,
Printed in Germanv
4
10 Engine, Crankcase
23. Loosen bolts at transmission carrier, — Caution
Do not place engine on the reactors, which would
cause them to leak,
If vehicle is to be moved (with the engine/trans-
mission removed), drive shafts must be supported
so that they hang horizontally to prevent damage
to drive shaft boots,
Installing
Note the following points on installation,
Caution
1. Be careful not to pinch the heater hoses.
Connect them to the heat exchangers just
before the engine/transmission assembly is
positioned correctly,
2, Torque specifications:
Socket head screws of drive shaft flange
42 Nm (4.2 kpm) |
Transmission carrier to body mountings
80 Nm (8.0 kpm)
Engine carrier to body mountings
49 Nm (4,9 kpm)
3, Engage the plug on the control unit and
press it into the socket until the spring
clip engages with an audible click,
25. Lower floor jack with engíne/transmission
assembly carefully and roll out toward rear,
Engine, Crankcase 10
DISMANTLING AND ASSEMBLING ENGINE/TRANSMISSION ASSEMBLY
Dismantling | Assembling
| Note the following points,
1. Remove wire at starter and backup light switch,
1, Apply a coat of all purpose grease with MoS
to all bearing surfaces of the clutch release
as well as the splines of the input shaft.
2. Loosen engine mounting bolt and nuts,
2, Place transmission on engine,
3. Pull transmission off engine.
3. Torque engine mounting bolt and nuts to
47 Nm (4.7 kpm) .
Printed in Germany Removing and Installing Engine 10 - 7
+
10 ‚ Engine, Crankcase
ENGINE CARRIER ASSEMBLY
Note when
a Description Qty. Removing Installing Remarks
1 Lock nut 2 Replace, install
correctly, torque
49 Nm (4.9 kpm)
2 | washer -. —. 4
3 Bolt 2
4 Mid grip nut 2 Replace, do not
damage rubber of
engine mount when
tightening
5 ‘Engine carrier 1 Install in correct
position, cast in part
number faces rear of
vehicle
6 Nut 2
7 Washer 2
8 Engine mount ‘2 Check for cracks,
replace if necessary
9 — Support 2 Install correctly
10 = R Remnvino and Installing Fnoine Carrier Printed in Germanv
TOOLS
Engine,
Crankshaft, Pistons
13
No. Description Special Remarks
Tool
1 Inside micrometer — US 1032
2 Feeler gauge - Commercial item
3 Micrometer 75 - 100 mm US 1075
4 Piston pin drift VW 207c
5 Angled circlip pliers Commercial item
6 Piston ring compressor US 1008a
я Piston ring pliers Commercial item
— Printed in Germanv
mE a.
13
Engine, Crankshaft, Pistons
т
2
|
|
en
AY
+
cf 8,
ik
"
—
Note when |
. i ty.
No Description Q 7 Removing Installing Remarks
1 Cylinder head 4 Replace
gasket
2 Cylinder 4 Mark installed Cylinder seat in crank-
Co position, Check case and cylinder head,
for wear, If as well as bearing sur-
Е necessary, install faces in cylinder, and
new cylinder and gasket surfaces must be
piston of same size perfectly clean since
group. foreign particles will
lead to leaks.
Coat with oil, Studs See page 13-6
must not be in contact
with cooling fins, Use
piston ring compressor,
3 Cylinder base 4 Replace,
gasket
4 Circlip 8 Use circlip pliers.
5 Piston pin 4 Use piston pin drift Coat with oil, If pin
VW 207c, is tight, heat piston о
to approx. 80 С/176 Е.
13-2 Cylinders and Pistons Exploded View Printed in Germanv
Engine, Crankshaft, Pistons
13
Note when
No, Description Qty. | Removing Installing Remarks
6 Piston 4 Mark installed Note mating with See page
| position, cylinder, Heat 13 - 6
Check for wear. when installing
E piston pin, Coat
Ta with oil, Clean
т piston ring grooves.
Max. weight dif-
ference is 10 g.
7 Upper ring 4 | Always use piston Fit rings. See page
8. Lower ring 4 ring pliers for Check ring gaps. . | 13-44»
100 [| removal and Top" must face
9 Oil scraper ring 4 installation piston crown. Check
(page 13-6) ring side clearance.
Stagger piston ring
gaps.
Printed in Germany Cvlinders and Pistons Exploded View 13 = 3
13 Engine, Crankshaft, Pistons
PISTON MARKINGS
A Моне 1
Рой
-
go
==
РТ ны
=
«==
=
-
—
”-—
Ean J
rl
= E
A - Letter adjacent to arrow corresponds
with index of spare part number of
respective piston; it serves as an
identification mark, Checking piston ring end gap.
B - Arrow (embossed) shows direction piston
t tal t .
LE a ue owards fly wheel, Slide in ring at right angles through bottom of
C - Paint mark indicating size group (blue, ;
cylinder opening, at approximately 4 to 5 mm
pink). .
from edge of cylinder,
D - Weight group indication (+ or - )
| embossed or stamped ín ink,
E - Weight group indication by paint mark
(brown = - weight, gray = + weight).
F - Piston size in mm. . End Grap Wear Limit
mm mm
G PIS
CHECKING PISTONS Upper compression ring | 0.35-0.55 | 0.90
Lower compression ring | 0,35-0,55 0.90
: | Oil scraper ring 0.25-0,40 0,95
a - Upper compression ring
b - Lower compression ring
с = Oil scraper ring with spring
13-4 Piston Marking Checking Pistons Printed in Germanv
Engine, Crankshaft, Pistons 13
Checking piston ring side clearance,
Side Clearance | Wear Limit :
mm mm =
Upper compression |
ring 0.04-0,07 0.12 Checking cylinder bore,
Lower compression
ring 0.04-0,07 0.10 Measure the cylinder bore approximately 10 to
Oil scraper ring 0,02-0,05 0,10 15 mm below the top edge of the cylinder,
Installed Clearance Wear Limit
Inspect and fit pistons, Depending on given
_ tolerances, some piston pins can be pushed into 0,02 - 0.05 mm 0.2 mm
the cold piston by hand, This is normal, even if
the pin should slide out of the piston under its own
weight, It is not appropriate in such cases to | ZN
replace either the piston pin or piston, or both, Ea EPEAT ia LIRA Eo 2 EE
4
ю dl RA A“ > 29 r ‘ а A a
he: 3 a ax La - # + 5 = ой 1 E
- E = Li JE
NU A
CHECKING CYLINDER TO PISTON
CLEARANCE
The cylinder bore is measured with an inside
micrometer, First adjust the inside micrometer
with a master gauge,
Checking piston diameter.
The nominal piston diameter is embossed on
the piston crown, Measurements are made at the
lower end of skirt, perpendicular to the piston
pin axis,
Printed in Germany Checking Pistons Checking Piston to Cylinder Clearance | 13 - 5.
13 Engine, Crankshaft, Pistons
Cylinders and pistons are matched in size groups shown in the chart below,
Size Group Color Code Cylinder Dia. Matching Piston Dia,
mm mm
Standard size
Nominal dia, 94.0 mm Co.
1st oversize
Nominal dia, mm
2nd oversize
Nominal día, mm
If the measurement reveals that clearance between piston and cylinder is close to 0,2 mm, replace
piston and cylinder with a set of same size group (standard or oversize). The weight of pistons in a
given engine should not differ more than 10 g. Damaged pistons from cylinders which show traces of
wear should not be replaced alone, However, if the given cylinder shows no traces of wear, its piston
may be replaced alone with one of the respective size group. |
To maintain normal compression ratio, bored out cylinders are fitted with oversize pistons of lower
height (measured between piston pin bore and piston crown).
CAUTION
Only cylinders and pistons of one given size group may be installed in a given engine,
Engine oil consumption, together with wear, is a determining factor in replacing pistons and cylinders.
If the oil consumption exceeds 1.5 ltr/gt per 600 mi, it is generally an indication for the need of an
engine overhaul,
PISTON AND CYLINDER INSTALLATION
Piston rings, removing and installing Cylinder on piston, installing
13 - 6 - Checking Cylinder to Piston Clearance Printed in Germany
TOOLS
Engine,
Crankshaft, Pistons
13
Printed in Germany
No. | Description Special Remarks
Tool
1 Crankshaft seal installer | VW 190
| (fan pulley end)
2 Crankshaft seal installer vw 191
(flywheel end)
8 Dial gauge holder VW 659/2
or VW 387
4 Not applicable
5 Fan hub thrust plate VW 185
6 Flywheel lock VW 21oc
Tools 13-7
13 15 10 11 12 14 2120 25 27 18 17
13 Engine, Crankshaft, Pistons
24 22 19
i ||
чт %
2 | |
> = ви”
a
. |
=
RN
@ .…
Note when
; ` a ti . t ,
No Description Qty Removing Installing Remarks
1 Bolt 5 | Torque to 107,9
M 12 x 1,5 | В Nm (11 mkg).
self locking
2 Washer 1 Replace,
8 Felt ring, needle 1 Dip in oil,
bearing |
4 Flywheel 1 Damaged teeth can be Clutch disc contact
machined up to max, surface must be free of
2 mm on clutch end. grease or oil, Lubri-
. Machine chamfer on cate oil seal seating
teeth, Replace fly- surface, Use flywheel
wheel if bolt holes lock VW 215c.
are wor too large,
Make sure that needle
bearing fits properly.
13 - 8 Crankcase and Flywheel Exploded View . | Printed in Germany
13
Printed in Germany
Engine, Crankshaft, Pistons
Note when
+ - + t - a | +
No Description | Qty Removing Installing Remarks
5 Needle bearing 1 Lubricate if it was washed.| See page
Note installation depth, 13-11
6 Rubber seal, 1 Replace. Lubricate
flywheel lightly,
7 Spring pin 1 Replace flywheel if
spring pin is loose,
8 Seal 95 mm dia., 1 Replace, Lubricate . See page
crankshaft lightly, Install with VW 13-13
191 all the way ín. Do .
not cant,
9 Spacer 3 Determine thickness by See page
adjusting end play, Use 13 - 12
dial gauge holder VW
659/2 or VW 387,
10 Bolt 1 Torque to 31,4 Nm
M 8x 30 (3.2 mkg)
self locking
11 Washer 1
12 Hub, fan 1 Use 3 bolts See page
M8 and VW 185 13 - 13
13 Woodruff key 1
14 Rubber seal, hub 1 Replace, Lubricate
lightly,
15 Seal 65 mm dia., 1 Replace. Lubricate See page
crankshaft lightly, Use installer 13 - 13
VW 190,
16 Bolt M 8 4 Torque to 29,4
self locking Nm (3.0 mkg)
17 Nut 6 Torque to 32.4
M10 x 1.25 Nm (3.3 mkg). Replace
damaged nuts, Coat with
sealing compound D 3,
Crankcase and Flywheel Exploded View 13 - 9
13
Engine, Crankshaft, Pistons
. Remarks
No, Description Qty Removing Note when Installing em
19 Bolt | 6 Coat bolt heads with
| M 10 x 1.25 x 213 sealing compound D 3
20 Seal 1 Replace
21 | Bolt 1
M 8 x 113
(oil pipe)
- 22 Nut M 8 10 Torque to 19,6
Nm (2.0 mkg).
23 | Washer 20
24 Bolt M 8 5
25 ‘Nut M 6 2
26 Washer 2
21 Ignition cable holder | 1
28 Bolt M 6 2
29 Seal 2 Replace,
30 Cover 1
31 Cable 1
32 Gasket - 1 Replace, Coat both
sides with sealing
compound,
33 Cover 1 Replace,
34 Seal 1 Replace.
35 Temperature sensor 1
36 Seal 1 Replace.
37 Crankcase 1 Use rubber mallet, Check for external
Do not damage mating damage and cracks,
surfaces by using sharp Clean mating surfaces
edged tools with cleaning solution,
Check flatness, Break
edges of bearing bores
if necessary, Flush oil
~ passages dry with
compressed air, Check
tightness of studs.
13 ~ 10
Crankcase and Flywheel Exploded View
Printed in Germanv
Engine, Crankshaft, Pistons 13
CHECKING FLYWHEEL
CHECKING ASSEMBLING CRANKCASE
1, Check cam follower bores in crankcase,
2. Join crankcase halves and first tighten the
oil suction pipe mounting screw slightly,
using a seal,
2. Join crankcase halves and torque bolts to 8 a new se
specifications, Use inside micrometer and
master gauge to check crankshaft bearing
- bores in crankcase, 3. Then install and tighten the M 10 x 1,25
nuts,
Assembling | 4. Now tighten the M 8 and M 6 nuts,
1. Apply an even thin coat of sealing compound
to the mating surfaces of the crankcase halves, 5. Turn crankshaft to check for free rotation,
Make sure that no sealing compound comes in
the oil passages for the crankshaft and cams-
haft bearings.
Printed in Germany Checking Flywheel Checking and Assembling Crankcase 13 - 11
13 Engine, Crankshaft, Pistons
CRANKSHAFT END PLAY
End play: New: 0,07 - 0,13 mm 6. Insert seals for crankshaft and flywheel as
Wear limit: 0.15 mm well as felt ring.
7. Install flywheel with all three shims and a
new washer.
8. Recheck end play,
Shims are available in the following thick-
nesses.
0.24 mm 0.34 mm
0.30 mm 0.36 mm
0.32 mm 0.38 mm
The thickness is etched on each shim. If
necessary check the shim thickness with a
micrometer,
Adjusting End Play
1, Install flywheel with two spacers, but.
h hi tal b ed t
without the seals for crankshaft and flywheel, Three shims must always be used to make
up the given total thickness, -
2. Install dial gauge holder with a dial gauge
-on crankcase. |
3. Move crankshaft back and forth. Read end
play on dial gauge.
4, Determine thickness of third shim,
- Dial gauge reading
= 0.10 mm mean end play
= 3rd shim thickness
5. Remove flywheel,
13-12 Adjusting Crankshaft End Play Printed ín Germanv
Engine, Crankshaft, Pistons 13
REMOVING AND INSTALLING CRANKSHAFT SEALS
Hub for fan, removing Seal - crankshaft, installing (flywheel end)
Seal - crankshaft, installing (fan end)
Printed in Germany Removing and Installing Crankshaft Seals = 13 - 13
13
Engine, Crankshaft, Pistons
Description
Qty.
Note when
Removing
Installing Remarks
Camshaft
Check rivets securing
gear to camshaft,
Check cams and
bearing journals
for wear and contact
pattern,
Check runout, Check See page
end play at thrust 13 - 16
bearing, Note pair-
ing and timing with
crankshaft, Check
backlash over
entire camshaft gear
13 -l14
Preassembled Crankshaft and Camshaft Exploded View
Printed in Germany
13
Printed in Germany
Engine, Crankshaft, Pistons
N D ot Qt Note when
> SEP or Ye Removing Installing Remarks
2 Crankshaft with 1 Oil bores in crankshaft
connecting rods journals and bearings
should not have sharp
edges, Check that dowel
pins fit properly in
bearings.
3 Crankshaft 1 Check for wear, Lubricate, Dowel pin
bearing 1 bore faces flywheel,
4 Crankshaft bearing 1 Check for wear, Lubricate, Groove
4 faces fan,
5 End plug, cam- 1 Install with sealing
shaft compound, +
6 Bearing shell, 1
camshaft bearing 1
7 Bearing shell, cam-| 1 Check for wear, Lubricate, Be sure tabs
shaft bearing 2 engage in recesses in
crankcase,
8 Bearing shell, left, 1
camshaft bearing 3
(with shoulder)
9 Dowel pin, crank- 4 Check tightness,
| shaft bearing
10 Bearing shell, crank-| 1 Check for wear Lubricate,
shaft bearing 2
il Crankcase, left 1 Crankcase with circum-
half ferential retaining web
7 for oil splash shield,
12 ibration d 6
vibration dampers The following parts are not illustrated, but must be
installed in right crankcase half prior to assembly,
13 Dowel pin, crank- 1 Check tightness,
shaft bearing 2
14 Bearing shell, crank4j 1 Check for wear Lubricate.
shaft bearing 2
15 Bearing shell, cam- | 1
shaft bearing à
16 Bearing shell, cam-| 1 Check for wear. ~ Lubricate, Be sure tabs
shaft bearing 2 engage in recesses in
crankcase,
17 Bearing shell, right, | 1
camshaft bearing 3
18 Oil suction pipe 1
19 Seal, oil suction 1 Replace,
pipe
20 Oil splash shield 1
Preassembled Crankshaft and Camshaft Exploded View 13 - 15
Pistons
13 Engine, Crankshaft,
Checking and Installing Camshaft
Checking Runout:
New: Max. 0,02 mm
Max. 0.04 mm
Wear limit:
+
es
«о
r7
%
A
Camshaft runout, checking
Checking End Play (at thrust bearing)
New: 0,04 - 0.13 mm
Wear limit: 0.16 mm
| |
y
Camshaft end play, checking
Check backlash over entire circumference of
camshaft gear.
The backlash between the camshaft gear and
crankshaft gear is 0,00 - 0,05 mm,
The camshaft gear is of the right size when
the backlash is hardly noticeable and the
camshaft does not lift when the crankshaft is
turned in reverse direction .
To obtain the specified backlash, camshafts
are available with various sized timing gears
under different part numbers,
The gears are marked on the side facing the
cams below the teeth with stamped numerals
such as "-1", "O", "+1", "+2" etc, , The
numerals indicate by 1/100 mm how the
pitch circle radius differs from the blueprint
dimension "O".
Caution!
Do not confuse the numeral O with the symbol
O which is a timing mark,
Crankshaft gears are available in one size only
and bear no size markings,
Camshaft - Installation Position
13 - 16, Checking and Installing Camshaft
Printed in Germany
Crankshaft, Pistons 13
Engine,
TOOLS
TTT A 3
#
13 = 17
Tools
Printed in Germany
13
Engine, Crankshaft, Pistons
No, Description Special Remarks
Tool
1 Support VW 4517
(adapter) plates
2 Not applicable
3 Tube 60 mm dia. VW 415a
4 Guide sleeve, tapered / VW 428a
5 Crankshaft holder Vw 801
6 Connecting rod aligning and Vw 214f
reaming set
7 Press plate VW 402
8 Tube . VW 421
9 Tube VW 416b
10 Press block VW 409
11 Circlip pliers VW 161a
12 Feeler gauge Commercial item
13 - 18 Tools
Printed in Germany
Engine, Crankshaft, Pistons
13
No.
Description
Qty.
Note when
Removing
Installing
Remarks
Crankshaft
Circlip
Check for wear, Ring
test,
Use VW 16la
Clean oil passages with
compressed air, Check
runout,
Do not store without
oiling or greasing, Mi-
nor seizure burrs on
crankshaft or distribu~
tor drive gears can be
removed carefully,
Use VW 415a and
VW 428a
See page "
13-21
Printed in Germany
Crankshaft with Connecting Rods Exploded View
13-19
13
Engine, Crankshaft, Pistons
Description
Qty.
Note when
Removing
Installing
Remarks
10
11
12
Distributor drive
gear
Spacer
Crankshaft gear
Crankshaft
bearing 3
Woodruff key
Nut, connecting
rod
Connecting rod
| Connecting rod
bearing shell
Connecting rod
bushing
Spacer
Use VW 457. Check
for wear.
Use press and VW 457
Check for wear,
Replace, if
damaged,
Check with vw 214f
Check for wear,
Check for wear. Use
VW 402, VW 409,
VW 416b and VW 421
Heat to approx 80“ C/
176 F, Use VW 415a
and VW 428a-, Check
teeth,
Heat to approx 80 C/
176 F. Chamfer fac-
es bearing. 3, Use VW
415a and VW 428a,
Check teeth, -
Lubricate, Dowel pin
bore faces crankshaft
web,
Replace. Torque to
32.4 Nm (3.3 mkg).
Lubricate bearing
surface,
Max. weight dif-
ference 6 g, Note
position and weight,
Check end play,
Lubricate,
Use VW 402, VW 409
and Vw 421. Piston
pin must slide in under
light finger pressure,
See page
13 - 21
See page
13-21
See page
13 - 24
See page
13 - 23
See page
13 - 24
13 - 20
Crankshaft with Connecting Rods Exploded View
Printed in Germany
Engine, Crankshaft, Pistons 13
DISASSEMBLING AND PREASSEMBLING CRANKSHAFT
Crankshaft gear and distributor drive gear,
pressing on
Circlip, assembling
Runout at bearings Bearing Imbalance
2 and 4 (bearings journal out
1 and 3 on V-block) of round
Max. 0.02 mm Max.0.03mm Max,l2cmg
Crankshaft gear and distributor drive gear, pressing
off
Printed in Germany Disassembling and Preassembling Crankshaft 13 - 21
13 Engine, Crankshaft, Pistons
REGRINDING CRANKSHAFT
Main bearing Crankpin journals Main bearing
journals (d 1) journal 4 (d 2)
1, 2 and 3 (d)
Nominal Lapped Nominal Lapped Nominal Lapped
dia. mm dia, mm dia. mm dia, mm dia, mm dia. mm
Standard 60,00 59,990 50,00 49,996 40.00 , 40,000
59.971 49,983 39,984
lst Undersize 59,75 59.740 49.75 49,746 39, 75 39.750
09,721 49,733 39,734
2nd Undersize 59,50 59.490 49,50 49.496 39..50 39,500
59.471 49,483 39,484
3rd Undersize 59,25 59.240 49,25 49,246 39.25 39,250
59.221 49.233 39.234
X
NT
—+ + di + +
HDL.
171
7 | —1-9
Careful grinding of main bearing and crankpin journal radii is very important for the service life of
the crankshaft, A radius of 2,5 mm would be ideal, The radii surfaces must be polished smooth,
Never recondition the bearing shells.
Make sure that after grinding the oil bores do not have sharp edges. Break the edges slightly, if
necessary.
The crankshaft gear and distributor drive gear must have an interference fit of 42.006 mm dia. on the
41,995 mm día,
crankshaft, If frequent removal and installation of these gears have resulted in the loss of the inter-
ference fit, it can be restored by chroming or metal spraying in the appropriate areas.
Make sure that the crankshaft has no cracks by checking it with a ringing test, Then check the
crankshaft for runout, |
13 - 22 Reconditioning Crankshaft Printed in Germany
Engine, Crankshaft, Pistons 13
CHECKING AND INSTALLING CONNECTING RODS
Check connecting rod weight,
Connecting rods used in a given engine must not
differ in weight by more than 6 g.
Note
Connecting rods cannot be reconditioned,
The installed weight classes are available as
spare parts,
2 A > "
hs YE
ALTER
ll
ES
ИТ
=~
a
The codes on the mating surfaces of connecting
rod and cap must be on the same side when
assembled,
Side Play
New: - 0.1 - 0.4 mm
Wear limit: 0,7 mm
Minor binding, which can occur in the bearing
shells when the connecting rod bolts are tightened,
can be eliminated by applying light blows to
both sides of the connecting rod with a hammer,
Connecting rod side play, checking,
Printed in Germany Checking and Installing Connecting Rods | 13 - 23
Pistons
13 Engine, Crankshaft,
RECONDITIONING CONNECTING RODS
Connecting rods which are slightly bent or have
worn piston pin bushings should be straightened
and have new bushings installed.
i= Fi
ES
W421
|
Ne
JE ==
Connecting rod bushing, pressing out.
Clamp connecting rod in fixture VW 214f.
A = Mandrel D - Support
B - Locking lever Е - Piston pin
C - Washer F - Gauge
1, The mandrel À is turned until its milled
surface is at right angles to the center line
of the connecting rod.
2, After installing washer C, tighten lever B
so that the connecting rod can still be
turned in both directions, Support D is
left loose.
45 . MA Dannanditinnino Cnnnactina Rade
Printed in Germany
3. Insert pin E into connecting rod and press it with
two fingers against mandrel A so that no tilting
occurs between the mandrel and connecting
rod or connecting rod bushing and pin,
4, Check connecting rod for twist and parallelism
with the aid of the gauge. The illustration
shows inspection for parallelism.
If connecting rod is misaligned, tighten lever
B and straighten with the aid of the bar.
Connecting rod bushing, pressing in.
Engine, Crankshaft, Pistons 13
5, Drill 8.5 mm dia. oil holes.
6. Insert shaft of reamer through the connecting
rod small end and the respective hole in the
working fixture, The conical bushing will
center the small end of the connecting rod,
Tighten lever B and support D.
Inside diameter of
. ; ; 24,015 - 24,024 mm
piston pin bushing:
+
The inner surface of the bushing must be free
of scoring or chatter marks, The piston pin
must enter under light finger pressure without
lubrication,
Always replace a bushing with excessive wear,
Never install a piston pin with a larger diameter.
7. Recheck parallelism and twist, this time using
the piston pin, in the manner described above,
If there is still misalignment, it can be
corrected with the aid of a bar inserted into
the connecting rod small end.
Printed in Germanv Reranditinnino Cannectino Rade | 13 - 95
Engine, Cylinder Head, Valves 15
TOOLS.
No, Description Special Remarks
| Tool
1 Checking device for valve guide US 4404A +
clearance US 4420
2 Feeler gauge Commercial item
3 Valve adjuster US 1101 or commercial item
4 Valve lapper Commercial item
5 Valve spring compressor VW 311 s
Printed in Germany Tools 15 -1
15 Engine, Cylinder Head, Valves
18 32 31 17 34 3 21 20 9% 30 29 28 27 4 3
Note when
+ ; i ti +
No Description Qty Removing Installing Remarks
1 | Cylinder head cover 2 Clean,
2 Gasket, cylinder head 2 Replace, paste,
cover | |
3 Nut M 7 | 8 | Torque to 13.7 Nm
(1.4 mkg).
4 Washer 8
5 Bearing support 8 Check for wear and Slot faces down, See page
scoring marks. Chamfered edge 15 - 5
faces outward,
15 - 2 Cylinder Head and Valves Exploded View Printed in Germanv
Engine, Cylinder Head, Valves
15
N D cription ° Qt Note when Remarks
Oe EE у. Removing Installing
6 Exhaust rocker arm 4 Check for wear and
scoring marks,
7 Thrust washer 8
8 Spring 4
9 Intake rocker arm 4 Check for wear and
scoring marks,
10 Valve adjusting 8 — Replace if binding.
screw s
11 Nut M 10 x 1 8 Replace if binding.
12 Rocker arm shaft 4 Check for wear and
scoring marks,
13 Retaining clip for 2 Must engage in bearing See page
push rod tubes support slots and rest on 15 - 5
lower edges of cover,
14 Push rod 8 Mount on centers to
check runout, Max,
0.3 mm,
15 Seal, gray 8 Replace.
16 Seal, black 8 Replace.
17 Tube, push rod 8 Push in to stop.
18 Cam follower 8 Check for wear and Lubricate with engine
scoring marks, oil when installing,
19 Nut M 10 16 Tighten in sequence, See page
Tighten lightly first, 15 - 5
then torque to 31,4 Nm
(3.2 mkg).
20 Washer 16
Printed in Germanv Cain Ana Hna d nd atras Пенн АЯ АЙ Vine» 16 - 9
15
Engine, Cylinder Head, Valves
2 Note when
No, | D tion ty.
) escription Qty Removing Installing Remarks
21 Cylinder head 2 Check for cracks in
combustion chambers
and exhaust ports, also
for leaks along cylinder
mating surfaces. Check
spark plug threads for
damage or tightness,
Install heli-coil inserts
if necessary.
Left cylinder head has
threaded bore for
temperature sensor.
22 Screw M 5 x 10 2
23 Washer . 2
24 | Screw M 6 4
25 Washer 4
26 Baffle 2 Left and right different,
27 Valve keeper 16 Replace worn valve
keeper,
28 Valve spring retainer 8
29 Valve spring 8
30 Not applicable
31 Intake valve 4 Use VW 311s, Check Coat valve stem with See page
seat for burnt spots or molybdenum disulfide 15 - 5
wear, reface if paste,
necessary,
Remove burrs from
keeper bearing sur-
faces,
33 Intake valve guide 4 Check for wear, See page
15 - 8
34 Exhaust valve guide 4
15 - 4 Cylinder Head and Valves Exploded View Printed in Germany
Engine, Cylinder Head, Valves 15
INSTALLATION NOTES ON CYLINDER HEAD AND VALVES
JO TUE
С OIQ
oo e
Lh" Ne”
Screw on cylinder head nuts lightly and then
tighten in sequence illustrated above,
Retaining clip, installing
Bearing support, installing | Valve springs, removing and installing
Printed in Germany Installation Notes on Cylinder Head and Valves 15 - 5
15 Engine, Cylinder Head, Valves
MACHINING INTAKE VALVES REFACING VALVE SEATS
— с z—
o - - - а
Intake Valve | Exhaust Valve
à | 41,8-42,2 mm dia.| 35.8-36.2 mm dia.
b} 7,94-7.95mm dia.| 8.91-8,92 mm dia,
с 116.8 mm 117 mm
45 45
Caution | |
| Valve seats showing wear or burnt spots can be
refaced as long as the permissible seat width
can be maintained and the 15 chamfer at its
outer circumference does not exceed the out-
side diameter of the valve seat insert, If it
does, replace cylinder head with a new or
overhauled unit, The valve seat inserts cannot
be replaced with conventional shop tools
~ because the inserts are (cold) shrunk in.
Exhaust valves must not be turned, Only
grinding in is permissible,
When grinding in valves, frequently lift and
turn valve to avoid scoring,
Valve Seat Width (a)
Intake 1.8 - 2.2 mm
Exhaust 2,0 - 2.5 mm
is - 6 Machining Valves Refacing Valve Qeate
о |
Machining 45° Surface
45°
Remove a minimum of base material, Conse-
quentiy the work must be stopped as soon as the
whole seat surface has been machined,
Machining 75° Surface
—— +
75°
SN A ^^
“о xo
в МММ `
AN
NEIN
Chamfer bottom edge of exhaust valve seat
insert slightly,
Engine, Cylinder Head, Valves 15
Machining 15° Surface
Ma So
*
N SN
bY
a,
o -
Pa
+
= . 7
Pa =
Machine the upper edge of the valve seat insert
until the specified seat width is reached.
Printed in Germany
Refacing Valve Seats | 15-7
15 Engine, Cylinder Head, Valves
CHECKING VALVE GUIDES REPLACING VALVE GUIDES
1. Remove deposits with cleaning reamer, Worn or damaged valve guides can be replaced
with the universal cylinder head repair set,
Oversize valve guides with a shoulder are
| available for repairs,
2. Place cylinder head on mounting plate
US 4420 and fasten with bracket.
3. Insert new valve in guide, End of valve 1. Clean and check cylinder head. Cracked
stem must be flush with guide, cylinder heads and or heads with valve seat
. inserts which cannot be refaced, are not
suitable for the installation of new valve
guides,
4. Determine side play,
Fasten cylinder head with the combustion
end facing the mounting plate.
N
Adjust inclination of mounting plate to 13°,
со
`
4. Drill out valve guides with a step drill to
a depth of 40 ~ 50 mm (drill speed about
100 rpm).
Intake Exhaust |
Wear
valve valve ,
limit
guide guide
Side play 0.30 mm 1.2 mm
nsid
Inside 8.02mm! 9.02mm | 9.06mm
diameter
dia, dia, dia,
15 -8 Checking Valve Guides Replacing Valve Guides Printed in Germany
Engine, Cylinder Head, Valves 15
9. Drive out drilled guides with a drift. Caution
The pressure for installing should be between 1 and
2 tons,
7. Ream inside bores of valve guides, Always use
a cutting solution while reaming.
E 7
Ja
6. Coat 1st oversize valve guides with engine oil
and install them with the aid of a press,
A
[E Bae A
LE TT —
8. Check dimensions of reamed valve guides,
ola Ta
pe Tl ET
lt SE TFT a OR Lt TE FIT
9. Reface valve seats,
ee ED
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Ftd O SWE ET Fo EEE E BACA
Na Pr
i
||
Printed in Germany Replacing Valve Guides | 15 - 9
15 Engine, Cylinder Head, Valves
CHECKING AND ADJUSTING VALVE CLEARANCE
The valve clearance must always be checked
and /or adjusted when the engine is cold,
Specifications: Intake = 0,15 mm
Exhaust = 0,20 mm
The valve clearance is adjusted in the
sequence of 1st, 2nd, 3rd and 4th cylinders.
The piston of the cylinder in question must be 2. Check valve clearance with feeler gauge,
at TDC of the compression cycle, because both adjusting to specifications if necessary,
valves are then closed, e
1. Move cylinder 1 to TDC, 3. To adjust the valves of cylinders 2, 3 and
- 4, turn the crankshaft counterclockwise
until the distributor rotor arm moves 90
each time,
15 - 10 Adjusting Valve Clearance Drinea AI. ~
Engine, Lubrication 1 7
TOOLS
No, Description | Special Remarks
Tool
1. Oil cooler tester VW 661/2
2 Oil pump cover puller | VW 803
3 Oil filter wrench | US 4462 or commercial item
4 Internal head socket, M 14 | US 1007 or Commercial item
5 Oil pressure and oil pressure switch test set | VW 662/2
6 Oil pressure switch wreach commercial item
Printed in Germany Tools 17 <1
17 Engine, Lubrication
41 42 44 39 1
27 26 25 24 18 17 1
17-2 Oil Circuit = Exploded View oo
17
Engine, Lubrication
Note when
| . Remark
No. Descrip tion Qty Removing Installing cars
1 Oil filler cap 1
2 Oil filler 1
3 Nut M 6 2
4 Washer 2
5 Oil filler gasket 1 Replace
6 Oil breather 1
7 Gasket 1 Replace
8 Oil dipstick 1
9 Nut M 8 4 Torque to 19,6 Nm
(2.0 mkg).
10 Washer 4
11 Oil pump housing 1 Check for wear, Use 2 Clean gasket surface, See page
levers. (especially gear Center by turning 17-6
bearing surface). crankshaft twice,
Tighten nuts,
12 Gasket, oil pump 1 Replace,
housing
4 Nut M 6, self-
locking
14 Washer 4
15 Oil pump cover 1 Use VW 803, Check See page
for scoring, 17 - 6
16 Seal, oil pump 1 Replace, Lubricate,
| cover
17 Oil pump gear 1 Check for wear, Lubricate. Check for
free movement,
18 Drive shaft 1 Check for wear, Lubricate, Lug must be
flush with slot in
camshaft,
19 Oil pressure switch 1
20 Plug M 22 x 1,5 1
Printed in Germany ОЙ Стен! = Fynladed Viowu зо‘
17
Engine, Lubrication
2, Note when
No. Description Qty, , , Remarks
Re moving Installing
21 Seal 1 Replace.
22 Spring, oil pressure 1 Check, Compressed
relief valve (bottom) spring length: 39,0mm,
Load: 66.7-86,3 N
(6.8 - 8,8 kg)
23 Plunger, oil pressure 1 Check for wear, Smooth scoring marks
relief valve carefully, Use thread
tap if necessary,
24 Plug M 16 x 1,5 1 Use internal socket
M 14.
25 Seal 1 Replace,
26 Spring, oil pressure 1 Check, Compressed
relief valve (side) spring length: 16,8mm,
Load: 42.7 N
(4.39 kg).
27 Plunger, oil pressure 1 Check for wear. Smooth scoring marks
relief valve carefully, Use thread
tap if necessary.
28 Nut M 8 1 Max, torque 12.7 Nm
(1.3 mkg).
29 Seal 1 Replace.
30 Oil strainer cover 1 Gasket surface must be
straight, Clean gasket
surface,
31 Gasket 2 Replace,
32 Oil strainer 1 Clean. Check for
damage,
33 Plug 1 Torque to 21,6 Nm
(2.2 mkg).
34 Seal 1 Replace,
35 Nut M 6 3
36 Washer 3
37 Washer 3
38 Oil cooler 1 Check shrouding for See page
tightness, Check for 17-6
leaks with oil cooler
tester VW 661/2,
Test pressure 5.9 bar
(6 atm), Check oil
pressure relief valve,
if cooler leaks,
17 - 4
Oil Circuit = Fxninded View
Engine, Lubrication 17
t
No, "Description Qty. ‚ Note when ‚ Remarks
Removing Installing
39 Seal, oil cooler 2 Replace
40 Oil filter 1 | | Clean gasket surface See page
and oil lightly, Tight- 17 - 6
en oil filter with wrench,
41 Nut M 6 2
42 Washer 2
43 Flange, oil filter 1 Clean mating surface,
44 Gasket l Replace
Printed in Germany Oil Circuit - Exploded View : 17 нЕ
17 Engine, Lubrication
À
:
!
3
|
:
Oil filter, removing and installing
17 = 6 Removing and Installino Nil Pimn Hancina 1 Favor Mil Bilt aw Drintad
. E
trs à —— — —
Engine, Lubrication
CHECKING OIL PRESSURE AND OIL PRESSURE SWITCH
1. Remove oil pressure switch and screw it into
tester,
2. Install tester in crankcase in place of oil
pressure switch, Connect test lamp to oil
pressure switch and terminal 15 of ignition
coil,
3. Turn on ignition,
If test lamp does not light, replace switch,
4, Start engine, Increase speed slowly, Lamp
must go out at pressure of 0,15 to 0,45 atm
(2.1 to 6.4 psi),
d. Increase speed further,
At 2000 rpm and 80 °c/176°F oil temperature
the oil pressure must be at least 2.0 atm
(28 psi),
Printed in Germany Checking Oil Pressure and Oil Pressure Switch
FM
Engine, Cooling System 19
26 24 2325 32 31 10 12 11 8 6 9 1
Printed in Germany Cooling System - Exploded View - 19" = 1
19
Engine, Cooling System
ipti | Qt Note when Remarks
No. Description a Removing Installing
1 Belt, air pump 1 Check for wear. Replace
if necessary.
2 Cap, end cover 1
3 Socket head screw 1 Loosen to adjust belt, See page
19 - 5
4 Washer 1
5 Square nut 1
6 Bolt 3 Torque to 20 Nm
(2.0 kpm).
7 Washer 3
8 Bolt 3
9 Drive shaft with 1
pulley
10 Scale, ignition 1
timing
11 Belt 1 Check for wear. Replace Check tightness by
if necessary. applying heavy thumb
pressure at middle of
belt, Should deflect
approx 15 mm,
12 Fan 1
13 | Spacer oa
14 Bolt 1
15 Washer 1.
16 Nut 1.
17 Screw 1
18 Washer 1
19 Shroud, alternator 1
20 Alternator 1
21 Seal, alternator 1
19 - 2 Cooling Svstem = Fxploded View Dedmend fm man.
Engine, Cooling System 19
No. [Description | Qty. Removing Note when Installing Remarks
22 Adapter, alternator 1 Insert into front fan
housing half,
23 Nut 4 Torque to 20 Nm
(2.0 kpm),
24 Washer 4
25 Fan housing half rear 1
Remove and install together,
26 Fan housing half, front 1
27 Bolt 3
28 Washer 3
29 Screw 7
30 Washer 7
31 Shaft 2
32 Non-return air flap 2 Check for free
movement,
33 Bolt 1
Máx8
34 Washer 1
39 Square nut 1
36 Screw 2
37 Washer 2
38 Support spring, shaft 2
39 Control flap with 1
shaft, right
40 Support 2
41 Bracket, control flap 1
42 Control flap, left 1
44 Bolt M6 1
Printed in Germany Cooling System = Exploded View | 19 -'3
19 Engine, Cooling System
Note wh
No. Description Qty. ore wien ; Remarks
Removing Installing
45 Pulley, cooling air 1
control cable
46 Washer 1
47 Cable, cooling air 1 Detach before removing See page
control fan housing, 19 - 6
48 Bolt 1
49 Washer 1
50 Washer, thermostat 1
51 Thermostat 1 Test in water, See page
19 - 6
52 |. Holder, thermostat 1
Drintad im 7 Reem о
19 - 4 Cooling Svstem =~ Fxnladed View
Engine, Cooling System 19
CHECKING AND ADJUSTING BELT TENSION
Check tightness of belt by applying considerable
thumb pressure at center of belt,
Deflection: ca. 15 mm
Belt tension, adjusting Fan housing, removing and installing
Detach the cooling air control cable before
removing housing,
—_— Note:
Both housing halves can be taken out together
and without removal of the alternator,
Printed in Germany Checking and Adinistino Ralt Tanetmn в —
19 Engine, Cooling System
CHECKING THERMOSTAT
RE
|
| < >
C | —
C )
C ` )
C - D
( | : >
а C I J
( J)
С —
C | J -
( - —
С —
C >
f À
| — | ] —
1
> Length "a" of the unit must be at least 46 mm |
when the water in which the thermostat is
submerged has a temperature of 85 to 90°c/
185 to 194 F,
ADIUSTING CONTROL FLAPS
The bent ends of the return spring must be
located on the retaining spring boss and
behind the cable guide (arrows).
Engine cold, ambient temperature ca, 20 C/
68 F, press control flaps toward closed
position and clamp the cable without tension,
19-6 Checking Thermostat Adjusting Control Flans
Dive nea foo N Lt
Fuel System 20
REMOVING AND INSTALLING FUEL PUMP
+
Removing
1. Disconnect battery ground strap. 5. Remove rubber boots and detach electrical
connections,
2. Remove guard,
3. Pinch suction line with a commercial hose
clip and loosen hose clamp,
6. Loosen fuel pump strap and remove pump.
4. Loosen pressure hose clamp and pull off hose, Installing
Catch escaping fuel,
J 1. Slide fuel pump onto suction hose, place
rubber band around pump and fasten pump
with strap,
Install pump with negative connection on
top at an angle of about 55° toward front,
=
di
a А
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Printed in Germany | Removing and Installing Fuel Pump - 20 +1
20 Fuel System
2. Tighten suction hose clamp, 7. Check hose connections for leaks,
3. Make electrical connections. Watch polarity 8. Install guard,
marks,
9. Connect battery ground strap.
4, Install rubber boots,
Note
Make sure that the boots fit properly to
prevent corrosion on the terminals.
-
9. Connect pressure hose and hold tight with
hose clamp,
6. Remove commercial hose clip,
20 - 2 Removing and Installing Fuel Pump Printed in Germany
Fuel System 20
CHECKING FUEL PUMP DELIVERY RATE
1. Loosen adapter hose clamp and pull adapter 4. Hold end of fuel return line in a measuring
off of air volume control, glass (approx 1000 cc) and open flap by hand
until the pump delivers fuel, Let fuel run
into glass for 30 seconds.
a == : E - À | ии
Brig rb ERR WT Se M3
2. Detach fuel return line in engine compartment
and loosen clamp.
0. Release flap after 30 seconds, Flap closed,
pump contact breaks and pump stops delivering
fuel,
6. The amount of fuel must be at least 500 cc,
Note
Check the fuel pump current draw if the
amount of fuel does not meet specifications,
Replace fuel pump if necessary,
Fuel Pump Test Specifications
The fuel pump delivery rate for testing is
500 cc at 30 seconds and 12 volt nominal,
Nominal voltage = 12 V
3. Turn on ignition, Operating voltage = 7-15V
Current draw = Max. 4.5 À
u
Operating pressure Max. 2.5 (35psi)
Printed in Germany Checking Fuel Pump Delivery Rate 20 - 3
20 Fuel System
REMOVING AND INSTALLING FUEL FILTER
Removing 2. Fasten clamp and fuel hoses,
Caution!
Clamp must not be too tight to prevent
1. Disconnect battery ground strap, damaging the filter
2. Detach fuel hoses, pinching ends,
3. Connect battery ground strap, Let engine
Warning: | ; run briefly and check connections for leaks,
Catch escaping fuel in an appropriate container,
3. Loosen clamp and remove filter.
Installing
1, Install filter so that the arrow on the
filter faces in the direction of flow.
20 - 4 Removing and Installing Fuel Filter Printed in Germanv
24
Fuel Injection
Fuel System,
OA _ na
TIT 90
6 350 TF0 906 220 SFO 906 3320 00 TOT S09 666 00 TIT 909 $66 00 10T 819 £28 3
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13
Faninment Chart
Printed in Germany
Fuel System, Fuel Injection 24
REMOVING AND INSTALLING INTAKE AIR SENSOR WITH AIR CLEANER
Removing
1. Detach strap, breather hose and clips,
3. Remove intake air sensor with top section of
air cleaner,
4. Loosen winged screw and remove air cleaner,
Printed in Germany Removing and Installing Intake Air Sensor with Air Cleaner 24 -1
+
24 Fuel System, Fuel Injection
REMOVING AND INSTALLING THROTTLE VALVE HOUSING
Removing Installing
1. Loosen and remove hose between intake air 1. When installing make sure that the gasket
sensor and throttle valve housing, is positioned correctly between air distri-
butor and throttle valve housing. Screws
must not be too tight,
2. Detach return spring, disconnect operating
cable, pull off vacuum hoses, loosen
mounting screws and remove throttle valve 2. Engage long end of return spring on throttle
housing with gasket, valve housing.
REMOVING AND INSTALLING THROTTLE
VALVE SWITCH
EA
Ww Г.
NE
LY
if ъ "
LO ire. TER ra. dir
"Maia! TT aldrerdEL a
ыы ат
МА, e .
EA 1. Remove throttle valve housing.
` ры
2. Loosen screws and remove throttle valve
switch,
24 - 2 Removing and Installing Throttle Valve Housing Drintad in 7 arman
Fuel System, Fuel Injection 24
REMOVING AND INSTALLING CONTROL REMOVING AND INSTALLING COLD
UNIT STARTING VALVE
Removing Removing
1. Disconnect plug at control unit by pushing Disconnect electrical plug and fuel lines,
back spring and pulling out of socket at the loosen screws and remove cold starting valve
with gasket,
same time.
2, Loosen screws and remove control unit,
Installing
Installing 1. Install new gasket,
Connect plug at control unit and press into socket
until the spring clip engages with an audible
click.
2. Make electrical connection (blue plug).
Printed in Germany Removing and Installing Control Unit | 24 -3
TY a ae a LA Trad Vta 7 II PALIZA EY...
24 Fuel System, Fuel Injection
REMOVING AND INSTALLING AUXILIARY AIR REGULATOR
Removing
Disconnect hoses and electrical connection,
loosen mounting screws and remove auxiliary
air regulator,
Make electrical connection (brown plug).
Installing
Make electrical connection (black plug).
REMOVING AND INSTALLING
THERMO TIME SWITCH
Removing
Disconnect electrical connection, loosen
mounting screw and remove thermo time
switch,
24 -4 Removing and Installing Auxiliary Air Regulator Printed in Germany
Fuel System, Fuel Injection 24
REMOVING AND INSTALLING REMOVING AND INSTALLING
TEMPERATURE SENSOR II PRESSURE REGULATOR
. Removin
Temperature sensor II is screwed in the cylinder emoving
head next to the spark plug for the 3rd cylinder,
Disconnect fuel hoses and vacuum hose, loosen
mounting nuts and take pressure regulator out
Removing | of holder,
1. Detach line between temperature sensor and
wire connector,
2. Remove rubber cover and pull off over
connecting wire,
3. Unscrew temperature sensor with aid of socket.
US 1054.
Caution!
Be careful not to bend holder when loosening
or tightening mounting nuts,
Installing
1, Screw in temperature sensor.
Caution!
Not too tight,
2. Install rubber cover in proper position,
Printed in Germany Removing and Installing Temperature Sensor II 24. = 5
24 Fuel System, Fuel Injection
CHECKING FUEL PRESSURE
1. Loosen injector supply line plug. 4, Detach hose between throttle housing and
intake air sensor at intake air sensor,
y
| I |
su}
ZU
5. Turn on ignition.
'
E.
—=
a
=
=
=
ENT
6. Open stator flap by hand a little until the
pump contact makes and then read the fuel
pressure at the same time,
(4
ALL
a
- o
|
|
\
2. Connect the pressure gauge of P 378 with
an appropriate adapter or a similar pressure
gauge {rated 1, 0) to the injector supply
line,
Specifications: 2.5 = 0,2 atm/35 * 1,4 psi
: with vacuum hose disconnected.
Replace pressure regulat
3. Disconnect vacuum hose between air
or if specifications are
not met, |
distributor and pressure regulator.
1. Replace injector supply line plug.
+
24 - 6 Checking Fuel Pressure
Printed ín Germanv
CHECKING INTAKE AIR SENSOR
1. Pull plugs off of intake air sensor,
2, Connect ohmmeter to terminals 6 and 9.
Specifications: 200 to 400 ohm.
3. Connect ohmmeter to terminals 7 and 8.
Specifications: 120 to 200 ohm,
4, Connect ohmmeter to terminals 6 and 27
(temperature sensor 1).
Specifications: approx. 2000 ohms at room
temperature,
5. Connect ohmmeter to terminals 36 and 39
(fuel pump contacts), When stator flap ís
moved by hand (pump contacts close),
ohmmeter needle should move,
Replace the intake air sensor if specifications
are not met,
CHECKING THROTTLE VALVE SWITCH
1. Pull plugs off of throttle valve switch,
2. Connect ohmmeter to terminals 18 and 3.
Throttle valve closed: continuity
Throttle valve open: continuity
3. Connect ohmmeter to terminals 18 and 2.
Throttle valve closed: continuity
"Throttle valve open: no continuity
Fuel System, Fuel Injection
24
CHECKING AUXILIARY AIR REGULATOR
1. Remove auxiliary air regulator,
2. Connect ohmmeter to both terminals of
auxiliary air regulator and read meter,
Specifications: approx. 30 ohm,
Replace regulator if necessary,
3. Blow in air.
Regulator must be open if engine is cold,
4, Connect battery to both terminals of
removed auxiliary air regulator, As the
heat increases, the opening in the auxiliary.
air regulator must become smaller,
CHECKING THERMO TIME SWITCH
1. Pull plug off of cold start valve.
2. Connect ohmmeter between both contacts
of plug.
3. Both contacts must be connected with each
other at an engine temperature less than
approx + 35 C/95 F .
4, Above approx + 35 C/95 F the ohmmeter
must indicate interruption.
Replace valve if necessary,
Printed in Germany
Checking Intake Air Sensor, Checking Throttle Valve Switch 24 =.7
24 Fuel System, Fuel Injection
CHECKING COLD START VALVE CHECKING TEMPERATURE SENSOR II
1. Connect pressure gauge to injector supply 1. Disconnect plug,
line,
2. Disconnect wire from terminal 1 of ignition
coil, Operate starter briefly to build up 2. Connect ohmmeter between temperature
fuel pressure, sensor and ground and read meter,
3. Pull plug off of cold start valve, Specifications: 0,5 to 2.5 kohm (dependent on
temperature, higher temperatures =
less ohm),
4, t d t t +
Connect B+ and ground to cold star valve Reference value: approx 2.5 kohm at approx
20 C/68 F engine temperature.
5. Watch pressure gauge - pressure must drop Replace sensor if necessary,
slowly,
Replace valve if necessary,
CHECKING COLD START VALVE FOR
LEAKS .
1. Pull plug off of cold start valve,
2. Take cold start valve off of air distributor,
but leave it connected to the injector
supply line.
3. Pull wire off of terminal 1 of ignition coil,
4. Operate starter, observing cold start valve
for leaks,
Replace valve if necessary.
24 - 8 Checking Cold Start Valve, Checking Cold Start Valve for Leaks Printed in Germany
Fuel System, Fuel Injection 24
CHECKING OPERATION OF ANTI - BACKFIRE VALVE
1. Disconnect hose between valve and intake air
sensor adapter at valve and insert a plug in
open end of hose,
a TE
La
| Â L 4 г
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Ll e 14
: = [hi 4
| AE =. i E = E
“e ы ‘25 = B A
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O XT Ered р
2. Start engine. Increase speed briefly to 3000 rpm.
Close throttle valve suddenly.
3. Check if air is being sucked in through valve
hose connection, Replace valve if suction
- cannot be felt,
Printed in Germany . Checking Operation of Anti-backfire Valve | 24 - 9
24
Fuel System, Fuel Injection
ADJUSTING IDLE
1, Run engine to operating temperature
(50 - 70 C/122-158 F),
2. Connect CO tester according to instructions
of manufacturer, Use separate tachometers
from tester or similar,
3. Disconnect activated charcoal filter hose
at air cleaner,
4, Take air injection hose off of check valve
and insert an appropriate plug in the check
valve opening to give a tight seal,
m
ARLE Fa CER ,
has. Ma E
НЫ * .
a
Ро
a
5. Let engine run at idle and adjust the idle
speed on the control screw or bypass screw
on the throttle housing to specifications -
+
925 - 50 rpm,
6. Measure CO, adjusting if necessary by
taking the plug out of the intake air sensor
and changing the CO with the adjusting
screw, Turning clockwise enriches mixture;
counterclockwise leans mixture,
CO Specifications: 0,5 to 1,2 %,
7. Recheck idle speed and correct if necessary,
8. Install plug after adjustments,
Caution
Make adjustments as quickly as possible to
prevent excessive heat in intake lines.
24 - 10 Adjusting Idle
Printed in Germany
TOOLS
Exhaust System
26
Description
No, Special Remarks
- Tool
1 Universal joint socket wrench 13 mm P 120 b
Printed in Germany Tools 26 - 1
26 Exhaust System
13
12 14 24
16
17
19
26 - 2 Exhaust System - Exploded View Printed in Germany
Exhaust System
26
Printed in Germany
| Note when
. R k
No, Description Qty Removing Installing emarks
1 Nut 2
2 Washer 2
3 Gasket 1 Replace
4 Nut 2
5 Washer 2
6 “ Bolt 2
7 Gasket 1 Replace
8 Exhaust gas filter 1
9 Gasket 1 Replace
10 Thermag nut 6 Replace
11 Bolt 6
12 Gasket 2 Replace
13 Muffler 1
14 Screw 4
15 Cover with gasket 2 Install correctly,
16 Thermag nut 2 Replace
17 Bolt 6
18 Holder, right and 2 Replace
left Install correctly,
19 Heat exchanger 2
20 Gasket 2 Replace
21 Mid grip nut 4 Replace, Coat threads See page
with dry Mos. Torque 26 - 4
crosswise and evenly to
22 Nm (2.2 kpm).
22 Reactor 2 Mark for reinstallation, Check parallelism of
sealing flange, Smooth
flange if necessary,
24 Gasket 2 Replace,
Exhaust System - Exploded View 26 - 3
26 Exhaust System
INSTALLATION NOTES
Tighten reactor mounting nuts crosswise and
evenly, Keep to torque specifications.
CHECKING REACTOR FOR LEAKS
Note
The reactor 's operation need not be checked,
Only check it for leaks,
1. Run engine at idle speed.
2. Insert an appropriate plug in the muffler 's
outlet pipe and check reactor by listening
for leaks.
Replace a reactor which leaks,
CHECKING EXHAUST GAS
RECIRCULATION
1. Warm-up engine and then let it run at idle
speed. The bypass line between the muffler
and EGR valve will be hot, which is
necessary to check operation,
2. Increase engine speed to 4000 rpm, Now
the exhaust line between the EGR valve
and the intake must be hot, too,
If the exhaust line leading to the intake is not
hot, the following problems could be causing
this,
a) EGR valve defective
b) EGR lines plugged
¢) Vacuum bore in throttle housing plugged
d) Vacuum hose plugged or leaks
e) Exhaust filter between muffler and EGR valve
contaminated
REMOVING AND INSTALLING EXHAUST
GAS RECIRCULATION (EGR) VALVE
Removing
1. Pull off vacuum hose,
2. Remove mounting screws,
3. Take out valve,
Installing
Use new gaskets,
26 - 4
f'Hanbinne Panal oF mew -
Exhaust System - Installation Notes, Checking Reactor for Leaks,
Printed in Germany
28
Ignition
EQUIPMENT CHARTS
Ignition Coil
Type/Model Version Remarks
912 E 022 905 115 C
Distributor
Type/Model Version Remarks
912 E 923 602 021 00 Centrifugal and single
(without speed limiter) action vacuum control
(retarded)
Spark Plugs
Type/ Model Version *) Remarks
912 E Bosch W 175 M 30 M 14 x 1,25 x 19,0
Beru 175/14/3 L threads 0,7 mm gap
*) Or other spark plugs with the same heat range from other manufacturers as approved by VW.
Printed in Germany Equipment Charts
28 = 1
Ignition 28
ADJUSTING IGNITION TIMING
Check the dwell angle before adjusting the
ignition timing and, if necessary, correct it
to47-3,
1. Connect engine to engine tester,
2. The timing is adjusted on a arm engine
(oil temperature approx, 60 C/140 F)
with a stroboscopic timing light. Pull off
vacuum hose at either distributor or throttle
housing,
3. At an engine speed of approx. 3500 rpm the
white mark on the fan must appear to stop
at 27, To alter the ignition timing loosen the
nut on the distributor and turn the distributor,
Printed in Germany | Adjusting Ignition Timing | 28 - 3
28 Ignition
CHECKING IGNITION TIMING CONTROL IN VEHICLE
1. Adjust ignition timing according to instructions.
2. Disconnect vacuum hose and read ignition angle at 1000 rpm, 2000 rpm and 3000 rpm, and
compare with timing curve. The measurements must be within both lines.
Ignition Advance Curve for Distributor Bosch 0231176 060
BTDC
40°
30°
20°
Dwell Angle 47
Advance at Crank Shaft
Action Range of Speed Limiter
О ‚1000 2000 3000 4000 5000 6000 7000
Engine Speed (rpm) >
3. Connect vacuum hose for idle speed. The ignition timing must then move about 10° on the
crankshaft toward retarded ignition. Use a stroboscopic timing light with a meter for checking
timing advance.
28 - 4 Checking Ignition Timing Control in Vehicle Printed in Germany
Ignition 28
CHECKING DISTRIBUTOR IGNITION CURVES ON DISTRIBUTOR TEST STAND
Read ignition angles at various speeds and vacuum values, and compare data with ignition curves. The
measurements must be within both lines.
Centrifugal Advance Curve for Distributor Bosch 0231176 060
BTDC
209
150
10
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0 500 1000 1500 2000 2500 3000 3500
Distributor Shaft Speed (rpm) >
Printed in Germany Centrifugal Advance Curve 28 = 5
28 Ignitio
n
Vacuum Advance Curve for Distributor
Bosch 0231176 060
ATDC
09 N
N
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£
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109 Y
Vacuum (Torr) 50 100 150 200 250 —> 300
Vacuum (mbar) 100 200 300 400
28 - 6 Vacuum Advance Curve Printed in Germany
Ignition 28
INSTALLING DISTRIBUTOR
1. Move cylinder 1 to TDC. 2. Install distributor so that the distributor rotor
The white mark on the fan must be opposite faces cylinder 1 mark on the distributor
the 0 mark on the timing angle scale. housing.
Offset slot in top end of distributor drive shaft
should be at an angle of approx, 12 to longi-
tudinal axis of engine. Larger slot segment
faces inward. |
3. Insert distributor,
Printed in Germany Installing Distributor | 28 = 1
28 Ignition
REMOVING AND INSTALLING DISTRIBUTOR DRIVE SHAFT
1. Remove distributor drive shaft with puller. Set cylinder 1 to TDC mark. White mark on fan
pulley must be opposite 0 mark on timing scale.
2, Take out washer from under drive shaft,
3. Offset slot in top end of distributor drive о
shaft should be at an angle of approx, 12
to longitudinal axis of engine. Larger slot
segment faces inward,
28 = 8 Removing and Installing Distributor Drive Shaft Printed in Germany |
General 30
MANUAL TRANSMISSION FOR 912 E - 1976 MODEL
A five speed manual transmission is installed in conjunction with the four cylinder engine and only
differs from the 1976 model transmissions 915 in a few details,
Clutch guide tube, clutch operation,
input shaft with smaller clutch hub splines,
different ratios,
In general transmission 923/02 can be installed in all models,
Printed in Germany Technical Data 30 - 01
30 General
TECHNICAL DATA
General Data
Manual Transmission 923 (Model 76)
Ratios 923/02
1st gear AZ 11: 35 3.181
2nd gear HX 18 : 33 1.833
3rd gear NT 23: 29 1.261
4th gear QP 26 : 25 0.962
Sth gear TL 29 : 21 3.207
Reverse 12:21 = 20:38 3.324
Final drive 7:31 4,429
Capacity Approx 3 liters/3,2 gt of SAE 90 gear lube meeting
Specifications MIL-L 2105 or MIL-L 2105 В
Transmission weight
56 kp/123 1b ready for installation with oil
and starter
General data
Clutch
Type
Pressure plate
Clutch disc
Single disc, dry
Diaphragm spring
Double spring
30 - 02 Technical Data
Printed in Germany
Clutch, Controls 30
TOOL 5
| №. Description Special Remarks
Tool
1 Steel ruler | Min, length 200 mm
2 Feeler gauge Commercial item
3 Input shaft
4 Flywheel lock VW 215¢
Printed in Germany Removing and Installing Clutch Disc a 30 - 1
30 Clutch, Controls
Note when
Removing . Installing
No. | Description Qty. Remarks
1 Bolt 6 Loosen alternately Torque crosswise to 23.5
M 8 x 15 1 to 2 threads cross- Nm (2.5 mkg).
wise,
2 Washer 6
3 Diaphragm spring 1 | Mark for installation, Check rivets, Clean
clutch bearing surface in fly-
wheel, Check for wear,
Remove surface cracks
and scoring by grinding
or turning,
4 Clutch disc 1 Check for wear, Check teeth, Disc must
be easy to slide on
input shaft without too
much radial play,
Check rivets, Check
lateral runout, Coat
input shaft teeth with
molybdenum.disulfide
powder. Center on
input shaft,
30 - 2 Clutch - Exploded View — Printed in Germany
Clutch, Controls 30
REMOVING AND INSTALLING CLUTCH
1. Insert flywheel lock VW 215c. Check spring connections between pressure plate
and cover for cracks, Check tightness of rivets,
~ 2. Loosen bolts on clutch cover.
Replace clutches which are damaged or have
loose rivets,
Checking Clutch
Check bearing surface of pressure plate for
Check ends of diaphragm springs for wear (from cracks, burnt spots and wear. Pressure plates bent
clutch release bearing). Scoring up to 0,3 mm inward by up to 0.3 mm are still useable.
deep is not serious,
Printed in Germany Removing and Installing Clutch Checking Clutch 30, - 3
30 | Clutch, Controls
Installing Clutch
The diaphragm spring is riveted to the cover 1. Center pressure plate on input shaft,
b t ire rings.
etween two wire ring 2. Insert flywheel lock VW 215 c.
Clutches with visible wear on the rivet head 3. Bolt clutch pressure plate. Torque to 25 Nm
or wire ring must be replaced. | (2.5 kpm).
Checking Clutch Disc
pr
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Ц
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wo
Maximum Lateral Runout: 0,5 mm
(measured at 210 mm dia.)
30 - 4 Checking Clutch Disc
+ а —
Printed in Germany
Clutch, Controls 30
Adjusting Clutch Play
Pull out clutch pedal in direction of arrow to
check, The specified play is 20 to 25 mm,
The clutch cable is adjusted by the counternuts
on the end of the cable,
1. Press in clutch lever to center rib by hand.
2. Pull out engaging cable with pivot in opposite
direction,
There must be about 4 mm of play between the
‘lever and pivot.
To facilitate adjustments, a 4 mm dia. spacer
(drill bit) can be placed between the lever and
pivot.
CE
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Printed in Germany Adjusting Clutch Play | 30 - 5
Manual Transmission, Controls, Case 34
DISASSEMBLING AND ASSEMBLING NOTES
Manual Transmission 923
The splines of the input shaft are smaller than that of manual transmission 915. To disassemble, the
transmission must be locked with Special Tool P 37 (old transmission 911 and 914),
5th gear has to be engaged in addition to the other work.
Printed in Germany Disassembling and Assembling Notes 34-1
Manual Transmission, Controls, Case 34
TOOLS
25
<—————— > ; 125 >
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№. Description Special | Remarks
Tool
1 Sleeve Local manufacture
2 Hook - Local manufacture, same
as hook for Turbo Carrera
3 Mandrel | P 375
Printed in Germany Disassembling and Assembling Case 34 - 3
34 Manual Transmission, Controls, Case
34 - 4 Disassembling and Assembling Case | Printed in Germany
34
Manual Transmission, Controls, Case
Note
* t t +
No ; Descrip fon | Qty Removing Installing Remarks
1 Release bearing 1 Do not wash, Just wipe
dry. Coat sliding sur-
faces for guide tube with
a MoS о all purpose lube,
2 Phillips screw 2 Torque to specifi-
cations,
3 Guide tube 1 Use hock. Coat with MoS о all See page
purpose lube, 35 - 2
4 O-ring 1 Replace. Lubricate, ,
5 Seal, input shaft 1 Use angled Use local manufac- See page
screwdriver, tured sleeve. — 35 - 2
6 Key 1 Drive out with Replace, if necessary.
right size mandrel.
7 Circlip 1 Replace, if necessary.
8 Release lever 1 Mark for installation Adjust, if necessary.
| on lever shaft,
9 Seal 1 Replace, if necessary.
10 Lever shaft 1 Use Mos, all purpose
lube,
11 Release fork 1 Mark for installation Adjust, if necessary.
on levershaft.
12 Protective tube 1
13 Sleeve 2 Drive out with Drive in properly with
P 375 P 375
14 Delrin bearing 1 Pry out alternately Replace, if necessary,
sleeve with angled screw-
driver.
15 Plug 1 Clean and torque to
specifications.
16 Snap ring 1 Use small Must fit properly.
screwdriver,
17 Bearing outer race 1 Heat case to approx. Heal case to approx,
| 120 C/248 F and 120 C/248 F and
drive out with drive in with
US 8050, US 8050 b.
Disassembling and Assembling Case 34 -5
Printed ín Germany
34 Manual Transmission, Controls, Case
Note
. ti , ty.
No Description Qty Removing Installing Remarks
18 Bearing outer race - 1 | Heat case to approx, Heat case to approx.
120 C/248 F and 120 C/248 F and
drive out with - drive in with
US 8050. US 8050,
19 Breather 1 Install correctly
and torque to
specifications,
20 Transmission case 1 | Check for damage.
34 - 6 Disassembling and Assembling Case Printed in Germany
Manual Transmission, Controls, Case 34
DISASSEMBLING AND ASSEMBLING NOTES
To assure perfect clutching, the release fork and
release lever must be matched with each other
at the splines of the lever shaft, .
- NE. ue 5 À
oS > =}
A o” e “ 5?
|] P375
The adjustments are as follows:
Ti
a F2)
About 71 mm on the fork from the clutch bell EN AE es } “es
housing flange surface to the release bearing ERA Y 1574 В. 2
surface. VR a a A
Bushing for lever shaft, driving in and out with
P 375.
. About 101 mm from the depression in the lever
to and including the center rib of the transmission.
Printed in Germany Disassembling and Assembling Case 34 - 7
Manual Transmission, Gears and Shafts 35
TOOLS
‘ 25 >
125 >
a
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No. Description Special Remarks
Tool
1 Sleeve = Local manufacture
2 Hook - Local manufacture, same
as hook for Turbo Carrera
Printed in Germany
Removing and Installing Input Shaft Oil Seal | 35 -1
35 Manual Transmission, Gears and Shafts
REMOVING AND INSTALLING INPUT SHAFT OIL SEAL
It is very easy to replace the input shaft oil seal of manual transmission 923, without having to
disassemble the transmission.
Removing Installing
1. Remove engine/transmission assembly and 1. Drive in oil seal to stop with locally
take off the transmission. a manufactured sleeve.
2. Remove both Phillips screws on guide tube,
Pull out guide tube for input shaft oil seal
with locally manufactured hook,
2. Place new O-ring on neck of guide tube,
| 3. Apply a light coat of oil to sealing lip
- of seal in guide tube and O-ring on guide
tube neck,
4. Drive in guide tube so that the mounting
3, Remove oil seal with an appropriate 1 mandrel
screws can be inserted,
or screwdriver.
9. Insert mounting screws and torque to
specifications,
6, Coat release bearing guide tube with MoS
paste.
2
35-2 . Removing and Installíng Input Shaft-Oil Seal E Printed in Germany
TECHNICAL DATA
Front suspension
Springing
Torsion bars
Height setting
(at DIN curb weight)
Difference in height left to right
Wheelbase
Track
Shock absorbers
Make
Stabilizer
Front wheel Suspension 40
Independent, with shock absorber struts and transverse
control arms
One round torsion bar per wheel in driving direction
18.8 mm dia,
+
99 - 5 mm from center of wheel to center of torsion bar
à mm
2271 mm
1360 mm
Double action, hydraulic
Boge
16 mm dia,
Printed in Germany
Technical Data 40 - 01
TECHNICAL DATA
Rear suspension
Springing
Torsion bars
Height setting
(at DIN curb weight)
Difference in height left to right
Spring strut angle
with air conditioner
Shock absorbers
Make
Wheelbase
(at DIN curb weight)
Track
(at DIN curb weight)
Rear Wheel Suspension, Propeller Shaft 42
Independent, with control arms
One round torsion bar per wheel transversely
mounted
23 mm dia.
37 mm from center of cross tube to center
of wheel
Max, 8 mm ,
40°
о
40 30°
Double action, hydraulic
Boge
2271 mm
1330 mm
Printed in Germany
Technical Data 42 - 01
Wheels, Tires,
AXLE ALIGNMENT DATA
Axle Alignment 44
The following data is based on a car at curb weight according to DIN 70020 (car with full fuel tank, spare
wheel and tools),
Front Axle
Height settings:
Center of wheel to center of torsion bar
Toe (pressed by 15 kp)
Track difference angle at 20° lock
(toward toe-in)
Camber
(wheels straight ahead)
Caster
Rear Axle
Height settings:
Center of cross tube to center of wheel
Strut inclination
with air conditioner
Every 1° change in strut inclination =
approx 8 - 9 mm difference in car height
Toe per wheel
Camber
Specification
and tolerances
Max. difference
left to right
99 * 5 mm
0° to 30"
0° 308 * 10°
6 5 “ 15’
37 * 5 mm
о
40
40 30'
o mm
Can be altered by
exchanging steering
arm,
10"
30"
10"
20"
Printed in Germany
Axle Alignment Data
44 Wheels,
TECHNICAL DATA,
Wheels and Tires
Wheels
Standard tires, front
rear
Cold tire pressure, front
rear
Optional extra tires,
front and rear
Cold tire pressure, front
rear
Winter tires, front/rear
Cold tire pressure
Spare wheel
Axle Alignment
Steel rims 5 1/2] x 15
165 HR 15
29 psi (2.0 kp/em)
34 psi (2.4 Кр/ст )
185 HR 14 on forged light
alloy rims 5 1/2 J 14
29 psi (2,0 kp/em >)
34 psi (2.4 Кр/ст )
165 SR 15 MS or 185/70 SR 15 М5
on standard rims 51/21 15
Same as standard tires
Space Saver tire on steel rim 5 1/2 J 15
with inflator
44 - 02
Technical Data
Printed in Germany ,
TECHNICAL DATA
Tandem Brake Master Cylinder
Bore
Stroke
Ratio at brake pedal
Operating rod/piston play
Front Wheel Brakes
Solid disk brake outside dia.
Thickness, new
Min. thickness after machining)
Brake disk surface peak-to-valley
height after machining
Thickness tolerance
Brake disk lateral runout
Lateral runout after installation
Caliper piston dia,
Pad thickness
Wear limit
Clearance
“ Pad surface per wheel
Rear Wheel Brakes
Solid disk brake outside día,
Thickness, new
Min. thickness after machining *)
Thickness tolerance
Brake disk lateral runout
Lateral runout after installation
Brake disk surface peak-to-valley
height after machining
Caliper piston dia,
Pad thickness
Wear limit
Clearance
Pad surface per wheel
Brakes,
19.05 mm dia.
18/13 mm
5.4:1
1 mm
282 mm
12.7 mm
11.7 mm
Max. 0,006 mm
Max. 0,03 mm
Max. 0,05 mm
0,2 mm
48 mm
10 mm
2.0 mm
0,2 mm
76 cm
290 mm
10.5 mm
9.5 mm
Max. 0,03 mm
Max, 0,05 mm
Max, 0.2 mm
Max, 0.006 mm
38 mm
10 mm
2.0 mm
0.2 mm
52.5 cm“
Hydraulics
47
Printed in Germany
Technical Data
47 -'01
47 Brakes, Hydraulics
Parking Brakes
Brake drum dia. 180 mm
Brake shoe width 25 mm
Effective braking surface per wheel 85 em“
*) Machine brake disks uniformly on both sides,
47 - 02 Technical Data Printed in Germany
Brakes, Hydraulics 47
CHECKING AND MACHINING BRAKE DISKS
The brake disk can be reconditioned if it has certain types of surface damage, excessive lateral runout
and excessive thickness tolerances,
Wear can take on the following patterns:
1. Wavy lines in the cross section, as illystrated below, are not serious.
2. Peak scoring, as illustrated below, can be removed by reconditioning.
Refer to the Technical Data on page 44.01 for machining data and limits,
Note
Machine brake disks uniformly on both sides.
а
Printed in Germany Checking and Machining Brake Disks 47 «1
47 Brakes, Hydraulics
‘ Distance "a" is used to check to symmetrical machining of the brake disk and/or to determine the
brake disk thickness wear limit. | |
7 < |
77 7 >
IN à
N
a
Arrows indicate the reference and/or take-up surfaces for machining the brake disk.
+
Distance "a"
Brake Disk Type Location of Brake | Distance "a" (in reference New Brake Disk
Disk to new brake disk thickness) Thickness:
Solid Disk - Front Wheel 35 > 0,1 mm | 12.7 - 0.2mm
Solid Disk Rear Wheel 76 = 0,2 mm 10,5 - 0,2 mm
47 - 2 Checking and Machining Brake Disks Printed in Germany
Steering 48
TECHNICAL DATA
Steering
Steering wheel 400 mm dia, (lattice wheel with impact pad)
Steering ratio at center
(steering wheel angle to road wheel angle) 17,78 : 1
Turning circle diameter 10,9m (36 ft)
Track circle diameter | 10,35 m (34 ft)
Steering wheel turns from stop to stop approx. 3.1
Steering frictional torque 0,8 to1.4 Nm (8 = 14 kpcm)
(measured at steering gear flange,
tie rods disconnected) -
Printed in Germany | Technical Data 48 - 01
Gauges, Instruments, Radio 90
LOCATION OF RELAYS AND FUSES
Up to three relays can be installed in the fusebox Relay Plate in Engine Compartment
located in the luggage compartment,
1 - Open 1 - Relay plate
2 - Foglight relay (optional) 2 - Rear window defogger unit relay
3 - Hom relay 3 - Heater fan unit relay
4 - Open 4 - Voltage stabilizer
5 - Electric window regulator relay (optional) ‚5 - Doublerelay (fuel pump, power supply
6 - Open for control unit)
7 - Open 6 - Resistance for fuel injectors
7 - Radio interference suppression
8 - fuseb
The hazard light relay is on the luggage compart- Rear fusebox
ment floor to the left as seen in the driving
direction - same as Type 911.
The fusebox holds 18 fuses, They are numbered
consecutively on the current flow diagram,
whereby the fuse up front as seen in the driving
direction is designated S 1.
Printed in Germany Location of Relays and Fuses | 90 - 1
Current flow diagram, Type 912 E, Model 76
Description
E -— Windshield wiper switch
- Headlight switch
— Turn signal switch
— Emergency fiasher switch
— Dimmer switch
— Headlight fiasher switch
— Fresh air blower switch
— Rear window defogger switch
19 — Parking light switch
E? ... Instrument pane! illumination potentiometer
E26 — Switch for glove compartment light
F — Stop light switch
F? — Left door switch
F% — Right door switch
F4 — Back-up light switch
F* -— Switch for luggage compartment light
H — Horn switch
mmm mmm
H? — Ногпз
Hé — Key warning buzzer contact
Ji — Hazard/turn signal flasher
J* — Horn relay
J? — Rear window defogger relay
J¥ - Diode for seat belt warning system
K! — High beam indicator light
K* -— Parking lights indicator light
K5 — Turn signal indicator light
Ké — Hazard flasher indicator light
K% — Blower indicator. light
K?9 — Rear window defogger Indicator light
L? — Sealed beam unit, left headlight
L? - Sealed beam unit, right headlight
Lé — Speedometer illumination light
L7 -- Fuel gauge illumination light
L® — Clock illumination light
L¥5 — Ashtray illumination light
16 — Heater control assembly illumination light
L?' — Temperature control lever illumination light
L24 — Cil temperature indicator illumination light
L?6 — Tachometer illumination light
L¥ -— Oil pressure indicator illumination light
M2 — Right stop / rear light
M* — Left stop / rear light
M3 — Left front turn signal / parking light
Mé — Left rear turn signal
M7 — Right front turn signal / parking light
M% — Right rear turn signal
MIT — Front side marker light
MI? — Rear side marker light
M1 — Left back-up light
-MY — Right back-up light
№ — Resistor
5? — Fuses
to —on
Ss’ — the
SV — fuse
S18 box
S24 — Fuse on the rear fuse box
T! — Cable connector, single
a — near regulator panel
b — behind sealed beam unit, left
c — behind sealed beam unit, right
d — behind fuse box
e — on luggage compartment floor
f — behind instrument panei
h — near left rear lights
Té — Cable connector, sixfoid
a — in engine compartment, rear left
b — in engine compartment, rear right
c — below instrument panel
d — below instrument panel
e — below instrument panel
g — below instrument panei
п — below instrument panel |
T'4 — Cable connector, fourteenfold on regulator panel
U! - Cigar lighter
У — Windshield wiper motor
Vz - Blower motor
V5 — Washer pump
W Interior light
W3% — Luggage compartment light
Wé — Glove compartment light
X — License plate light
Y — Clock
Z' —- Rear window defogger
Current track
39, 61, 62, 63
6, 8, 9, 11, 15, 20
28
24, 25 28, 31, 34
6, 39
4
57, 58
52, 53
13
20
41
SERESAS
-
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BERNER
$
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9, 15, 11, 8, 7
4, 3, 31, 25, 48
52, 61, 59, 58
34
40
54
14, 53, 54, 55
11, 25
15, 31
37, 63
22, 42, 44, 45, 46, 56
6, 22, 24, 28, 55,
56, 57
24
9, 13, 24, 26, 48, 51
10, 17, 30, 49, 50
61, 62, 63 05
59 Kl K
61, 62 | |
56, 57
3 4 5 6.7.8 9 10°>:1° 12. 9 MO 15 в п 18 19 20 21 22 23
sf s"[
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40 . 41 - Lo 42:43 44" 1745
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51
49
47
52
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Cables 9 7
Currentflow diagram, Type 912 E, Model 76
|
Current flow diagram, Type 912 E, Model 76
Description
A — Battery
В - Starter
С — Generator
C? - Voltage regulator
Cé — Ignition condenser
D — Ingnition / starter switch
E!s — Heater blower switch
E24 - Loft seat belt switch
F! — Oil pressure switch
Её — Brake warning switch
Е? — Parking brake switch
F?5 — Throttle valve switch
F26 — Thermo — switch for cold start valve
F?7 — Mileage counter switch (EGR)
G — Fuel sender unit
G' -— Fuel gauge
G* ..- Tachometer
G* — Fuel pump
G8 — Oil temperature sender unit
G? — Oil temperature indicator
С!” — Temperature sensor |
G'8 — Temperature sensor |l
С!” — Air flow meter
62! — Speedometer
G22 — Speedometer sensor
J14 — Relay for heater blower
J?1 — Electronic fuel injection unit
J3 — Seat belt warning system relay with
integrated buzzer
J4 — Double relay
К? — Generator charge indicator light
K3 —- Oil pressure indicator light
K? — Parking brake / brake warning indicator light
K'¢ — Low fuel warning light
K' — Seat belt warning light
K?? — EGR warning light
N — Ignition coil
Né -- Resistor
N'Y — Cold start valve
№ — injection valves cyl. 1 and 4
N20 — Injection valves cyl. 2 and 3
№1 — Supplementary air valve
O — Distributor
P — Spark plug connector
Q — Spark plug
Ss? — Fuse on rear fuse box
Т! — Cable connector, single
a — near regulator panel
e — on luggage compartment floor
f — behind instrument panel
T? — Cable connector, double
¢ — near left seat
d — in engine compartment
i — in tunnel, rear
T¢t — Cable connector, sixfold below instrument panel
T*4 — Cable connector, fourteenfold on regulator panel
v* — Heater blower
Current track
95
91, 92
87, 88, 89, 90
87, 88, 89
116
68, 69, 70, 71, 72
98
71
85
77
78
115
103, 104
75,76, 78
82
81
106
113
106, 107, 108
75
83
96, 97
101—118
69, 72, 74
99, 100, 101, 102
75
85
76
83
75
80
118
109, 110, 111, 112
104
109, 110
111, 112
100
117, 119, 120
118, 119, 120, 121
118, 119, 120, 121
96
84, 99
74
70, 71, 77, 78
71,72
96
83
66, 67, 74, 93, 94
84, 85, 87, 88, 89, 90,
92, 98, 120
96
: , = ll eg
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LE A E ALIADA
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99 X su,
96 97 98
“93 94 95
Er - 89
° 87
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7
075 075 075
| | | | = |
1 10 10 10
6 Ra _—_ 4 1
№ [Г
|
mm Mm
103 104 | ‘105 108 107 3 108 i 109, © “mo 1" 12 113 114 115 ‚ n6 “M7 ne we
A ES E
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