ServiceManual cRepairs andmaintenance
o a' o
a o Volvosa€ sold in versionsadapteclfor differentmark€ts. Th€seadaptalionsdependon many facrorcincludingle9al,taxationand marketrequirem€nts, This manual may thereforeshow illustrationsand text which do nol apply to cars in your country.
Group 34 lgnition sysLem Contents
0
Group34 lgnitionsystem Contents Page Soecialools .. Generalnstructions Specifications: lgnition sFtem withcontactbr66ket.... ... ... ... ... ... . B r e a k ee B Bi g n i t r o3ny 3 l e m . . . . . . . . . . C o m p u t e r i zi g en d i t i o3ny 3 l e m. . . . . . . . . . . . . . . . . Inspection of lgnitionsy3t6mwith contactbreakeBB 20 A, B 17-A 23 A Breakerles.ignilionsyltem B 20 F, B 19 E, ET, B 2 1 E ,E T ,F F T , 8 2 3 e , 8 2 7 1 2A8. E a n dF . . . . . . . . . . . . . . . . . . . . . . . . . Compurerized ignitionsFiem B 21 F-MPG(1981),B 21 F-Cl (1982), B 2 1 F - L H( 1 9 8 2A) ,2 s F - L H0 9 8 3 - 1 9 8 4B)2, 3 0F - L H( 1 9 8 5 -.). . . . . . . . .
Indexpage79
Indicatesrevisedinformalion:
Ordernumbor:TP 30432/2
0
We rcservethe rightlo makealterations withoulpriornotilicalion. O 1985.VOLVOCAFSOF NORTHAMERICA, A Dvson ol VolvoNorlhAm€icaCorporation
2 3 5 10 2-l 24 37 57
Specialtools
Special tools
Ohm-Oiode Tesler Monole3ter- Owellangle,ignitionsetting - lgnitionseliing Stfoboscop€ FlywheelAdapter- lgnitionsetringlvlY1984-
,: E-,1-.t
v!a' - -,: {' , -t_*_.-
Generalinstructions
lgnition system - general instructions
0
Measuringresistance Before measuring the resistanceof a compononl make from it. s u r e t h a t a l l l e a d sh a v e b e e n d i s c o n n e c t e d R e s i s tnac ev a l u e ss p e c i f i e di n t h i s m a n u a l a p p l y a t 2 0 " c (68'F).
Electronicignition systems Electronic ignition systems operate at very high vol tages - often in excessof 30 000 V. Such hig h volrages a r e a d a n g e r t o l i f e a n d s p e c i a lp r e c a u t i o n sm u s l b e l a k e nw h e n w o r k i n g o n v e h i c l e ss o f i t t e d . T h e ? s y m b o r u s e d( h r o u g h o u t t hs T a l u a I n d r c a t e s t e r m i n a l sw h e r e d a n g e r o u sh i g h v o l t a g e sc a n b e e x
Engine type and model year designation 11 = 4317 {820 1975 761 6:827 {1975-79) 2:819 24=E 26 = E Turbo 4=821 44=E 45=F{5} 46 = E-Turbo
1e8o: VC 244 45 L 10ooooo 1 9 8 1: Y V 1 A X 4 5 4 X E 1 0 O O O 0 O 19ao: 2 4 5 !15 1 9 8 1: Y V 12 4 4 40
I
o
L 1 000000 18 1000000
T
48=F(8) 49=F(9)
64 = E (-1980) 65=F 6 = 828 (1980-) 62=A 6 8 = E ( 1 9 8 1) 69=F 8 = A23IB23O 81 84 E 88
General instruclions
Boschpart numbers S t a m p e di n s i d e o f d i s l r i b u t o rb o d y .
o 0231-....
<--Bosch
number
JFU1 <--
O Direction of rotation N u m b e ro f c y l i n d e . s
C e n t r i f u g aal d v a n c e
t)
Distributob r ody diameter P = 71-83mm
Qr
f)
O
t
Ignition system with contact breaker
i$
tgnition coil
Specifications lgnition system with contact breaker B20A,817_8234
R e ss t a n c eo f p r m a . y c o i ( a c r o s s l e r mn a s 1 l ) a n d l 5 ( + ) ) R e s i s t a n c oe f s e c o n d a r yc o i l a c r o s sr e r m i n as 1 1 ) a n d H T
A - e n g i n e s- 1 9 7 8 2 . 8 5 1 0 . r5 ( )
A-€nganes'1979-
9 . 5 1 2 . 5k ( )
9 . 5 1 t . 5k O 1 . 3 1 0 . 1O ( 0 . 9 : t 0 1
Bollo r'p i5to
r0
,0
1 . 9 1 0 . 10
Spark plugs
820 BI/
B o s c hW 7 B E o s c hW 7 D C 0.7 0.8 mm 2 5 - 5 N m ( 1 8 1 3 . 5f i . l b s )
B.J
T g h l e n i n tgo r q u e{ u n o € d p l ! s )
Hightensionleads'
{r
d$ a-
240 ,o-.
1ko
0(ym
1976-aO d__r-'-
0
240
_}.*_
_---
+'E--------.------:c+
1kn --1
oo 1975-76
Oa / m
-f\}.__ !.,2_--.J,
1 . 4k f ) Jr'-1..Jr\
oo
5 , 6k o / m
oa
1ko
g a/m
1k')
0 c)
5,6ko/m
oo
1ko
OO r m
5ka
'Nore: Fes,srancevaluesare gtvenin K O perneter af length.(Measureteadin otder ta camputecorcct value) All vatues have a permEsable tolerance of . 20o/o
Specifications
lgnitionsystemwith contactbreaker Rotol 5r1 ko
Resrstance.
Firing ordel 420
817-823
1 3-4-2
'l-3-4-2
lgnition setting , S A a n dC a n a d a{ a l s oS w i t z e r l a n d1 9 8 3 ' r n o d e l s ) h a vdee t a i l so f W i t h e f f e c t f r o m1 9 7 6 v, e h i c l e s f o S r w e d e nA , u s t r a l i aU i g n i t i o ns e t t i n gs t a m p e do n a p l a t el o l e f t o f e n g i n ec o m p a r t m e n t . lgnition setting (before T.D.C.,vacuum control unit disconnected)
B1 7 A
'1979 84
11.7-13.3 r/s 700-800r/min '12"
819A
19'/71t 1978 ltaly 1 9 7 8 8 0 O t h e rm a r k e t s 1981-84
15' 15" 12" 10'
Enginetype
Modelyear/Marlet
B19K
0)
2A 32' 32-36' 32-36' 2A 32' 26-30' 17 23"
B20A
1915-76
B21A
1975 1916 7711 1978 Sweden3) Othermarkets 1979-8o'z) 1981 Scandinavia,Australia Olhermarkets '1982-83 Scandinavia,Australia 1984
B23A
2500/min
Othermarkets Scandinavia,Switzerland Auslralia Europe Canada
1981-82 Scandinaviaa) 1982 O t h e rm a r k e t s 1983 84 Europe Overseas
10" '12' '15' 12" 15' 12' 10" 12' '10" 12" 10" 10" 7" 5" 5'
23-21' 24 24" 32 36" 2a-32' 32 36" 28 32" 26 32' 2A 32' 26 32' 24-30" 2A-32' 20 26" 26-32" 17 23" 24-30' 2t 26" 19-2{ 17-22" 19 2q
SDecialvehicles 8 W 3 5 , 8 W 5 5 ,M 4 6 a n d s p e c i a l v e h r . " Sweden:245wilh 2 1 1 9 7 9 - 8 0 : S w e d e n , O v e r s e a s w i t h e n g i n e l y p e s 4 9 S T 5 5 a n d 4 9 E S l l a n d s p e c i s v e h i c l e s w i t h m a n u a g e a r b o. x. . .
10" 10" .. .. .. 8" S p e c a l v e h i c l e s w i t h a u l o h a t c s e a r b o .x. . . . . . . . . . . 3 r 2 4 0 w i i he n g i n e t y p e 4 g S r5'and32-36' 528 ') lgnilion setting can be retarded lo 5' if, despite uslng 98 ociane f!el, engine is prone lo pre ignition (knockins). Specialvehicle refers 1o heavy veh c e rypes slch as 245 GL with auiomatic rransmission.
0'
lgnition system with contact breaker
Distributor E n g i n et y p e
( A p p i e s i o a i m a r k e i su n e s s o t h e r w s e
qA B17A
1979-80 1981 84
B19A
1977 1978 1979 1980
T h a i l a n d ,M a l a y s i a ,n d o n e s i a
1981-84
B19K B20A
1984
B21A
1915
1975-76
1976 11 1978 Othermarkets S w e d e n ,A u s t r a l i a C , a n a d a ,O v e . s e a s O l h e r m a r k e t s( i n c . T h a i l a n d ,I n d o n e sa ) S w e d e n ,A u s t r a l i a C , a n a d a ,O v e r s e a s , hailand, O t h e r m a r k e r s( i n c . M a l a y s i a T
1979
i0
1980 1981 83
S w e d e n ,A u s l r a l i a( 1 9 8 2 a l s o S w i t z e r l a n dc, a n a d a )
1984
i0
8 2 3A
1981 82 1983 84
Europe
lgnition setting
nttl
1 266 478 I 2 1 96 6 1 1 2 1 96 6 1 1 2 1 96 6 1 1 266 478 1 266 418 1 2 1 96 6 1 1 266 474 1 2 1 96 6 1 1 332410
0 2 3 11 7 61 0 3 0 185 0 185 0 185 6 103 6 103 0 185 6 103 0 185 0 302 0 085 0 134 0 173 0 185 6 103 0 185 6 103 0 185 6 103 0 185
463 692 1 2 1 96 2 5 I 2 1 96 6 1 1 266 414 1 219661 1 266 478 1 2 1 96 6 1 1 266 478 1 2 1 96 6 1
103
1 266 474
o 244 0 185 0 302 0 284 o 247 0 302 o 241
1 306792 1 2 1 96 6 1 1 332 410 1 306792
462 657
306872 332 410 306872
Oiagram key: B o s c hn ! m b e r a t b o t t o m s t a m p e d n d i s i r i b u t o rb o d y .
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I Breakerless ig n it io n system
Specifications Breakerlessignition system B20 F, 8 19 E. ET. 8 21 E, ET, F, FT, 8 23 E, 8 27 A, E, F, B 2A A, E' F
0
lgnitioncoil
R e s i s t a n c oe f p r i m a r Yc o i a c r o s s t e r r n l n la{l s ) a n d1 5 { + ) Resistanco e i s e c o n d a r Yc o i l e r n r a l a c r o 5 5 l p r - r n d l sl l Ballastresistor .. ..
l"ldtTl
820,819-823
827/824
1 . 9 1 0 . 1i )
0 . 5 r 0 . 1{ )
9 . 5 1 1 . 5k l ) 0 . 9 1 0 . 1{ }
9 . 5 1 1 . 5k l ) 1 1 0 . 1( l
O
Spark plugs 4.cyl engines B20F 8 1 9 E ,B 2 1 E
1976 1975 84
B o s c hW 6 D C
BoschW6 DC
B 1 9 E TB. 2 1 E T B21F
B o s c hW 7 D C 1 9 7 67 9 B o s c hW R 7 D S 1980-82USA 1980-84Others
B2I FT
1981-85
B23E
1979 80 1 9 8 1- 8 4
0
B o s c hW R 7 D S B o s c hW 5 D C B o s c hW 6 D C
0.7 0.8mm 2 5 1 5N m ( 1 8 1 3 .f5t . l b s )
E e.rodegdp T i g h t e n i r gl o r q u e( u n o i l e dp l ! g )
6-cyl engines 827 A
a27 E B27F B28A and E B 2AF
19J5 l9 1975-14 1979 80 1976 79
t980 84 1980-84USA 1980 84 Others
F r p rr r o d . g d o T 9 h ' P 1 r n qr o q J p r u l o : p d o J q r
10
0
B o s c hH 6 D B o s c hH 6 D B o s c hH 5 D B o s c hH 6 D B o s c hH 6 D B o s c hH R 6 D S B o s c hH 6 D
0.60.7mm t.lbs) 1 2 1 2N m ( 8 . 7 1 1 .f 5
0
Breakerl ess tgn i ti o n system
Rotor 5-1 ka
3
High tension leads.
i.J ifll
240
:_i,
0
D 5 lllr-
i
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24O --=_
oo m
,0 -
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260
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:
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tok.l
5.6
'Nore: F.srslrnce yaliresa.e glven n K a permeter ol length.(Measureteadn ardet to computecoftect value) Al vatueshave a pe.ntssabletoleranceof ! 2A%
F i r i n go r d e r 820
819
1342
1342
823
827, 828 r 6 3 5-2,4
,
tt
-I
Breake rl ess ig n ition system l g n i t i o n s e t t i n g ( b e f o r eT . D . C w i l h v a c u u m c o n l r o l u n i t d l s c o n n e c l e d ) , u s l r a l i aU , S Aa n d C a n a d al a L s oS w t z e ra n d I 9 8 3 _ m o c lse) h a v ed e t a l s o i W l t h e f f e c lf r o m 1 9 7 6 v, e h i c l e sf o r S w e d e n A g n i t i o n s e l l i n g s t a m p e do n a p l a t ei o l e f l o i e n g n e c o m p a . t m e n t
4-cyl E-engines E n g i n et y p e
Modelyear/market
1 1 . 7 1 3 . 3r / s 700 800tm n
B19E
1977 83 1984
8' 10'
B19ET
1982 a4
15'
B 2 IE
1975 82 r
B2l ET
t98t 84
15'
8 2 3E
1979 82 1983 canada Othermarkets
5' 10 5'
8_
2 5 0 0n m i n 28 33' 24 2A21 26'
2 a 33' 21 25 25 25
26 3A' 29' 3A'
4-cyl F-engines 1975
B21F
1976 1977
5'
15" 12' 15.
USA Olher rnarkets
124
1978 1979
B2t t\
C a l f o r n a ,J a p a n Olher markels 1980 Canada Olher markels l98l 84 Japan 1981 USA 1981 85
10" '10" 8' 8'
Adjusrat 15 ris (900r/min) Adjusrat 15 r/s (900r/min) 12'
20 25', 25 30' 2a 32' 25 30 2A-32' 22 26' 26 30' 24-24' 22 26' 22 26'
22 25 22 25'
1977 lA r979 80
10' 10' 10' 10' 10' t0' t0'
1 9 8 18 2 1983 84
10' 12'
,25 29 2t 31'
1975 79
B28A
1980 84
B27E
1975 1976
B28E
S w € d e n ,A u s t r a a O t h e rm a r k e l s
0)
25 30'
6-cyl A and E-engines a27 A
I
a)
' r 1 s 7 6 8 0 : a ! s t r a i a , s w e d e n S p e c6 v e h i c L e s
B20F
0
30 22 30 30 25
34 26', 34 3429'
c 0
r 1 9 7 8 : S w e d e n , A u d r a l i a , S p e cv ae h c l e s
6-cyl F-engines 827 F
1976 1977
Ca ifornia Olhermarkets
1979 8 2 8F
1980 82
A d j l s t a l 1 5 r A ( 9 0 0r / m i n ) 1 9 8 1 :C a l i f o r n i aJ, a p a n 1 9 8 2A : ll
12
10' 7' 10' 10' l0'
27 20 27 20 2A
32' 24' 32' 24' 24'
0t
Breake ess ignition system
Distributor 4-cyl E-engines
is
E n gi n e t y p e
Bosch P/N 0 23700
B19E
1977 83 1984
2 017 2 039
1 2 1 99 5 7 1 276 403
Bl9ET
r982 84 1975 1976
3 021 2 001 2 A1A 2 401 2 014 2 Q17 2 011
1 216101
B2I E
3 427 2 All 2 039 2 017 2 039
1 216 /01
19/7 8Q
S w e d e n ,A u s t r a l i a( O v e r s e a s1 9 7 9 ) O t l r e rm a r k e t s( l n c l .T h a l a n d 1 9 7 9 )
1981 82 8 2 1E T
1981 84 1979 82 1983
:e
1Sa4
B 2 0F
1975
BW 35 (Ca iorn:a to engineno 500) fvl 40iM 41 {Caifornia:to enq ne no 500) eo 501) C a i f o r n i aB l r 3 5 ( e n g r n n C a i o r n l aM 4 0 / N 4 1 ( e n g n en o 5 0 1 - )
2 003 2 002 2 009 2 008
462 762 462 496 '| 218 672 1 218 671
B21F
1976
USA
t3t;
Ca io.n a. Canada.Japan
1979
C a i o r n i a J a p a n( C a n a d a 1 9 8 0 )
r980 8l 1980 84
U S A( C a n a d al 9 8 l 8 2 )
2 001 3 003 2 007 3 009 3 003 2 039 2 038 2 039 2 039 3 024
463 694 1 219848 463 694 1 266466 1 219848 1 216 403 1 266904 1 276 443 1 276 443
I21 FT
1981 84
1 276143
6-cyl A and E-engines Model year Desc,iption
I
1 219957 1 276 443 1 2 1 99 5 7 1 276 4Q3
4-cyl F-engines
r I
463 832 1 219 662 463 832 1 219662 1 219 951 1 219957
827 A lB21E
2 006
1 9 75 7 9
001 005 001 005 007 013
1976 1911 1A 1979 80 B28A
r980 84
8 2 8E
1981 84
B o s c hP / N 0 231 44. 269 2 6 9 323 2 6 9 565 269 323 269 565 269 733 1 269 1 9 1 269995 2 Q13
2 6 91 9 1
6-cyl F-engines B 2 - IF
1976 19/7 lA USA
0
1979
269134 269 134 269739 1 269 291
1980 84
ll
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Specitications
Breakerlessig nition system
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Computerized ignnion systems
Specifications Computerized ignition systems
=
B 21 F-MPG 1981,B 21 F-Ct 1982,B 21 F-LH 1982,B 23 F 1983-1984 B 2 3 0F 1 9 8 5 lgnition coil
I
B c s s t a n c eo f p r n r a r yc o l ( a c r o s st e r m i n a s1 ( ) and15(r) Fes slafce ol secondarycoil (acrosslermnals l( ) andHT C"pd o
-
I
rJl '( )
I210.1 O
Eosch L2:r0.1 o
1 06 r ' 1 . 0 k ( )
8 . 5 - 0 . 8ko
50 250nF
Spark plugs
.N BoschWB 7 DS
B2]F.B 23F B23OF
sao
T ghle.na 'o oLp Lr o -d
0
Lg
07 08mm 2 5 - 5 N m( 1 8 r 3s f t b s )
High tension leads R - - ss r . r c e o l f i l d b e l w e e ni ! t n i l o n . o r a n d d s r f b u r o r R e ss t a r c ea f s D a r kp ! ! l s ! p p r e s s o f R e ss t . n c eo l d s l f i b u t o rs ! p p r e s s o r
5.6kQ/m 5ko lko
0 Firing order I342
setting (vac!umgovernoron controlunt disconnecied) seeInstrucnons on page6s
0
Enqinetype 421 F
B23F 8230
r98r.-82 r983-
1 1 . 7 - 1 34. 3s 700-800rimrn
2 500 rimn
12" 12"
16 ?4"
21
l Specifications Computei zed ign ition systems
Distributol Enginetype B2'IF
1 9 8 18 2
1 3060s9
a23F
1983 1984
1 332 684 1 336 737
B23OF
T985-
1 332587
$,
4I
t,
(
lgnition advance graphs, control unit Legend: [=l
vdridl'oror ionir'orserrinsw lh v.r Lrrr
M a x v a c ! u m a d v a n c ei n r e l a t i o nl o
l.l-l r- n---t
V a r i d t i o lo l i g l i l , o r \ " l r n 9 w i t h e r g i n e r p r
l,S)l JwF' I
at 30./s(l 800r/min) Example conirolunitP/N1306057: of vacuumadvance cannotbe moreth.n 90' regardless extentof depression.
(
.:-..'_l -
D I 821
I
lji.-1:
f..l )
tLt)
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:L :1317873
22
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t.:
),
Com puterized ig n i tton setting
821 F-LH 1982 I
ido
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tt
i0
I
B 2 3 F L H A u t o t r a n s m i s s i o n1 9 8 3 - 8 4 Manual gearbox 1983 engine P/N 499802 l c h a n q e d e n s i n e v e r so n 1 9 8 3 )
L
0
.o?r::]
1317295 l L
B23F-LH
I
l .L..l
Manual gearbox 1983 engine piN 499a9O Manual gearbox 1984
t;
I 23
I Contents Computerizedignitiansystems,lgnitiansystem with contactbreakerassenbly
B 230 F-LH 1985-
0 -
f,
0(
lgnition system with contact breaker assembly Contents lgnition coil and HT leads Distributor cap and rotor arm Replacingcontact breaker points C h e c k i n gi q n l i o i s F i I 1 9 c h " c l r r g c P ' r t r 'Jf g d l a d v a n ( e C l ' e c l i n gv d c u r r a d v a . . e
Reconditioning distributol R e p l a ri r 9 v . ' J J - c o n t ' o l L 1 r ' Repid.irg dislribJrol Checl rg side p a!
Distributortest bench
t) B1-82 83-815 B6 B1 B8 814 ct -c6 c1 c2 c3-c4 C5 c6 Dl D4
26 27 2A 29 29 30 32 32 32 33 33
ll
I
);
(
Distribulor lgnition svstem with contact breaker assenary
,{
r0 '0
'o I
25
-t
Distributor lgnition system wnh contact breaker assemblY
A. lgnition coil and HT leads At HT leads Testingignitioncoil,ballastresistorand
4 a
{
C o m p o n e n t ss h o u l d b e a l a t e m p e r a t ! r eo f a b o L r2t 0 ' C (68"F). from the componenls A l l l e a d sm u s t b e d i s c o n n e c t e d w h e n t a k i n gn r e a s u r e m e n r s
Measuring resistance oI ballast resistor fittedto 1979modelsonwaros Ballast resistor O (eanY79) Resistance:0.9 1 3 {) {others)
A3 Checkingignition coil: checkoutercasingof ignilioncoilIo. crackselc acrossternrinas1( ) and 15 measurer€sistance ( +) . 3.0f! 1978 Resisrance:2.7 1.8-2.01)1979 84
fj
(
r)
|
0 t'
m e a s u r er e s i s t a n c ea c r o s st e r m i n a 1 ( ) a n d h g h t e n s i o nt e r m i n a l . B e s i s t . n c e7: . 0 - 1 2 . 0 ( ) - 1 9 7 8 8 . 0 1 1 . 0{ } 1 9 7 9 8 4 -
|)
26
l Distributor tgnition system with conncr breaker assembly Checking resistancet ot HT leads
240 i_,
MU
-
r4,1
24O
m
i+ 'E
'975
O')/m
1kf)
1kf}
rgrs fI \> €-Oo
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oQ/m
l ko
r975-76
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oo
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o.)
--1
-'-----
lko
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-
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o Q,m
5k'J
Reststance values are given in K Q .per neter af tength. (Measure tead in *-,:**'":,"::^,:) vatueshave a petmissabtetoleranceof ! 20%.
B. Distributor
e Distributor cap
0
b u r n tl e r m n a s , l r a c k i n q
I B2
\,,/-
Checkingrolor Replace rotoril cracked y burn1. or excessive = Resistance5tl k|).
. .-
I 2l
I
Distributol
Ignitionsystemwith contactbrcakerassembly
B3 Replacingcontact breake.points creasecamsafterinstallingnewpoints. is on untilfibreheeloncontactbreaker Turncrankshaft Adjustgapto 0.i10mm on B 17-823. 0.35mm on 820 wick oilto spindle Apply1 2 dropsof engine
,1 't
(
(
B4
t
T
Adjust dwell to 59-65" Volvo lMonotester or dwell meter' points gap decrease dwellangle andincrease to neduce gapto increase angle, Refitrotor and distributorcap,
{)
B5 Checkdwell angle at 42 t/s (2500r/min) tl dwell angle differs by more than 2" from reading at idle, check distributor for wear.
6 2A
Distributor
lgnitionsystemwith contactbreakerassembly B6 Adlustignitionsettingat 11.7 13.3r/s {700-800r/min) D i s c o n n e chl o s ef r o m v a c u u m u n i t o n d i s t r i b u t o r . A d j u s ti g n i t i o nt i m ' n g t o v a l u ei n d c a l e di n t a b t eb e t o w .
B7 Checkcentritugaladvanceat 42 r/s {2500r/min} C h e c kt h a l i g i n i t i o na d v a n c ei s a c c o r d i n gt o s p e c i f i c a t i o n , s e e l a b l e b e l o w . l t a d v a n c ei s n o l a c c o r d i n gt o s p e c i f i c a l i o nc,h e c ka d v . n c e w e i g h t a s s e m by .
'0 lgnition settinq Withelfectfrom (alsoSwitzertand 1976, vehicles for Sweden, Auslralia, USAandCanada 1983,modets)have detatts of ignitionsettlngstampedon a plaleto lefrof enginecompartment.
0
I
l g n i t i o n s e t t i n g ( b e f o r eT . O . C .v, a c u u mc o n t r o u n i t d i s c o n n e c r e d ) E n g i n et y p e
Modelyear/Market
B17A
1 9 7 9- 8 4
a 19A
9771 978 978 80 98',1 84
taly Othermarkets
1 1 . 7 - 1 3 .r3/ s 1700800r/min) 12"
12s00r/min) 2A 32"
t5' t5' 12'10'
32 36' 32-36' 2A 32" 26-32',
B19K
r984
B20A
1975 76
10'
23-2/'
B21A
1975 1916 77 ) 1978 Sweden3r O t h e rn r a r k e t s 1979 80'r 1981 Scandinavia,Australia Othermarkets '1982 8 3 S c a n dn a v i a ,A u s l r a l l a
12' 15' '12'
24 28' 32 36' 2A-32', 32 36' 28 32' 26-32', 28 32' 26 32' 24 30' 28 32' 20-26' 27 33' 1 7- 2 3 ' 24 3A'
0 I
1984
I23A
1981 82 1942 1983 84
17 22'
15' 12' 10' 12' 10'
Otherma*ers S c a n d i n a va , S w i t z € n € n d A u s l r al a
12' 10" 10" 1' 7'
Scandinaviaa) Olhermarkets Europe Overseas
1' 5'
21 26' 19-24' 17 22'
5'
Specialvehicles
I
r r S w e d e n : 2 4 5 wt h B w 3 5 , 8 W 5 5 ,M 4 6 ' ' 1 9 7 9 8 0 S w e d e nO , v e r s e a s wl h e n gi n € t y p e 4 9 87 5 5 a n d 4 9 88 1 1a n d s p e c i av e h i c l e s w i hm a n u a g e a r b o x '' 240w theng.clype498 528 1 r g n i t o n s e n g c a n b e r e r a r d e do i 5 r i f , d e s p i t eu s i n g9 s o c r a n ef o e , e n g t n e s p r o n er o p r e . g n i i t o nl k n o c k t f g ) S p e ca v e h c e r e f e r st o h e a v yv e h i ce l y p e s s u c h a s 2 4 5 c L E w i l h z u l o m a rc r r a . s m i s s i o n
10'
t0'
29
Distributor lgnition system with contact breaker assembly B8 Vacuum advance/retard witha vacuumconlrol areequipped Sonredislributors casesthe contro hoses. In such wlth 1wo vac!um unir and retard. bothvacuumadvance unil regulales
' 0
I
B9 Delayvalve B e c a u s eo f e x h a u s te m i s s i o n a w s s o m e v e h r c l e sa r e e q u i p p e dw i t h a d e a y v a l v e c o n n e c t e db e t w e e nt h e i n l e t r n a n i f o l da n d v a c u u m c o n t r o l u n n S € v e r a l d i f f e r e nt yt p e so f v a v e s a r e n u s e O n a l t y p e s "DlST must facedistributor. C h e c kt h a t i t l s p o s s i b l et o s u c ka i r t h r o u g h t" D L S T "s i d e o i v a l v ea n d t h a t i t i s v e r Y d i f f l c ! t 1 0 b l o w a r l h r o u g h
F
rlr
I
,))
(
|
I
810 Checking vacuum advance Connect a vacuurnpumpto vacuumcontrolunii-R!n englneat id e speedand recordignilionadvanceln a r d c l e r k r 1 . l r q l i ro r d d v . r c P . _ l i i g n i t i o n a d v a n c ed o e s n o t i n c r e a s ec h e c k v a c ! u m
(
811 vacuumretard Checking R u n e n g i n ea l i d e s p e e d . C h e c kt h a t i g n i l i o n i s r e t a r d e dw h e n v a c u u m h o s e i s l f n o t ,c h e c kc o n d i t i o no f h o s e .l f h o s ei s i n g o o d c o n d i t i o n c h e c kv a c u L r mc o n t r o l u n r t .
30
Disttibutor
lgnition systemwith contactbreakerassembly Bl2 Checkvacuumadvancewith a vacuumpump C h e c kd i s l r i b u t o rn u m b e ra n d i i n d c o t r e c ti g n i t l o na d v a n c eg r a p h o n p a g e s7 a n d 8 .
I
S e l e c la p r e s s u r ef r o m g r a p h a n d p u n r p ! p v a c ! u m pump to thrsva ue. R e c o r di g n i t i o na d v a n c e . S u b t r a c tb a s i c i g n i t i o n s e t t i n gf r o m r e c o r d e di g n i t i o n a d v a n c ea n d c h e c kt h a t v a u e c o n f o r m st o g r a p h .
i.,0
813 Example:Bosch number 0 231 170287 on B23A 1981 82 Sweden Youdecideto checkvacuumadvance at 200mm Hg. pressure Recorded advanceal this is found 1o be 16-21". Basiclgnitionserting: 7'.
0
D fference- 9
E,
,r f]
0 I
,?' ;)..
14'whichls as specifiecl.
L
814 Checkvacuum unit for leakage Connect a vacuumpump. ncrease vacuumto 500mm Hg (67kPa). Recordpressure for 1 minute.Pressure nruslnot drop by morethan100mm Hg {13.5kP.).
815 Pre-ignition
B23A Sweden 1981 82
.=-
l f , d e s p i t eu s e o f 9 8 o c t a f e f u e , e n s i n e s p r o n e t o p r e - l g n i t l o n( k n o c k i n g )i,g n i i i o n c a n b e r e t a r d e dt o 5 ' .
: rt\
l g n i t i o ns e t t i n gc a na l s ob e r e t a r d e dl o 2 ' b e f o r eT . D . Ci f . o i er h a tf u e v e h i c l ei s r e q u i r e df o r t o w i n g p u r p o s e s N c o n s u m p t i o nw i l l i n c r e a s ea n d t h a t i g n i t o n s h o u d b e r e s e tt o s p e c i f i c a l i o nc l u r i n gn o r m a l u s a g e .
{
3r
Distributor, reconditioning lgnition system with cantact breaket assembly
C. Reconditioning distributor C1
Replacingvacuum control unit ( 8 2 0 : d i s t r i b u t o rm u s t b e r e m o v e df r o m e n g i n eb e f o r e . e e o p e r a t i o nC 3 . ) v a c u u mu n i t c a n b e r e p l a c e dS
-
0i
a
s
trap condensation
a
C2 position Mark ol distributol vacuumunitrelain' Turndistributorto obtainaccesslo Replace vacuumunit. Turndistriburor back1omark. Fit: - condensatLon trap
rI
I
rul
I
r)
(
t'
(
ignitionsetting. ChecUadjust
c3 Replacingdistributol -
trap. condensation
T u r n c r a n k s h a fut n t i l r o t o r p o i n t st o w a r d ss c r i b e d i n e i n d i s t r i b u t o rb o d y . R e m o v er e l a i n i n gs c r e w a n d i f t a w a y d i s t r i b u t o r .
To install: - turn rotor approx-60" clockwiseaway frorn ine in distributor body.(Doesnot applylo I20) - fil distributor rotor should now point lowardsline. Reconnect lrap and vacuumhoseand wire. Fit condensation caP. reclampdislributor igniliontimins. Checuadjust
0 32
Distributor, reconditioning lgnition systemwith contactbrcakerassembly
c5 Checkingside play of distributor shaft Maxsideplay= 0.2mm(0.079 in).Fita newdistributor
I
i f s i d e p l a y i s g r e a t € rt h a n 0 . 2 m m .
(0 Lubrication
,0
t
(c a
I 7 A = d i s t r i b u t o rg r e a s eP / N 1 ' 1 6' 1 1 3 6 - o r B o s c hF t 1 v 4 = B d i s t r i b u t o rS r e a s eP / N 1 1 6 1 1 3 6 - 7o r B o s c hF v 2 6
Dist r ib u tor, recon d it io n i ng lgnition system with contact breaker assemblY
D. Testing distributor on a test bench R e f e rt o t h e m a n u f a c t u r e r ' si n s t r u c t i o n sa t a L t i m e s w h e n t e s t i n gd i s t r i b l t o r s o n a t e s t b e n c h T h e n u m b e ro n t h e s i d e o f t h e d l s t r i b u t o ri s t h e B o s c h
D1
t
T
checking dwell angle Conditionr Newcontactbreakerpo nls (200-250r/m n) at 3.5-4.2revs/sec Rundistributor to setdwell Adjustdwellangleto 59-65'.(ll isadvisable as camwears) angleto 59' as angleincreases Increase speedto 25 r/s (1500r/min).
I rl)
Readoff dwellanqle. Dwellanglemusl not varYbY morethan2'from pre_ for wear,damageelc ii deviatlonis Checkdistributor
D2
0
Checking firing r t 3 - 5 r e v s / s e c( 2 0 0 - 3 0 0, m i n ) o n t e s t R u nd i s t r i b u t o a S e t d i s t r i b u t o r" 0 " t o p o s i t i o nw h i c h c o r r e s p o n d sl o f i r i n g o i c y l i n d e r1 . F i r i n gs h o u l d b e 0 9 0 - 1 8 0 - 2 7 0 " C h e c ks h a p eo f a t r o w s ( o r e q u i v a l e n ts y m b o l d e p e n d l f d e v i a t i o ni s m o r e t h a n2 " l h i s i n d i c a l e st h a t s i d ep l a Yi s t o o l a r g eo r c a m i s w o r n .
D3 Checkingmechanicaladvance 3t 3.5r/s (200r/min) Caibratemeter' Rundistribulor con_ speedandcheckthatmechanicaLadvance lncrease formsto specification. l fn o t , c h e c k t h a i b a l a n c e w e i g h t s a r e l u b n c a t e d a n d d o Alsocheckspranss.
I
Distributor, reconditioni ng
Ignitionsystemwithcontactbrcakerassembly D4 Checking vacuumadvance
,1
Rundistributor at 10 r/s (600r/min). Calibratemeter. Increase vacuumandcomparevatueto specificarion.
i0
,0
I
0
35
Contents Breaketlessignition system
,0 Breakerless ignition system Contents
.......... Ignitioncoil and HT leads.. .... Checkingdistributor cap and rotot ....... Checkingimpulsesenderandairgap...... .... Checking ignition advance Basrc-sett;.g M e c h a n i c aal d v a n c e vacuumadvance R € t a r d. . . . . . . . . . . . . . . .
. .
.
.
. ..
OPeration
Page
E1E4 F1-F2 F3-F4 Fs F1]
38 3s 40
F5 F6 F7-F1o F11
R e c o n d i t i o n i n gd i s t r i b u t o r . . . . . . . . . . . . . . . . . . . . G l G 2 8 . . . . .. . R e p l a c i n g v a c u u m c ounntirt.o. . . . . . ReplacingdistrlbutorBlg-E23...... R e p l a c i n s i m p u l s e s e n d e r B l 9 - 8 2 3 ... . . ReplacingdistributorB2T/828............... . impulsesenderB2T/828 Replacins Checkingsideplay .. . . . .. L u b r i c a t i o. .n. .. . . . . . .
Replacingcontrolunit.............. Testing distlibutor on test bench . . . . . . . . . . . . . Wiringdiagram .. Faultracing .
G]-G2 G3-G4 G5Gll G12-G21 G22-G21 G28 G29
G30 G31-G34
40 40 40 42
I
0
43 43 47 49 51 52 52 53 55
0
N
t.
I
56
N
36
Brcakerlessignition system
c
F
(-% \.-:z Eu
,-/-]4.
$#
,-F...-, g
0
grcakerless ignition system
E. lgnition coil and HT leads E1 Testingignitioncoil.ballastresistorandHTleads
0'
. l g n i t i o n c o i l a n d b a l l a s t r e s i s t o ra t a p p r o x i m a t ey 20"c (68"F) . A l l l e a d sd i s c o n n e c t e fdr o m c o m p o n e n t su n d e rt e s t .
I
E2 Meesuring resistance ot ballast resistor B20,B 19-8 23 0.910.',t o 82t,824......... 1.010.1f) areconnected in series) {Bolhresistors
E3
0
I
,[
Checking ignitioncoil - checkoutercasingfor cracks - measure j ( )and15(+). resistance acrossterminats 8 2 0 , B 1 98 2 3 . . . . . . .. ... ... t.gio.to B 2 7 , B 2 A. . . .. .. 0.510.1()
-
m e a s u r er e s i s t a n c a e c r o s s t e r m i n all( - ) a n d H T t e r
A l l m o d e l s :9 . 5 i 1 . 5 k ( ) .
38
t
I
Distributor B reakerless ig n ition system E4
Checking HT leads*
*A -\ip
"r ..f
260
\,::
t
nlj
lko reE &
orvm
r
5,6ko/m
_' , "-' -^L !_4 -I-r_ _ \ . ]- - -
1>#.-_--\]
oo
oo
56ko/h
oo
g
260
I
E
95>:-
oo
-
ij.i q -j:'
tko
dli-,
oo
0
A
H
-i!-
0(l
0
24o
240
_rih oo
i? U
,r?5 II]i-!+,-+:l-i-
oo
ffi=FaP*
1ko l-_
lfl--_-----=a|-Oq 5.6[o/m
t
_-,__it>
!-+JFqir-3
Oo
5ko
lko
Besistance vatues are given tn K Q -|F.r neter of tength (tvleasuretead ln oder ta compute carrect vatDe.)At values have a permssable tolerance of ! 20Va.
F. Distributor Checking distributor
cap
- b u r n t e e d r o d e s ,t r a c k i n g - c a r b o n b r u s hf o r w e a r o r d a m a s e
I
h p o f i a n r l T o p r e v e n lr e l an n g s p r i n s si f o m d a m a s h s . o l o r d o n o l c r a . k e n g i n ew h e . d s r r b u t o r c a p i s o f i
F2 Checkingrotor Rotorshoud be freefromcracksandetectrode shoutd = 5t1 kc]. Measure resistance. Resistance
39
Distributor ignition system Brcakerless F3 Checkingimpulsesender of s€nder' Measure resistance 095-t25ko B2 0B , 1 9 - 82 3 a 2 1 , 8 2.8. . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 5 4 - 0 . 6 6 k O
e
C h e c kt h a t n o a r c i n gi o e a ( h o c c u r s lf meter pointerswingslo far right {ie open circuit) r e m o v oi m p u l s es e n d e ra n d c h e c ki f s e n d e ro r l e a d r s
\
I checkingair gap set rotorandstatortipsoppositeeachotherandmea_ sureair gaPwilh feelergaugein) 6 cyl engines:min 0.3mm (0-012 4 cyl ensines:min 0.25mm {0.010in)
I I
Adjusi if necessary'
F5 basicsettingat'l 1.7-13.3r/s Checking/adjusting (700-800 r/min)
0
D i s c o n n e cht o s e f . o m v a c u u m c o n l . o l u n i t . Adiust isnition settins to specificalion. See nexr page.
(
(
I F6 Checkingcentrifugaladvanceal 42 r/s (2500r/min) Check ihat ignitjon advance is according to speciiica_ tion. See next Page. l f n o t , e x a m i n ec e n t r i f u g a al d v a n c em e c h a n r s m
40
I
:t f
Dislnbutor Breakerless ig nit ion system lgnilion setting (beforeT.O.C., disconnected vacuumcontrounitl (alsoSwilzerand1983,models)have Witheffeclfrom1976, vehicesforSweden, Ausrralia, USAandCanada deraits of ignitionsettingstampedon a platelo leftof enginecompartmenr.
t
4-cyl E-engines E n g i n et y p e B19E
B19ET a21E
e
B21ET 823 E
Model year/Market
Description
1977-83 1984 1942 a4 1975-82 rr
'10" 15.
1981 84 1979-82 1983
11.7 13.3r/s (700-800r/min)
15"
10" 5' 10'
Canada Olhermarkeis
1984
(2500r/min) 28-33" 24-24' 21 26' 28 33' 21-26" 25 30" 25- 29' 25 30" 25 30'
/ 1 9 7 6 S 0 i A u s t r ai a , S w e d e n S p e c i va e h i c l e s
CI
4-cyl F-engines B20F
1975
B21F
1976 1977 1978 1979 1980
I
U S A ,C a l i f o r n i a O t h e rm a r k e t s C a l i f o r n l aJ, a p a n Olhermarkets Canada Olhermarkels
1981 84 A21FT
198r-85 ( 9 0 0/ m i n )
5' 15' 12' 15' 12' 8' 10' 10" 8' I' 12'
20 25' 25 30" 2A 32" 25 30" 2A 32" 22-26' 26 30" 24 2A' 22 26' 22 26'
10' 10" 10" 10' 10' 10' t0' 10" 12'
22 25'
26-30'
6-cyl A and E-engines 927 A
1917 79
8 2 8A
1980 84
827 E
1975 r976 1917 7A ) r 979-80
I B28E
S w e d e n ,A u s r r a l i a Othermarkets
1980-82 1983 84
22-25' 30-34' 22 26" 30 34" 30-34' 25-29" 25 29' 27 3f
r978:Sweden,Alsrraiaspecalvehicle.
8.
6-cyl F-engines B27F
- 1976 191/
10' Ca iiornia Othe.markets
1919
B28F
1980-82
Adjustat 15 r/s 1900r/min)ior 1981 California
10' 10" 10'
21 2A 27 20 20
32' 24' 32' 24' 24'
41
Disttibutor Brcakerlessignition system
Checking vacuum advance
c
C o n n e c ta v a c u u m p u m p t o v a c u u m u n i t . R u n e n g i n ea l i d l e s p e e da n d r e c o r di g n i t i o na d v a n c e . P u m p v a c u u m p u m p a n d c h e c kt h a t i g n i t i o n s e t t i n g l f i g n i t i o ns e ( l n g d o e s n o t a d v a n c ec h e c kv a c u u mc o n '
F8 Check Bosch number on distribuior and turn to appropriate graPh on Pages 16-20 Selectpressurefrom graph and pump up vac'rurn pumpto this value.Recordignitionsetting.Subtract to basicignitionsettingandcheckthatvalueconforms graph-
{
{
I
t
I
Example:Boschnumber 0 237 002 038 F9 and Japan) B21F 1979- (Excl.California Y o u s e l e c l d p e s s u r eo f 2 0 0 m m H g C r a n k s h a l d e ' g r e e sa l t h i s o r e s s ue 9 1 4 ' . B d s i ci g n i l r o r s e n i r g r s 1 0 . w h r c n m e a a s r h a l t 9 - 2 a ' s h o L d b e r e c o r d e dd t
!
I Fl0 Check vacuum control unit for leakage connecta vacuumpump and Increasevacuumto 67 kPa(500mm Hs). Pressure shouldnotdropby morethan13.5kPm(l00 mm Hg)duringone minute.
{,
42
Distti butot. reconditioni ng
Brcake essignition system FI1 Checkingignition retard Appliesto B 19/2'lE and F-Turboengines. Connect pressure gauge 5230 and pump 5496 to vacuumconirolunt, Startengineand run at idle. Recordignition advance.Increasepressureto 30 kPa andreadoff;gnitionsetting. lsnitionse(ins shoulddrop 3 7'. pumpandpressure gauge.Reconnect hose. Disconnect
0 G. Distributor - reconditioning
0 G1
Replacingvacuum control unit B 2 0 : R e r n o v ed i s t r i b u r o rrf o m e n g i n ep r i o r t o r e m o v i n g
I Mark position of diskibulor. T u r n d i s t r i b u t o r t oo b t a i na c c e s st o v a c u u mu n i t r e t a i n
0 t
R e m o v ev a c u u m u n i t .
Hook on vacuum unit R e t u r nd i s t r i b u t o rt o o r i g i n a lp o s i t i o n . Fit:
C h e c ki g n i t i o ns e t t i n g -
43
Distributor, rccondi tioni ng Breakerlessignition system G3
Replacingdistributor on B 19-B 23 Removing Unclip distributor cap and remove dust cover. T u r nc r a n k s h a f t u n tri o t o rp o i n t s t o w a r d sm a r ki n d i s l r i ' b u t o r b o d y ,s e e f i g .
i[)
{|
R e m o v ed i s t r i b u l o rr e t a i n i n gs c r e w a n dl i f t a w a y d i s t r i
G4 Installing Turn rotorapprox.60' clockwisefrom markin distribu' (Doesnot applyro 820.) in positionandfit screwloosely Placedistributor Checkthatrotorpointstowardsmark.
{'
Refitdistrib!tor cap. Checuadjust basicignitiontiming.
I G5
Replacing impulse sender on B 19-B 23
I
Removing nemove distributor asdescribed in G3. Remove/disconnect: - retaining clips
I
impulsesenderscrew,
i)
e
Distributor, recond ition i ng
Breakerlessign ition system G6 Uncliplockring and removeshimsas applicable Removerotor and lock pin Use lwo screwdrivers to pry rotor off shaft. R e m o v el o c k r i n g a n d i f t o u l i m p u s e s e n d e r
'[
JI
Fit new imoulse sender
'
i GB Attach lock ring
Distributor, teconditioning Breakerlessignilion system G9
Fit rotor and lock pin l f l o c k p i n h a s a g r o o v e l L r n t l o r a u eL e n l r es l - a ' l Fitshimsand lock rins.
0l
G10
i
Fitlconnect: rmpurse senoerscrew
I
I
retaining clips.
0.
(
I
Gl1 Turn shaft and checkfor grinding etc to turning action. M a g n e t sw i l l g i v e s l i g h t r e s i s t a n c e R e f i td i s t r i b u t o r S . ee G14. Check/adjustbasic ignition setting.
It
46
Distributor, reconditioning Brcakerlessignition system
Replacingdistributor on 827, B2a G12 827A, B28A startat operationG15 Other engine typesl 827 E 1975-74 P r o c e e dt o G 1 5 .
0 G13
0
Remove front Dart of inlet manifold Disconnect link rod fromthrotilepullev.
N
tr
G14 screws Removeair-luelcontrol unit retaining Liftunit up slightly.
0 I G15 All B 27,828 models U n c l i pd i s t r i b u t o rc a p a n d l i f t o ! 1 d u s i c o v e r . Turn crankshaftuntil rotor points towards mark in dislri Remove/disconnectl
Remove distributor.
Distributor,reconditioning Breake essignition system G16
lnstallingdistributor Turnrotorto pointtowards clip {)
G17 Checksetting
t,
{
I
R o t o rs h o u l d p o i n t t o w a r d s m a r k i n d i s t r i b u t o rb o d y . F i t r e t a i n i n gs c r e w l o o s e l y .
0)l
0)( G18 827A, B28A proceedto G21 827 E 1975-78 proceedto G20 Other 827 E modefsand 827 F, B28E and B28F lnstall air-fuelcontrol unit
(
R e c o n n e c lti n k r o d t o t h r o t t l e p u l l e y .T i g h t e n a i r f u e l
G19 Refit inlet manilold torque10-15 Nm (7 '11ft.lbs-). Tightening
{.
v 48
tDistributo r, rccon d ition ing
Breakerlessignition system G20 Fit air filter
(f
0
aI827, 528 ChecVadjust basicignition setting.
i:@
h Replacing impulse sendel on B27lB28 Removedistributor according to G12 G15.
0 I
I
Di stributo r, reconditioni ng
ign ition system Breakerless t^n
(._, -+lL
a(o)} \<7
G23 Lift off rotor washer. Uncliplockringandremove
!
Lift off rotor. (Pry rotor offshaft with two screwdrivers if T a k ec a r e n o l l o d r o p l o c k p n r a l o d i s t r i b J t o r '
I
G24 Removeimpulsesender R e m o v es c r e w sa n d l o c k r i n g
I
Install new impulse sender B e m o v es c r e w sf r o m i n p u l s es e n d e r . Place base plale section on shafl. M a k e s u r e t h a pt i n sa r e o p p o s i t el u g i n d i s t . i b u t o .b o d y F i l s c r e w sa n d l o c k r i n g .
0l {,
@
s? {lo.)4 \e
G25
Refit rotor l f l o c k p i n h a s a g r o o v e t u r n it to face centreshaflF i ts h i m s a n d l o c k r i n 9 .
f, 50
Distri butor, reconditioni ng
Breakerlessignition system G26 Refit:
0
(o
i| G27 Turn shaft and checkfor grinding etc [ 4 a g n e t sw i l o f f e r s l i g h t r e s i s t a n c e t o t u r n ] n 9a c t i o n .
CI
R e f i td i s r r i b u t o rS . ee G16-G21-
G28 Checkdistributor shaft side play in). l,.4ax. sideplay= 0.2mm (0.008 l f s i d ep l a y i s g r e a t e r t h a ns p e c i f l e dr,e p l a c ed i s t r i b u t o r .
0,2mm
51
Distributor,reconditioni ng Brcakerlessignition system G29
Lubrication
a
,' 4 f ))
I
I Distributorgrease(P/N1 1 6 1 1 3 6 - 7o )r B o s c hl u b r i c a n t Ft1v26.
f
t", G30 Replacingcontrol unit M a k e s L r r et h a t r u b b e r s e a l r e m a i n si n b o t t o m o f c o n n e c t o rw h e n d i s c o n n e c t i n gc o n l r o l u n i t .
f) 52
(
Distributor,testing Breakerlessig n i tto n system
Testing distlibutor on a test bench R e f e r t o t h e m a n u i a c t u r e r ' si n s t r u c t i o na t w h e n t e s t i n gd i s t r i b u t o r so n a t e s t b e n c h . T h e n u m b e ro n t h e s i d e o f t h e d i s t r i b u t o ri s i h e B o s c h
''f
p< \s{
(lt
6 connecrng leadto distributor 7 P o w e sr u p p l y( 1 4V ) L l o h h i n g( , ) s y m b os i n d i c a l d eanserous h i € hv o h a g et e r m i n a l s
'i ''rll:::!= ;s
'{f'
(l
L
.:-
Cran[shafl degrees D strlblror degrees
-
I G31 Calibratetest bench S e t z e r o a t d i s t f i b u t o rs h a f t s p e e d c o r r e s p o n d i n gt o z e r oa d v a n c eS . e ed i a g r a m so n p a g e s1 5 l T . T h i s c o m p e n s a t e sf o r t h e e l e c t r o n i ca d v a r c e f . o m t h e i m p u l s e
1 2
Zero ser ai (360 th n) c e n t r l u g a l a d v a n c eb e g i n s C e n r ri u g a i a d v a n c ee n d s Absollte lm r of gn r on advance
Distributor,testing Breake ess ignition syslem
+s
G32 Checking firing S e t d i s t r i b u t o r" 0 " r o p o s l t i o nw h i c h c o i i e s p o n d sl o firingoi cyl 1. F i r i n gs h o u l d b e i 4 cyl: 0 90 180-270 6cy:0-75 120 195 240 315 360 l M a x -d e v i a t i o n= I 1 . 5 ' . C h e c ks h a p eo f a r r o w s ( o r e q u l v a l e n sl y m b o l d e p e n d l f d e v i a t i o ni s m o r e t h a n2 ' t h i s i n d i c a t e st h a t s i d ep l a yi s too large.
{, I
G33 checkingcentrifugaladvance Rundistributor at 3.5r/s {200,min).Calibrate meter. I n c r e a s es p e e da n d c h e c kt h a t c e n l r i f ! g a la d v a n c ec o n formsto specification.
0) I
l f n o 1 ,c h e c kt h a l b a l a n c ew e i g h t sa r e l u b r i c a t e da n d d o A l s o c h e c ks p r i n g s .
G34 Checking vacuum advance Rundistributor at 10 r/s (600r/min). Calibrate merer. Increase vacuumand comparevalueto specificat on-
I
f)
|
Wiring diagram Breakerless ig n ition sYstem
Wiring diagram, breakerlessignition system I
1975 -1978
4 cyl
1979 1975 78
^'r'a
Err
.0 '.0
li C=
6 cyl 1979
(f I
t1 Y
1s75-,I,7a
Balastfesistor
--l-
| I
1979-
!-/"' E :rl[r:',t i-
fi' fr| TTrT !l.lt-[U-l r!,J!LJJtrJ!
l.]lillf-.I - JJ!u-t
L-, 4BNBN -a -'
er.r B"|::Q
-r i-u-, .-
;r1+
J
-@!u
.i4+
I
rmr'rlrl."
--@
h ."/|1+it.-lr@
55
Faull Ttacing
I reakerlessignition system
9 E
E *g i J! E E
!3E ;i; o
s!
-9
E:
;
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E B
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6:9':
i!i9i9 9! 9 -:-:6:
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56
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li I tE II I: l; E II t9 t l- i
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al
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Computerized ignition system
I
0 (t
Conlents Generalinstructions . .. .. points... .. Connectors and earth M o d i l i c a t i o nt os 1 9 8 3m o d e l s .... . lgnitioncol and HT leads Checkingdistribuiorcap and rotor. .. Checkingbasicignitionsetting.... Checking/adjusling microswilch B 2t L-\,10Cr98r,B 2 t--Cr1982 B 2r F-LH 1982 B 23 f LH 19831984 B 230 T-l Ll 1985-
Checkingignilionadvance. cenlri'Jgaladvance dserl a.gle .
Operation
Page
H1_H4
58
J1-J4
59
Kl-K8
60
L1_14
62
t\.i1-t\43
63
M4-M10
63
M5-1\46 I\t7 M8-M9
64 64 65
M11-M15 M11 M12 M!3 [,414-M15
65 65 66 66 66
R e c o n d i l i o n idnigs t r i b u l o( P r / N1 3 0 6 0 5 9 ) . . . . . . . .N 1 _ N 4
,n
replaci19dislr bulor
ReplacingdistributorP/N 1332684, 1336737, 1332587 replacrg mpLlse se.de. . reoldLi19dislr bulor
0
Replacingcontrolunit Wiringdiagram Faulttracing
N1-N2 N3-N4
67 67 67
N5-N14 N5-N8 Ng-N14
68 68 69
N15
70 71
I
I 5l
Generalinstructions Computerized ign ition systems
H. General instructions
.{ A l w a y ss w i t c ho f i t h e i g n i t i o nw h e n d i s c o n n e c n n g / c o n n e c l i n gi g n i t i o ns y s t e mt e r m i n a l s
H2 B e g i nb y € h e c k i n ga l l r e l e v a n t t e r m i n a l3sn d c o n n e c l o r s b e f o r ec a r r y i n go u t e x t e n s i v ef a u l l l r a c l n gp r o c e d u r e s
0, 1
ol
H3 N e v e r l e t s p a r k i e n g t h e x c e e d5 m m w h e n c h e c k i n g i g n i r i o ns y s t e m c i r c u i t so r c o n t r o u n i t m a y b e d a m aged. C o n s e q u e n d yc,o n n e c ts p a r kp l u g t o H T e a d a n d e a r t h plugvia engine.
rl)
CAUTION: To avoid damaging the conneclor sleeves DO NOTDISCONNECTCONNECTORlrom conlrol unil when checking vollage. The volt-/ohm-meler should be connecled direclly lo the wires.
o 58
Connectors Computei zed ig n ition systems
J. Gonnectors and earth points
!
0
JI
Controlunit
J2 Distributor
0
I Bulkhead
(o ,I J4
Controlunit earth
I 59
Guide sleeves Computenzed ig n ition systems
K. Modifications guide sleeves Connecting
j
K1 is connector Witheifecifrom1983modelslhe dislributor Thesesleevescanalsobe with guldesleeves. equipped fittedto eadiermodelsandto the conlrolunitconneclor. GuidesleevesP/N1 324 909-9. Note: Frommodelyear1984.the guidesleevesare installed in the controlunitat lhe taclory.
Note: Thewiing harnessfor lhe controlunilmuslbe il theconnector hasbeendisconnected rcplaced the controlunrt. or whenreplacing
]..
I
K2 Orill lor conneclingguide sleeves P/N9995268-1. 2mm
I
To installguidesleeve,placesleevein the driftandcheck 2 mm(0.08in.) that it protrudes f nol, shone.loollo drrensonsl'ownadacenl Easierlo insertguidesleeveit openings countersunk.
K3 Caretullycleanconnectoron distribulorand control unit Withdraw connector fromdistribulor. Scrape off PVC a n d o x i d e d e p o s i t sf r o m a l l l h r e e p i n s . Use tool 9549. A p p l y g r e a s et o p i n . C l e a nf e m a l ec o n n e c t o rw i t h a t a p e r e df i l e . W i t h d r a wc o n n e c t o frr o m c o n t r o lu n i t .S c r a p eo f f o x i d e from aroundpins3, 5 and L
K4 Placeguide sleevein tool 5268 P a c k( A ) w i t h g r e a s e .R e p e a tf o r e a c h s l e v e I n s e ( s l e e v ei n t o o l ,
+tt-tr 60
o
Guide sleeves Computerized ig n iti on systems
K5 Installguide sleeveson connectors Distributor:
I
On all pins.
_=
1o 1Oo
_::)
-f -_:)
_l ::l
3
3a-80 40
70
K6 Control unit O np i n s3 , 5 a n d9 .
K7 Check Presson guidesleeves so thatat Least 2 mm (0.08in)of pin is visibleabovesleeves. Reconnect terminais andcheckfunction.
,I Replacingsleeve insulators K8 Withdmw
connector
D e t a c hr u b b e rc o v e r a n d r e m o v ei n s u l a t o r . Fit new insulator P/N 949597'9. R e c o n n e cct o n n e c t o r .
I 61
Computerized ig n ition systems
L. lgnition coil and HT leads L1 Test conditions: of . lsnilioncoilandleadsshouldbeai a lenrperature about20'c {68'F). trom components . All ieadsmust be disconnected whentakingmeasurenrenls.
L2 Checking ignition coil checkoutercasingfor cracksetc - measure resistance acrossrerminals I (-)and 151+). = 1.1-1.3Q. Aesistance
L3 m e a s u r er e s i s t a n c ea c r o s s t e r m i n a l 1 ( ) a n d t h e h i g h t e n s i o nt e . m i n a . : 9 . 6 ' 1 1 . 6k O . Reslstance
iesi-
oa
iE6
-r1
1ko
L4
'--n
-
ll l+-r+
l:L)
Checking HT leads
oo u
5,6ko/m
_
i
R e s i s t a n coef H T l e a d b e t w e e nd i s t r i b u r o ra n d i g n i t i o n c o a s h o u d b e 2 3 . 5 k o h m sw h i c h i s e q u i v a l e n t o 5 . 6 Spd.l p ugs supp esso|esisldlce - 5 kol_ns
r-€<
5ko
Resistanco e f c a b l e c o n n e c t o ro n d i s t r i b u r o rc a p = 1
c
l" i I
Distributor,general Computerized ig nhio n systems
M. Distributor, general M1 Checking distributor cap
tracking, burnrterminals. NoterCentfeterminalis not springloaded.
M2
(f
Checking rotor Two types of rotor are in use.Useonlynewtypefor
j M3 checkingHallpick-upwire l M a k es u r e t h a t t h e w i r e s c a n n o t b e d a m a g e d b y t h e
,I M4 Checking/adiusting basic ignition setting Eeforecheckingignitionsettingcheckfunctionof
|
_Noie: see p"ge 65 for co'tectao.:slmerrorol1f_l
Distributor,general Cofiputelized ignition systems M5 Checking microswitch on 821 F-MPG 1981 and
821F-Cr '1982
C o n n e ca t t e s t l a m p b e t w e e nb a t t e r y( + ) a n d t e r m i n a l 2 ( y e l l o ww i r e ) o n m i c r o s w i t c h . I a m p s n o u l ob e o f f w h e n e n g r n ei s i d l , n g .l ' l a m o i s o n , adjust microswitch as described below. T u r n t h r o t t i ep u l l e y a n d c h e c kt h a t l a m p l i g h t s -
M6 Adjusting microswitch Pl6cea 0.4mmfeelergaugebetweenadjustmentscrew Unscrewmicroswitchretainingscrewsandturn switch unlillamplights.
Checking Placea 0,2mm feelergaugebetweenadjustnrentscrew Lampshouldlight. Remove feelerqaugeandinserta 0.4mm feelergauge. Lampshouldbe off.
CI)
M7
R*...q*5to'
Checkingmicroswitchon 821 F-LH 1982 D i s c o n n e cct o n n e c t o rf r o m v a c u u m s w i t c h .C o n n e c ra test lemp behveenbatre-y( ) a.ld orange wi'e o. S t a r te n g i n e . T e s t l a m p s h o u l d l i g h t w i t h e n g i n ei d l i n g . I n c r e a s ee n g i n e r p m a n d c h e c kt h a t l i g h l g o e s o u l . lf not, check hose to vacuum switch. lf intact, rep ace
o 64
DisLtibutor, general Computerized ig n ition systems M8 Checking microswilch on B 23F-LH 1983-1984; B 230 F-LH 1385Withengineofl, turn throttlepuLleyslowy and istento mlcroswitch. A cick shouldbe heardwhenthroltlevalve
\A. q.rl €
M9 Adjusting microswitch Unscrewrelaining screws. Turnswitchclockwise slightly.Thenturn swilchback untilit contacts slop,butnofunherasthrottlevalvewi Tightenretaining screws.
il M10 Check lhat basic signitionsetting is 12oa2'at 12.5r/s (750 r/min) Air condiioningdisconnected as applicabLe. Adlustignilonsellingby turningdstributor. Increase enginespeedto 2000rpmfor 5 seconds. Lel the englneidleandcheckidlequality. Makesurethe dle is slableand wthin specifications as variations coud afiectthe liming. M11 Check centrilugal advance Dsconnectvacuumhoselrom distributor. Runengineat 42 r/s (2 500r/rnin)andcheckthatignition advance is l6-24c beloreT D.C.ior B 23 F, B 230F and 22-30obeforeT.DC. tor othermodels. ll incorrect, replaceconlrolunit
0 65
Checking, control unit Computerized ign ition systems Mt2 Check vacuum advance Runengineat 25 /s (1500r/min). Re_ hose.Becordignitionadvance. Disconnectvacuum allers. connecthoseandcheckthatadvance lf not,checkfor vacuurnat controlunil {checksuctionat replace controlunit lf vacuum,but no advance,
M13 Checkdwell angle Readoff dwellangleat idle. Dwellangle= 36 38'. Increase enginerpm and checkthat dwell angLeinis recorded, replace controlI'nit, creases. if no increase
B23F Checkingknock sensor
M14
c o n n e c ta v o l v o M o n o t e s r e ro r e q u i v a l e n tl e s t n r e t e r . S r a r te n g i n e ( A C d i s c o n n e c t e d ) . I n c r e a s e n g i n es p e e da n d m a i n l a i na l s e l l e v e b y e . g . p L a c i n gs c r e w d r i v e ra c r o s st h r o t t l e p u l l e y .
t'; M15 T a p p l u go n r i s h t s i d eo n c y l i n d e rb l o c k w i t ha h a m m e r ' l g n i t i o ns h o u l dr e t a r db y m a x 6 ' a n d r e t u r na u l o m a t r c a l
66
Distributo r, recondi tion i ng Computerized ig n iti on systems
N. Distributor (Ghrysler),reconditioning 1 (P/N 1306059) ReplacingHall pick-up Remove: s p r i n g sr e t a i n i n gH a l l p i c k - u p - drsconnectconnector r e m o v eH a l l p i c k - u p .
r0 (0
N2 lnstall: - Hallpick,up springs C h e c kt h a t w i r e s c a n n o t b e d a m a g e db y r o t o r . R e f r ld i s r r i b u t o rc a p a n d r e c o n n e L cr o . l r e c l o r . Seep€ges60-61 for installinsgu de steeveson connectors.
il
N3 Replacing distributol Remove: - HTleadsfromdistributor cap T u . n c r a n k s h a f tu n t i l r o t o r p o i n t s t o w a r d s r u b b e r D i s c o n n e cct o n n e c t o r .
rl
Remove distributor.
Installdistributor Tubularpinprotrudesmoreononesidethanlheother. T u r n s h a f t u n t i l p i n i s o p p o s i t eg r o o v e i n d i s t r i b L r t o .
Fit: d i s t r i b u t o rc a p a n d r e c o n n e c H t T leads. Reconnectconnector.
I
C h e c v a d j u sb t a s i ci s n i t i o n t i m i n g . S e e o p e r a t i o nM 4 . Seepages60 61 foi instaling quidesleeveson connectors.
67
Djstrj b uto r, recondjtioni ng Computerized ignitton sYstems
Distributor(Bosch),reconditioning Type 2 (P/N 1332684,1336737,1332587) N5
Replacing distributol Remove/disconnect HTleadsiiom cap
CI N6 Setcyl 1 ro T.D.C. T u r n c r a n k s h a f t u n tri o t o rp o n l s t o w a r d sm a r ki n d i s t r i D l s c o n n e dc o n n e c t o r . R e m o v ed i s t r i b u l o r
lnstalldistributor C h e c kt h a t c y l 1 i s a t T D - C T u r n r o t o ra p p r o x .6 0 ' c o c k w i s ef r o m r n a r kl n ' l i s t r i b !
r:l
Rotorshould now point towards mark n distributor
f)
C h e c U a d l u sbl a s i ci g n i i i o nt m i n g . S e € l ! 1 4 . S € ep a g e s6 0 6 1r o r n s l aI n g s u i d es e c v e so n c o n n e c l o r s
68
o
r
Distributor, reconditioni ng Computerized ig n ition systems
Replacing Hall pick-up
ru9 Nole:
hp trd Sr.tL1 >-oJld -or be epla Fd on irbutors wilhii the lirst year oi warranty. cornpete disiributormust be replaced
Bemovedstr butor accordinglo operauonsN5-N6 Mount dlstrbulor in a vise (NOT SOFT VICE JAWS TO PREVENTDAI\,iAGE). R e e a s ec r c p r e t a i n i nlgr g g e r w h e e .
NlA (use roundPry oii trgger whee wiih two screwdrvers shalt screwdrvers 5mm diameler) Placetips ol screwdrve.son sleel hub. as shown. Take care not lo damagetriggerwheel
r e m o v ailr m ' r s rb e lfvqger whee s benlduring
Take care not lo lose ock p n
,)
Remove - Hal pickup retaning screws - plaslicp n (A)lor connector
I 69
Distributor, reconditioni ng N13 RemoveHaLlswtch andconnector.
lnstall: - New HalLswitch and connector circlip - retainng screws and plasticpin (1)
sa-4 I" a-,
a
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lnstall: - trgqerwheel(2) - Lockpin (3) - circlip(4) - condensation trap N7-N8. t o operations Instaldiskbuloraccordtng
Control unit N15 Replacingcontrol unit C h e c kc e n t r i f u g a a l n d v a c u u m a d v a n c ea c c o r d r n gt o o p e r a l i o n sM 1 1 - M 1 3 a f t e r i n s t a li n g c o n t r o l ' r n i l S e ep a g e s6 0 - 6 1l o r l n s l al i n gg ! i d es e e v e so ' c o n n e ' r o r s
Wiring diagram Computerized ig n ition systems
Wiringdiagram,computerized ignitionsystems B 2'I F_LH,B 23 F_LH
9
t"',"
0
Llllru rn!8
D = M i c r o s w n c ha 2 r F I
H = M l c r o s w t c hB 2 l F L H J e r r o n i c J - lvl cr;swiich 823 F K = K n o c ks e n s o rB 2 3 F
I
I _,,rxrt]x-D -l _ ! _rl-lfD
I
I
BL CN BN SB
71
Wiringdiagram Computerized ignition system
Wiringdiagram,computerizedignilionsystem B 230 F-LH,198s-
I C
lgnition switch B r e a k e ru n i t
F l g n i t i o nc o i l G oistributor 214 Control Unit LH Jetronic
H e a t e dr e a f w n d o w Overdrive
/2
0
NOIES
Oi
'D( 0(
o t).
t'
o
o
-E
Fault tracing chart B 21 F-MPG/LHB 23 F-LH
Adllsl advance by lurn ng dlstr
Checkthat ign tion advance s 12' al r2.5 r/s (750 r/min).
o
T!rn ofi ignition. Disconnect conneclor C h e c kf o r v o t a s e € t b i u e w i r e . V o l t a g e ?
i I
I C h e c l c o n l r o l! n i l e a r t h
0
i
olsconnecl HT leads irom disrri C h e c kt h a l e a c h p l ! g s p a r k s
C 5 p . l f o ' , o h a g e a r r o r n r a l A o r 3 - p o i eL o r n e 't o r R e p a c eF a l l p i c k ! p i n d s r r i b o r o r .
)
?
D s c o n n e c t3 p o l e c o n n e c l o r
N o t e i N o l 1 2 V . L a m pd i m . gnilioh shou d be ofi when d sconnecrn9 conneclors.
8 r d g e p i . s B a n dC w t h p i e c e
,.,.,
L_". C h e c ki o r v o l a g e a t t e r m i . a l 1 5 ( + ) o n i g n i -
.5p.r
wtrc( bdrwear g1t on rwrt a dnd ro
,o. r
C h e . l w r r el o d r 5 h b u r o r .
o
0
o o {D 0
C
o
-E 1o
o
Fault tracing chart B 230 F_LH
Adjust gnrlon advanceby turn.9
checklhal igntior advance is 12" ar 125 r/s (750rpm) Reler ro SB 34:105for selting
f. /42.4
o
€?. ll
A{i ca
'
Poshlest lampprobethroughb ue w.e covero. rconlro unt. Check tor vollage
Nole: Oo nol disconnectconnecror lrom con-
I
t I check controlunrt groundconnecto.
i
"-
Dsconneci HT ead irom dslri Check lhal each Pug sparks
Che.l lor vo lage ar terhrnalA on 3-poleconnecror
D sconnect 3 poe connector
Nole. Nol 12 V Lamp d m gntion sholld be oil when discon-
NoleiChecklype olconneclor. Bosch(1) Chryslef(2)
Co..ect a br dgew re acrossB
greenw recov Pushtestrampproberhrough
Checkror vollageatierminal15(+)on gnil on
Check wiresconnectedbetween anilon switch and conirol unt
oKNole: Also repLacecabe harnes Check conlro
uni
connector
€
0
o o D
e
0
7
lndex Operation
Page
83 84 84 85
28 28
Dwell angle
Earlh points . .
Checking.A €fg nes (4 cyt) Checking B 2 l F - M P GB , 21 F-LH, B23F LH.823OF-LH, ., Mt3
A e n gn e s { 4 c y ) .. EIF efg fes A-enqines(6 cy)
A2 E2
66
Engine speed control B 2 1 F . M P GB , 2 1 F L H ,8 2 3 F - L H . 8230F-1H... .. .. ..
26 38
Fault lracing E/Fengines.... B 21 F.MPG/LH 2] F-LH
59
rvl l
56 75 77
B 230 F-LH
if
C e n l r i r u g aal d v a n c e B 1 7 A - B2 3 A . B 1 9 K , B]9EB23E ., a 2/A B28F 821 MPGB23F LH.B23OF-LH
87 F6 F6 M8
8 2 1 F M P GB , 2 1 F L H .B 2 3 F - L H . B23OF LH J1-J3
R e p a c e m e n.t Checkng dwell ang e
'l
B3 B4
B19B23E.B27AB28F G30 B 2 ] F M P G . B 2 1F - L H , B 2 3 FL H , B23OF LH N16 Delay valve Oist buror {B 17 A-B 23 A) R e m o vn g - n s t a l l n g. Sdepay Testingon lesl bench . . Lubrcation
B9
c3 c4 c5 ..
D1-D4
c6
29 40 40 65
59 2A 28
65
Firingorder..... Groundpoints... lgnition coilg B17AB23A A]-A3 BlgE B23E.B27A-828F. E1_E4 8 2 1 F . M P G8 2 1 F _ L H 8 2 3 F - L H , 8230F-1H.......... Ll L4
26 38 62
lgnilion retard B 1 9 / 2 1E a n d F , T u r b o . . . . . .
F11
52
Knock 3en30r
M14-t\,415 66
70
Lubicalion, dBtributo. B17A-823A....... B 19 E B 23 E. A27 A-A 27 F .
c6 G29
30
33 34 33
B 2 1 F - M P GB, 2 1 F - C t1 9 8 2 . . . M5 t\46 B 2 l F - L H1 9 8 2 M7 B 2 3 F , L H1 3 8 3 1 9 8 5 ,B 2 3 0 F - L H M8 M9
33 52
64 64 65
K7 D i s r r i b u r o(fB 1 9 E - B 2 3 E ) B e m o v i n gn-s t al i n g. . Bepacemenloi impLrse sender Side play Testingon tesl bench .. Dislributor (B 21 F-MPG-B 23 F,LH, Removing nstaing. .. .. .. F e p a c e n r e n l oHf al s e n d e rt,y p e1 Bepiacernenl of Hallsender,type 2 Distriburor(B 27A-B 28 F) R e r n o v l n g - i n sitnag . Bepacementol mpulse sender Side play T e s l i n go f l e s t b e n c h . . . . .
G3 G4 G5 G11 G28 G 3 1 - G 3 4 53 I 230 F-LH) N3-N4 67 N1-N2 67 Ng-NI 4 69
c12 c21 c22-c27 G28 G31-G34
47 49 51 53
B17A_823A B8-Br4 B]9E-.823E.827A-B2AF. B2] F.I!IPG,821 F L H ,B 2 3 F - L H . 8230F-1H......... M9 Wiring diag16m 8 2 1 F M P G , B 2 ]F - L H , B 2 3 FL H . 8230F-1H.... 8230F-1H..... O l h e rE / Fe n g i n e s . . . . . . . . . .
30
71 72 55
