Professional Documents
Culture Documents
(excl.Wiring Diagrams)
and Battery
Alternator
31
32
lnstruments Starter Motor 33
lgnition System 34
242/244/245 Lights 35
Std. Equipment 36
Repairsand Instruments 38
Maintenance 1976-
Content of Manual
Group31: Battery
Generalinfomation
GrouD32: Alt€rnator
Specifications 3
N e wF e a l u r e s . . . . . . . , , , ,
D e s c r i p t i.o. .n. . . . . . . . . . 5
ServiceDiagnosis 6
Checo k f c h a r g ' nsgy s t e m ........... ..... A 1-A12 7
ServiceProcedures
Specialinstructions for work on alternator
equipment......... 12
Group33: StarterMotor
GeneralInfomation 22
SparePartslllustration 23
SpecialTools 24
Group34: lgnitionSystem
Specificarrons 32
L u b r a c a t. i.o. .n. . . . . . . . 32
lllusration 33
Bre8kerl€ss Electronic
lgnitionSysrem
General
ServiceProcedures:
Replacingdistriburor
Replacing impulsesender 81 816 39
Group35: Lights
Specifications 43
Headlamps 44
Front lights ?t5
Lights,242 and 244, DL and GT 46
Lights, 245 47
Group36: StandardElectricalEquipment
Switches ,$
Bulb FailureWarningLight 49
Tailgate Window Wiper and Washer. 245 50
WindshieldWiper Assembly 52
GrouD38: Instruments
InstrumentCluster 53
WarningLights 53
54
Replacinginstrument 55
56
Testingfuel gaugesand tank levelsenderc A1 A8 58
AddilionalInlomalion 61
NOTE:All references
to model240 in thismanualalsoapplyto DL,GL and GT.
TP 11402t2
3000.03.80
Printedin lJ.S.A.
Battery
Group31
GeneralInformalion
(@20'CrANDCHARGE
spEcrFrcGRAVTTY
SpecillcGravltyReadlng
(uselhe mlnlmumflguretor lestlng)
Minimum BatleruCharoe
1 . 2 6 0 . . . . . . . . . . . . . . . . . . 1 0 0C%h a r g e d
1 . 2 3 0 . . . . . . . . . . . . . . . . . .7 5 . /C
. harged
1.200. . . . . . . . . . . . . . . . . . 50%Charged
The Battery 1.170. . . . . . . . . . . . . . . . . . 25 Chaged
andmajorengine 1 . 1 4 0 .- . . . - . . . . . . . . . . . V e r yL i t l l P
e o w eLr e t l
compon€nts 1 . 1 0 . . .- . . - . . . - . . . . . . . C o m p l e tD
electrical e li ys c h a r g e d
'(80"F)
water,Thenflushwilhcleanwater.Be sureventcaps
are tight so no solutiongels into cellsto neulralize
the acid.
Alsowashbatlerycarrierand holddowns.
Donolovenighten bolts.Tighlboltswillstrain
holddorvn
General the battery.Checkbanerycase for cracks.
Lack ot eleclrolylecauses prcmaturelailure of bat-
when charged,a batterygiv€s off hydrogenand oxy-
teriestasierlhan anythingelse,Plalesexposedlo ai
o
gen,a mbdurewhichis highlyexplosive. Keepopen
delefioralerapidly.Check electrolylslevel fiequenlly, llamesaway Aom batleryand never disconnecta
especially in hot weatherwhenevaporalion asmore
chargerby removingthe connectional the batterypost.
likely.
Guad againslsparksby disconnecling tho ground
Filldeslilledwateronlyto the battery,neveracid. How- it lest. Be caretul
nol lo lel
cablelirst andconnecting
svsr, any watsr is batterthan no waler. Batlerylife is
WARNING!
Caution
We wouldliketo strcssthe importance ot not havjng
openllamesor spa*s in the vicinityof the batteryb€-
causeol theexplosivegaswhichlonnsin the battery.
Thereis thus a dangerof sparksfromshodingat lhe
batleryposlswhrchcan causethe gas to ignde.
Prccedures
-Both batteries (senderandreceiving) musthavethe
samevoltage.
-TheAmperageolthesenderbattery mustnotbevery
muchgreaterlhan lhatfor the receiverbattery.
-The battery cellcapsmustbein position (thisreduces
riskol gas igniting).
-lf lhereceiving batleryis frozen,il mustbeattowedlo
thawoulbetoreconnecling up thejumbercabtes.(A
flal batterylrcezesal -10"C. (15"F.))
Useof JumperCables
ING CAL
SENO -The senderbalteryenginemuslbeswitched off.The
receiverbatterymainswilchmustb€ off.Thebodies
ofbothlhecarsmuslnotbeinconiaclwith€achother
(risk oJ sparksfoming whenthe cablesare con-
nectedup.)
1. Connect the redcablefromsenderbatterypluster-
minallo receivingbatterypluspost.
2. Connectone endoflheblackcabte to agroundpoint
RECEIViNG
CAR somedistancelrom lhe receivingbatlery.Suitabty
lhe receivingbanery'sgroundconnectionshould
alsobe on the bodyor on the engine.
-Slart thecarof lhesenderbatteryandidteit at about
1500rpmfor severalminules.
N e g a ti v e -Starl the car of the receiverbattery.
os itive
Terminal
RE]'1OV CABLES
Gtoup31
2 Battery
Specifications
Group32
Alternator
Specifications
Alternator
Tlpe
Output
13.0-15.0V
I
55 Amps
\,4., sppFd .. 225 t/s = 13500rpnr
D r e c t i o no f r o t d to n .. Clockwise
q o r o . e _ g e a l r p r ' 3 r o._. . . . . . . . . 1:2
S I D ' r n g s .r n i - J m d i d m e l e . 3 1 . 5m m
ra: o-r oI o-no 0.O3 mm = O.OO12
Stdtor Loil res stdnce O.14ohm + 10%
F o r o r c o r lr e s r s t a n c e 4.Oohms+ 10%
O-rpu esl 48 Amps at 3000 rpm, 13.2 Vohs and
24oC ambienttemperature
Voltage Regulator
Tlp. .. ...
Colt'o. vordge ol 40OO pr 13.9-14.8Volts
I
Loadru r.rr owo 'wo co.racrs 4511 Amp
C o n t r o lr a n g e ,b e l w e e nu p p e ra n d l o w e r c o n t a c ts e t s . . . . . . . . . . . O O.4 Vohs
3-8 Amps
Description
o
1. &ush holdor
2. M6gn6iizingDiodes
3. Slip ng 6ndshield
4 B€crmd (slrien diodas)
-. A n a r F ' a t o r h a sa r o t a ! . S , r ed . o r l ( r o _ o ralr d . s l d .
T1. allernaror rs a th'e" pl'ase sld. Lonnpcl.d a
F c l ' i e ' rs burl rnro _ l _ es o r ' q tionary main coil(stator).The rotor is a 12 pole claw-
nar n9 un r. lhe "nd
shield and consisls of six silicon diodes. Aso ho{rsed pole rype w,rh rl"e l,ed Lo' 'ed ac oss lwo slip rings.
n rhe slip rng end shield are three so called mag
Since the ahernator outpul s self-limited(max. 55
ne /rng dodFs. wl_cl repd rhP rred via ll"e vor;9.
amps),a simplereguatoris used. t conlrolsthe vo tage
Gtoup 32
Ntomator
Specitications 3
Design
NewFeatures
Afteroldstyleallemaloris removedandin-carhamess
js disconnected,proceedwith the operationsshown
duringinslallation
oJlhe new allernator. .)
1. Conneclin-carharnessleadsto terminals
at backoi
newalternator
as followsi
a. Heavygauge,rcd twin
lead10B+ teminal.
b. Singlered leadto D+/61teminal.
c. Blackleadto D- teminal.
d. Useelecvicallapeto securely
fastengreenDFlead
2, Carelullytapetheold in-carwiingharnessconnec-
tor piugas shown.
Theconnectorplugiromlhe newmoldedalternalor
harnessshouldbe pluggedinlothe regulalor.
Nole: Do not underany circumslancescut anyoJ
the old leadssincetheymay be neededfor
Juturealtemalorinstallations.
Gtoup 32
4 Altemator
Design
Altomator
5Wr
t_-!
Group32
5
Diagnosis
ServiceDiagnosis
Action Possiblecause
Testlamp(12 volts2 wattstbetweenB+ and61/D+ Warninglamp burnedout or opencircuitto D+ on
on alternatorlights. regulator.
Test lamp betweenB+ and 61/D+ doesnot light. Positivediodeshorted.
Test lamp between61/D+ and groundlights.
Testlampbetween61/D+ andgroundgivesa weak
light.Removethe plug at the regulatorand connect
an ammeterbetweenB+ and DF on the alternator.
Action Possiblecause
Disconnectthe plug at the regulator CircuitshortedbetweenD+ ontheregulatorand
61/D
Controllamp still lights.
Warninglampgoesout-Re installtheplugi. the rcg-
ulatorandconnectan ammeterbetweenB+ and D+
Coil shoned.
I
Condition: Warninglamp lights with 6ngin6off bu1starts to give a weak light
when€ngineis running.
0.
Actionr Possiblecause
TestlampbeiweenB+ and61/D+ on the alternator resistance
Transition in thecharging
circuitor in the
wirh the enginerunningl leadto the waminglamp.
Doesnot light,
Givesa weak light. Defective (overcharging
regulator of thebattery)orde
(insufficient
fectiveahernaior chargingoflhe battery).
Installnew regulator.
Test lamp betweenB+
a n d6 1 / D + :
Doesnot light. Removed regulator defective.
Givesa weak light. Defectivealternator.
Group32
6
Diagnosis
Generalorientation
Connectionsat altemator
FEDwlFE. TO CHAFGTNG
CONTROL
LIGTIT
ir
iiJ"
t
FEDor aRowri
ro PLUGAT ALTERNATORWITHWIFE
LOOMTO VOLTAGEFEGUIATOF
o
D '1.,,
Connectionsal voltageregulaior
i d e n l i f c a l i o no f w t r e s n p l u g
Procedures
Gtoup 32
A2
Check batlery condition
A batteryin good conditionshouldbe usedfo' rhe
A3
Switch on ignition
Charginglighton instr!mentpanelshouldilluminaie
go to A4.
a. Light illuminates.
b. Lightdoesnot illuminate:discon.ectplugal vol
rage regulalorand ground red wire D+.
- Light illuminates:
go to 44
Lightdoesnot illuminatercheckwires,control
lightbulb etc.
A4
Connect a voltmeter to alternator B+ and
grouno
All lighlsandaccessodes switchedoff. Runengineal
// approx.2000 rpm for one minute,then read voltage.
a. Voltagereadingcoflecl go to ,q5,
II b. Readinghigherthan14.4volts:go to 410- 0)
II than13.0volts:go to A10.
c. Readinglovver
I I I
(Refer to s€ction Tesling the VoltageRegulatol for
chargingrats).
I \
VOLT-I']ETEF
A5
,
I
Voltmeter stillto alternator B+ and ground
Switchon blower,rearwindowheaterandheadlighl
\s
\\
BEDor BBOWN Vollagereadingshouldbe lessthan O.7volt lower
GREENof WtllTE
Group32
I
T
Diagnosb
A6
Connectvoltmeterto alternatorBi and bat-
tery plus
Switch on headlighruppe. beams.Run enginear ap-
prox. 1500 rpm. Voltmeter readingsho! d be O.O-O.3
A8
GFEEN
orWHm Charging system should be correct if all pre-
vious tests have proven satistactory.
Gtoup32
With incorrectsystemtest readings
A9
Re{erence
to A4
{Voltage reading higher than 14.4 volts)
Connectvoltmeter to D+ and B+ on alterna-
tor.
'/.-_'
Runengineat l5OOrpm.
/l a. Vollage readingexceeds0.5 volt ahernatormust
be defectiveand should be replacedor repaired.
At0
Reference to 44
(voltagereadingbelow 13.0 volrs)
of referenoo to a5
(voltagedrop more than O.7 voh)
Connect voltmeter to O+ and B+ on alterna-
Atl
Checkrotor circuitresistance
Disconnectwire DF (plud at vohage regulator.Use
ohmmetertocheckrotor resistanc€. Correctresistance
I I
I
R u n e n g i n ea t 1 5 0 0 r p m .
qoror ressrancechecksour coiiect: go to 41r. i
I OlIU.UETEB
b. Botof resistancechecks out lower than approx
Gtoup32
10
Diagnosis
JUMPEAW|FE At 2
,.-_-\ Full Fielding Test
( Thisis alullchargetestol alternator,
airnsdatdefinitety
separating allernalorproblemsfromvoltageregutator
I D+
REDWIBE a. Removethe plugat the vollageregulalorandcon-
\ necla jumperwircbetweenD+ andDF as shown.
\--
DF
GREENo. WHIIE
CAUTION:Donotrunenginehigherthan 2000RPN4 or
lor lengthlypedod-it coulddamagethe
o
batteryandotherelectricacircuitsdue lo
HighVoltage.
\s
\\
GREENor WHIIE
Group 32
Altematot 11
Removingaltenator
S€rviceProcedures
0l
Removingalternator 0(
BI
Removealternator
a. Disconnect wires at alternator.
b. Removebolt for tensionerbar, hex 13 mm
c. Lift off drive beltsand lower alternaior.
0),
Hex 13 mm
Group32
12
Diassembling dItematol
Disassembling
alternator
cl
Removenutand washerfrompulley.Pulloff pulleyand
C3
Remove nuts and bolts connecting akernator end
Gtoup32
Testing
tu,* C6
Femove nuts for p us diode plate.Lift up and bend
0
c7
frornthe terminal
Solderloosethe starorconnections 0
NOTE:Aways use a heat sink whensolderingand
arounddiodesto preventdamageto
soldering
alternator
Test of disassembled
C8
Stator
Test stalor insulation.
Connecta 40 Voll alternatingcuffeni across ground
and phase termrnal.
Correct resistance:indeiinite.
O
c9
Test stator coil resistance.
Connectthe iest instiurnentacrossthe phase termi
-.
Group32
14
Testing
c70
Rotor
Test rotor insulaton.
Conned a 40 Volt alternaringcunent across roror
g r o l n d a n d a s l r pr i n g .
Corred resistance:indefnite.
o
o Test rotor coil resistance.
Connect the test instrument across rhe slip rings.
Corect resstance 4.O ohms + 10%.
cl l
ct2
Brush holder
Group32
15
Replacingdefective rectifier diodes
ct3
Diodes
Test rhe diodeswith
NOTE:AlthoughBoschtestingequipmentis shown,
similarequipmenlis availabbfromdomeslic
manulaqurers.
Assemblingalternator
cl4
lnstallthe stator in the slip ring end shield.Solder the
stator wires to the terminals.
Install the plus diode plate assembly.
Gtoup32
16
,
Assembling altemator
c16
Pressdrive end bearings h i e d o n t o t h e r o t o f .
lnstal rhe spacernng.
cl7
Greasethe slip rlng €nd shield bearing wth grease
g .o a l t h e s L i pr i n q
B o s . r 'F r 1 V 3 5 o ' L o i i e s p o n d r nC
end shield bearingseal with N/lolykote. Assemblethe
D o o f o r g . r r o a s a . lr l - es o n n qo r l - - . [ p aq e_d
-oro-e
A s s e m b l ea l t e r n a r o rc o m p o l e l t \ . rcrarrlg
screws to 3.6 4.3 lb.ft. = 5.G-6.9 Nm and nuts to
3 . 3 4 . 3 L b . f t=
. .4.5-6.0 Nm.
ct8
rhe brushholder.
InsraLl
cl9
fan,spacerandpulley.Position
Installkey, thewasher
andlorquethe nutto 29 lb. tt. = 40 Nm.
c20
Teston a lest benchbeforeinstallalion.
Gtoup 32
17
lnstalling ahenatot
c21
Alternator terminals
L DF To field winding
2. 61/D+ Frommagnerizing
3. B+ To batrery
Installing alternator
DI
Installaltemator with bracket and tensioner
0
DAr
Hex 13 mm
Cl
D2
Installdrivebelts
Install bolt for tensione. bar. Adjust
f(
Oldallernalor
shown,
Group32
18
Tesnng voltage rcgulator
-{:-._:
Charging Regulator
with Marking
Sev P/N72610102
diode(ed
plate) Spot 1259303-4
Magnetizing Blueor
diode Black
Spol 12593026
SevP/N726-10002
r||gnetlzlng Olodo3
Group32
Altematot
Testing vohage rcgulatol
E -'l
L JI!
L-
t-
H 'l
'
D
Wiringdiagramfortssting
voltag€regulator
li.ii!
0,25-A,1O.r'm
0
E. Ammeter0 50 amps.
Voh€selamp 12 vohs F. Fesuarorresistance
c. Conlrollamp 12 vo rs, G. Batery 60 amparehours Voltageregulator -
L Fesularorcontacrfor 3. Sprinsrensoner (
D. V
rowerconrrorrange 4. spring uppersecrion
2. FegulalorcontaclJor Sreetspring
upperconlrolEnge Lowerseclioni
Br meta spfng
Runthealternatorat 5000rpm(alt.speed)or2500rpm
(enginespeed)for 15seconds.Readthevoltageonthe
voltmeler.
Wilhno loadon lhe allernatof,
thevollmeler
shouldread13.1-14.4 voltswilhthe regulator
ambient
lemperalureat 25rc (77"F).
Loadlhealtematorwilh
onheadlights
10-15amps,suchas switching
10ripperbeam,andreadthevollage. The
0
voltageshouldstill readbetwe€n13.1'14.4volts,bul
mustnotdropmorethan,4voltslessthantheunloaded
specification.
For exactvoltageat ambientlemperatures
agramsopposite.
see di- 0
-24 .2o .4O r80
Group32
20
Testing voltage regulatol
llvollageisoulsidespecificationlhe regulalorshouldbe
replaced. lf ihe voltageregulatoris to be tssledmorc
accuhtely,installitin thevehiclewhichshouldlhenb€
d v€n for approx,45 minulesat speedabove30 mph.
The €asonlorlhe diving is to letlhe regulator obtain
cofiecl wo*ing temperature.
NOTE:Thevehiclemustbedriven.lt isnotsufficient iusl
to havethe engineidling.
lmmediately after,or prelerably
duringdriving,measure
thevollag€betweenB+ andD on thealtemator. The
engineshouldbs tumingover al i50O rpm,whichis
approximatelytfie sameas 3000 lpm allernatorspeed
whenmeasung.Withregulator atambienttemperature
ol approximalely 25'C (7rD the voltageshouldbe
El€ctronlc F€gulalol! according to diagrams. Pleasenotevollagevariations
according lo ambientlemperalures.
Gtoup 32
Group33
StarterMotor
GeneralInformation
0 (
f'(
Specifications
D e s i g n a t i o. n. - . . . . . . . . . ................. Bosch 12V
I
Direction of rotation
O!iput 8 1 0 W (1 . 1
I
Group33
22 Staftet Motol
Mechanicaltest specificat;ons
A r m a r u r ee n d I ' o a l .. .. 0.01 O.03mm 0.0020.012-
Brushsping tension. t4 t6 N 3.1 3.5 tbs
DEranc" hor p,nron end ro ,ing gear race 1.2-4.4mn o.o47,0.173
F iclondl rorque oI 'olor brak- 25 40 Ncm 2 . 1 73 . 8 1 b .n
P i no i d l i n gI o q u e . . . IrL l8 Ncm 1 . 2 01 . 5 6b .n
Backlash 0.3-0.5 mm 0.006-o.oo
2.12
r . drd-ere' .
C o r n m u r a l om ... 33.5 mm r 318"
Brush min. length 13mm o.52'
Etecrricaltest specifications
nt,
t:
o 13
14
ie \15
\o
\
7 26 e 18 17
1 5 .C o n n u r o r o r . n dr i o m e
Group 33
Staftet Matol 23
-T
Specialtools
Renoval, disassembly
SpecialTools
ili
0
ServiceProcedures
Removal
0 (
A3
Removethe bolts which hold the starter motor to the
timlng gea. housing.
tl
I (
Disassembly
8l
Rernovethe two screws retainingthe cover-
Gtoup 33
24 starter
Motor
Disassembly
B2
Bemovelock ring and spacerrings.
thetwo screwsretaining
Remove thecornmutatorend
B3
Lift up the brushes.
Removerhe brushholderbridgelrom the armature
shaft.
The minusbrushesare retainedtogeiherwith the
o brushholderbridge.
The plus brushesstay with the field coils.
B4
Removethe nLrtconneclingthe field coil to the so_
B5
Remove ihe stator assembly from ihe pinion end
Group33
StafterMotor 25
Examination
B6
Removerubb€r stop and steel washer
Removethe pivotpinfor the pinionlevsr.Lift out ar-
matureassemblyfrom the piniondrive shield.
B7
Use 6 fitting sleeveto remove the end stop.
Removelock ring,stop and pinion. (
Examination
B8
Checkthe armaturefor damagssand wear.Replace
the armarLrre
if the shaft is worn or warped.
Turnthe commutatorin a latheif it is scorsd,pitted
Minimumdiameteris 33 mm = 1.3OO.
Max.permittedout-of-roundis 0.08 mm = O.0OO32'.
0 (
B9
UseaMicaundsrcutter to undercut0.4 mm = 0.008".
lf no machineis available,us€a properlygroundlrack-
Group33
26 StarterMotor
Examination
Bto
Bll
Use a "Growler" to check the armature for shorts.
Switch on and hold a hacksawblade close to the ac
mature. lf the blade vibrates in any position,one of
c
the following faults can exist:
- commutator shorted
812
lJse40VoltsACcufientoravailable
equipmentlo
check
the stalorcoil insulation.
(0
Bt3
Checkend shieldsand brushholdsr.
Replacsworn or damagedparts
No morethan0.005 (O12 mm)bushingplayis per-
Group33
StaftetMotor
Installing
bushings
T Bt4
m-
Beforeinstallation,new bushingsshouldbe immersed
in oil, Bosch 01 1 V 13 or similar,for at least 1/2
hour.OtherwisetheirseNicetime willbe considerably
Replacingfield coil
Bt5
lvlarkpoles and housing.The polesshouldbe rein- (
stalledin exactpositions.
Placethe siatorin a clampingdevice,BoschEFAW9
or similar,and slackenthe pole screws.
Removethe statorfrom the clampingdevice.
Removepolesand field coils.
816
Positionthe newfield coilsand the polesin the stator.
Heatthe f ieldcoilsslightlybefore installation.Orientate
the poles according to markings.
a (
, 1
..JI-J
Group33
28 Stafte,Motor
Replacingbrushes
Bt 7
-)-: ",, siroderthan9/ 16 = 14mm shouldbere
Brushes
-"''
1. Solder loosethe brushesfrom their attachments.
2. Solderon the new brlshes. llse a sufficienty hot
u; :i,,;
Assembling starter motor +
Bt8
Lubricateas shown- Use Bosch lubricanrsor similar:
I FI 2 V3 A p p l y a t h i nl a y e r o f g r e a s e oinn s u l a t L o n
washerc,shaft bearingsudaces,spacer
washers and lock r ng.
2. 01 M3 l m m e r s e t hbeu s h i n sn o i l 1 / 2 h o u rb e
fore lnstalation.
3. Ft 2 V3 Apply generouslyof grease in the ar
maluregeargd u e s a n di t h e p n i o nl e v
er groove.
4. Ft 2 V3 Apply a thin layerof greaseon the shatt
bearing sLrrfaces.
5 . 0 1 1 V 1 3 l m m e r s et h e b u s h l n g sl n o i l 1 / 2 h o u r
before installalion.
6. Fl 2 V3 Lubricateshifi leverjoints and solenoid
i.on core with a thin ayer of grease.
lnstallprnion,stop ring and lock ring.Tightenthe stop
$E rng into pace with a fitling puLler.
F
@
il &,
llnrr.LnJl
Bt9
Attach the shift lever to the pinion,
lnstall the armature n the drive end shied.
Install the shift lever pivot stud.
Group33
StarterMotor 29
AssmW
820
lnstall steel washer and rubber stoo.
821
Install solenoid. @ (
o (
822
{(
{(
823
Installbrushholderbridgeand brushes.
Gtoup33
StarterMotor
Install commuralor end shield.
Installthetwo long screwsthat hold rhe staner motor
825
Installspacerwashersand lock ring.Thearmatureend
play should be 0.002-0.006- = O.05-O.3 mn
Installsufficient amount of washersto keep the end
o playwithin theselimits.
Attach the smallcoveroverlhe shaftend.
Gtoup33
Staftet Motol
_...-!
Specifications
Group34
lgnitionSystem
Specifications
II
Metric US specs
Tvpe .. ... .. electronicignition
Ereakerless
F i r i no
s r d e r. . . . . . . . . . . . 13-4-2
lgnationtiming,vacuumunit disoonnoct€d(checkenginespecificalions).
Sparkplugs(Check6ngin€sp€cifications)
cap ... ... 0.7-08 mm 0.028-0.0032"
Tighreningrorque 20-30 Nm 15-22 tb.fr
Distributor
Bosch(Check engine
spscificalions)
@(
... .... ...
lsnitioncoil
EoschNo, 0221 122 006 @l
Bosch No. 0227 100 005
Centrifugalgovernor
Toral advance.distibutor degrees
Advance begins at, distibutor 7.2-1O| / s 430-600 rpm
Distributor rpm at 50 advance 15.2-14.3t/s 910-1100 lpm
9 ' a d v a n c e. . . . . . . . . . . . 23.3-34.5 r/s 1 4 O U 2 O 7rOy m
f ' r l la d v a n c e. . . . . . . . . . . 40 t/s 24OOtpm
Lubricating
distributor
Gtoup34
32 lgnition System
D
0
0
lr
Group34
lgnitionSystem 33
BreakerlessElectroniclgnition System
General
SpecificFunctionlnformation
0l
1. lmpulsesender
It is locatedin the distributorwhere the breakerpoints
Note 2:
When makingCylinderBalancstesting,most instru
mentsrequirethat a specialadapterbe used(or the
enginewill die).
Gtoup34
34 lgnitionSystem
Futiction
o 2. Electronicmodule
The electronic module is a solid state design with
transistors.h amplifiesthe impulsesfrom the impulse
'dwell
sender. lt also controls the angle".
Group34
lgnition System 35
Diagnosis
ffiH r! ^
!;;: :
i:;E:i
E
o ii iii !
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o
o
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:!:iii o(
o
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o tia ! :
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giit
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iEEi
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ili t s :
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L
o :| | I i':! i ! !
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o il rd ES:: i
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:
a
tt
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o l,l El
o
o
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o
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t
IE
o
lillii;;l
til Eqil
Gtoup34
36 lsnition Sysbm
Replacingdistribut$
ServiceProcedures
Replacingdistributor
AI
Disconnect
hightensionleads(orcapl primsrywire
andvacuumhoseat the distributor.
A3
Rotate crankshaft until No. 1 pisron is at top oeso
cent€r {TDC}.
- Thecamswillthenpointobliquetyupand pulleymark
will b€ at Oo.
Line up rotor
Turnrotor so markis approx.600frcm markon o|s-
tributorhousing.
Install distributor
Pushdistributorinto positionin engineblock.Check
that rnarkon rotor and mark on distributorhousino
lineup. Installdislnbutorretsiningboft,hex 13 mlrl-.
Group34
lgnhionSystem
A6
Install dust cover
Removerotor,fit dust cover,and r€-inst6llrotor.
Installdistributorcap
A7
e(
@l
A8
Reconnect
P mary wire, vacuumIinestc.
c)-
A9
Set timing
Referto v€hiclespecificatrons.
/./.'
Group34
38 lgnitionSYstem
BeplacingimpulsesEnder
Replacingimpulsesender
Ramoval
Unclaspthe lock clasps.
Bemovecap. rotor and dust cover,
Removevacuumunit anclclasps.
io Caution:
The retainingscrewshave ditterentlengthsand if im,
pnoperlyplacedcan projectand damagsmovingparts.
Theretore,alwaysplace the screwslogelher with the
componenl to whichtheybelong.
B3
Rsmovethe screwssecuringthe contact.
Removethecontactby pullingit carefully
straightout.
o
io
84
Remov€
thsscrewsretaining
thsimpulsesenderplat6.
Group34
I lgnitionSystem
Replacng impulse 'endel
B6
Lift off the armatureand the smalllock Din.
87
Use sn6p ring pliersto removethe snap ring.
Lift up the impulsesenderand plate.
88
thr€escrewsandreplace
Remove impulse
sendet.
Gtuup34
40 lgnitionSystem
Replacingimpulsesetd]aii
B9
lnstallation
Attachthe impuls€senderto the ptate.
Theconnectorpinsshouldbe ptacedoppositeabovs
the attachmentsar lor ths impulses€nderplate.
Bto
Installimpulses€nder.
S€cure it with ths two screws.
hstall sn6p ring.
Btl
Installthe armature.
Th€slotshouldbeopposit€ the dgeon thedistributor
shaft.
Fit the lock.pinso that the lift facesthe dg€ on the
distributor shafL
OtheMiss tha lock pin may be shear€doff.
Bt2
hstalt shimsand snap ng.
Gtoup34
lgnkion System 41
Replacingimpulse sendel
813
R€connect
thewir6 conn€ctor
andtightenthe screw.
Bt4
Installclaspsand vacuumuniL
R15
Installdust cover, rotor and cap,
Bt6
Check distlibutol
Rotats thg distributor shaft s6v6raltums in both di-
rections
It shouldrotatefreelyandwithout anynois€or s€izure.
i/r The only resistanc€which may occur is the littl6
t\ stiffnss causedby the magnetin the impulsosend€r
wh€n the teeth pass each oth€r.
Gtoup34
42 lgnition System
'v
Specifications
Group35
Lights
Specifications
Llghts,12 V USbulbNo. Powor Sockel No.ot bulbs
Headlights
244-245
DL4DWagon' 5Ya"Typ€ 1
5%" fype 2
S€aiedBeam
Headlighls
242,GI 7" rype 2 2
FositionLights,tiont67 5w4cp Balss 2
TumSignals,front 1073 21wl32cp Bal5s 2
TumSignals, rear 1073 21wl32cp 8a156 2
Tailljghb 67 5w4cp 8a15s 2
Stop Lighls 1073 21wl32cp Ba15s 2
Back-upLighls 1073 21wl32cp Balss 2
SidelvlarksrLights 57 3wlzcp S 8.5 2
The followingbulbsmay be obtainedfrom a Volvo dealefi
Socket No of bulbs
Re3r Ash Tray Light 1,2W w 't.8d ,I
LicensePlateLight 2
lntsriorLight s 8.5 1 \245:21
Glovs Locker Light Bags I
InstrumentPanslLight BaTs 3
ControlPanelLight 1.2W w 1.8d 3
Shift PositiongAutom.
1 . 2W wt.8d
EngineCompartmentLight 15w
ControlLamps
Charging w 1.4d l
Turn Signals 1.2W w1.8d 2
BrakeFailure 't.2 w w1.8d 1
ParkingBrake 1 . 2W wl.8d 1
Headlights 1 . 2W 1
Oil Pre:sure w 1.8d 1
Overdrive 1.2W w 1.8d I
WarningFlashers w 1.8d I
El. Heated Window 1.2W wr,8d 1
1.2W w1,8d ,I
Seat Belts 2W Bags 1
Bulb Failur€ 1.2W w 1.8d 1
Gtoup35
Lights 43
ServiceProcedures
ReplacingSealedBeamheadlamPs
q,:1,>.
Headlightalignment
Gtoup35
44 Lights Models240,DL 2d, and GT
flril
ii:,- :.;
iit;:::,4)
@,
D llttt
I ,ilJlll
i NNER-BqAM
BIA{,
sEAtE Tvpe1
K
OUTER
BEAIq,5 3/4"
SEALED
BEAfi TYPE2
l1\\\i
Models240, DL 4d and DL 5d
Group35
45
U9hE,242,244,DL & GT
2
q3>
@L
tr
@(
Irj? *s*.1-.. . @(
30
a
fr
J,l
t4
I
/.rfl
cr
c4
\OLVOPARTS
1 0 3 02 3 0 r 8
( 1 0 36 )
Lights 245
15 l/
@- rNTERroRLrcHrs
6;> IC t/
5 l,l
2t t/
€<" USBUL8No,l0/t
I
0
5 l,l 4 cp, LISBULB
flo.67 t
Group35
Lights
Group36
StandardElectricalEquipment
Replacingignitionswitch
A2
I
Atlach the new ignition swLtch,
Connect the terminat btock.
Re-instal panels. @l
Replacingturn signalswitch(headlightdimmer switch)
Replacinghorn l_l
CI
C2
Group36
48 Standad ElectricaI Equipment
Bulb Fatlurc Warntng System
Replacinglight switch
DI
D2
Pull out the switch knob.
Lift out the defroster outlet.
Remove ihe nut and lift out the switch.
D3
Disconnect the switch from the terminal
block.
Connectthe new switch.
lnstallswitch,defrosteroutet, switchhandleandde-
Grou?36
Standard ElectricalEquiqment 49
Bulb FailurcTailgaE
cl (
Group36
50 Standad ElecticalEquipment
Tailgatewindow Wiperlwasher
G7
Removing
Disconnectlhe batterygroundcable.Removelhe panel
on the insideof the tailgale.
Remove theretaining sc.ewsfor lhe wrpermotorpro-
G2
lnstalling
Reconnectthe wres to the molor'
Attach motor and protection plate
Reconne the link arm to the wiper moior' Installthe
protecnon plate relarnrn9screws
Insiallthe panelon the insideol lhe tailgale
Reconnectlhe batteryground cable,
Replacingbrushes
Gtuup36
Standard ElectricalEquipment 51
WindshieldWiper
Windshieldwiper assembly
CoNNEcroRAssEMBLY
A s S P A R EP A R T S
AVAILABLE
Replacingwiper unit
Removal lnstallation
Jl Disconnestbatterygroundc€ble K1 Installwiper ass€mbly.
Removeside panel, Remove device secudng wiper ass€mbly at
Removepanelunderdashboard. transportand handling.
J2 Removedefroster hoses K2 Install glove box
Removeglove box, dsfrostsr hosss
J3 Bemovewiper arms. side panels
/ Disconnect wip€r assembly and lift it out panel unclerdashboard
throughglovebox opening. K3 Installwiper arms.
Reconnectbattery ground cable,I
Checkfunction.
Group36
52 Standard EIecuicaI Equipment
l-
Group38
Instruments
Instrumentcluster
Odometer D Parkins brake reminderlight(red) Rightturn signalindicator(green)
Mile reading E High beam indicator(blue) H Oilpressurewarninslisht(red)
B Speedometer F Brake {aiturewarning light(red) I Alternatorwarninglightked)
Left turn signalindica'torlight{green)
A B c D E F G
c
J K L N o P
lf the pointer enters the .ed range repeatedly,
(last figures represents1/ 10 mile) checkcoolantleveland fan bek tension,see page
Trip odometer resst knob 49.
Push in to reset P Overdriveindicator(green)
Remlnder light, EGR Service (except Lambda-Sond) Lights when overdrive is engaged.
Tachometer(certainmodels) O Fuelgauge
Reads thousands of engine rpm. The fueltank capacityis approx 60 lhers= 15.8
O angp rdnge lor momentdrv Jse. during d' cel- U S s a l s . l 1 3 . 2l m p . s a l s .
Warning lights
These lights will light up when the ignitlon is turned this light tsndgrolnd is open. When the oi pressure
on. before the €ngineis started.This is also to prove drops below a pre-determinatedvalue, the pressure
rhar rhe lightr f-nLrioi. The light should go our d'ter sensitivevalveclosesthe circuhand the warn ng light
the engine has started.(However,the parking brake is illuminated.
rem nder light will not go out until the parkingbrake
Brakefailure
warninslishtked)
Oil pressure
lfthe lighr comes on whiledrivingand the brake peda
warninglight lredl c a _b e d e p e s s e df - f t h e ' t h a - r c r m d l i l i s d ni d i , d l i o r
lf the lishl comes on during drivlng,the oil pressure that one of the br.ke cncuits is oul of fLrnctior.
is too low Stop the engine immediaielyand check S h o - l d a ' a u k a . i s ei n a n y o i r h e l w o c ' c - i i s o l r l e
the engine oil evel, see page 46. After hard driving, hydraulic brake system, so that $ere is a pressure
rhe lignt will come on occdsrondllywle_ rhe "ngrr. difference between the circuits of more than 8 10
is idling. This is normal, provided it soes oul when kp/cmz 1114-142 psil when the brakes are applied,
the engin€ speed is increased. this actuatesthe valve and ihe warning light goes on.
The warning light for the oil pressurereceivescur.ent The warning lamp remains lighted r.rntilthe fallt n
via the ignition switch. lt is groundedthrough a pres- the brakesysternhas beenconected and the warn ng
s u r a s a n s t r v ev a l v eo n r l e F n S r n eW
. rrh lhp enginF vdlvere ser. 9e .e 'elthg rhe wa'n 19 vdve. s"e SeL
running and at normal pressufe,the circuit lhrolgh tion 5, Brake, Grolp 52.
Gtoup 38
53
lnstrument Cluster
Altemator Parkingbrake
warning light(red) reminderlight
lf the light comes on when engine is running,check This light wiL be on when the parking br6ke (hand
the ahernatordrive belt tension as soon as possrble. br.ke) is set. The parkingbrake lever is situated bet-
The alternator waming light lights up when lhe al- ween ihe lront seats.
ternator voltage is ower than the battery voLtage.As The parkingblake reminderlight receivescurent vla
the alternatorvohagerisesand commencesto charge the ign tion swich. When the parkingbr6keis app ied,
ihe battery,the warning light goes out, indicatingthat t h e w a r n i n gl i g h ti s g r o u n d e d
b y l h e s w i t c h . T h ew a r n
the alternator is charging. ing lamp femainslightedas long as ihe parkingbrake
Reminderlight, Bulbfailure
EGRservice(exceptLambda-Sond) warninglight
lf the vehlcle is equ pped with an EGR(ExhaustGas T h e l i g h , c o a e s o n i f . 1 y o i r h e ' o l l o w r n q . g l r 1 "i )
Be&culation) 15OO0 mile serviceremindef light, as
requiredbytheU.S. Envionmental ProtectionAgency. one of the lower beams
the lighi wil come on ar 15000 mile interuals.This One of the taillights
ls a reminderto gei the EGRvalve servlced.The light one of the license plate lights
wil stay on until .eset by rhe dealer. one of the take lights {when the brake peda is de
NOTE: Warning lights, generally,are lights which il
uminateto indicateth.t a deviceis noi operatrngpro- I n d i c a t o rl i g h t s .9 q " r a l . a e l g l ' r s w h . h ' u r r n d r o (
to indicate that a device is operating.
SDeedometerdrive cable
It is rnost important ihat the speedometercabe s bend be less than 100 mm (4"). lf it s ess than this,
correctlyiitted if the speedomeleris to functon wth- vibration and noise can occur in the inslrument.The
out trouble. t is vitaly imporiant thar the cable is nol drive couplingsmust run trle in the outer casing of
benl too sharply.At no point must the radius of a the cable. This is checked with
Group38
54
Replacinginstrumentcluster
Replacingtachometer
1 . (Removeinstrumentcluster,see above).
2. Removethree retainingscrews,
3. Carefullyremovethe instrument. The terminats
can easilybe damaged.
4. Installtachometer(or cove, as shown.
Replacingspeedometer assembly
t . Removeinstrumentcluster,see above,
2. Removetachom€ler (or blindcover,)
3. Removethreespeedometer retainingscrews.
Carefullyrcmovethe instrumem.
Replacinginstrumentplate("printedcircuit")
Group38
Gauges
Replacingclock
Replacingtemperaturegauge/fuelgauge
1. Removeinslrument
clusler.
2. Remove tachometer (or blind cover).
3. Remove speedometer.
4. Remove instrument.
5. Remove two retaining nuts on the instrument
t-
9,
Grcup38
56
Gauges
lf a lemperalure
orluelgaugeis notwo*ing properly,
the gaugesystemcanbe tesledas lollows:
METHOD
A. T€slingthe voltagesiabilizer.
1- Connect thetestresistor(panno.9995158-4)tothe
inslrumentwhichis functioning pfopedy.In other
words,il lhe,uelgaugsis nol functioning
prope y,
disconnect the lemperaturegaugecablefromthe
sensorand connectthe test resistorbelweenthe
sendercableandvehicleground.
2. 140,160-1974 240,260
The pointershouldnowbe horizontal
(tolerance
+ pointerwidlh).
lf the inslrumenlpolnterpointsoutsidethe toleF
ence range,thenthe voltagestabilizeris faulty.It
lhe instrumentpoinfer is within the tolennce
range!continuewilh SlepB.
B. Testingthe gaugeandsender.
1, Disconnect
lhecable!o thefaultyinslrumenlsender
andconnecithelest€sistancebetween ihe sender
cableandvehicleground.
w,@-19A/2AO,N
pointeris horlzontalor insidethe
2. ll the instrumenl
ma*, thenthesenderis laulty(tolerance + poanter
width).Checkthe luel gaugesenderaccordingto
Servace lvanual,S€c-3 240 or 260 se es, Elec.
System& Instrumenls (TP ii402 or 11413).lfthe
pointeris oulsidethe lolerancerange,thenlhe in-
strumentis faulty.
Test resistol
P/N:
9995158-4 (bluecable)Volvo140,160-1976,
240,260
SpareParts
P/N Resislor
9999145-7 100 1W5%140,160-1974
240,260
Replacing the resistor
Disconnect the cablesand openthe holder.Place
lhe newresislorin the holderandallowthe rcsistor
conneclions to projectlrom lhe holder.Insedthe
conneclioncablesandlightenup.Cutthopartofthe
resislorcablewhichprojecls.
Group38
Instruments 57
Testingfuelgaugesand tank levelsenders
Masteagauge
Obtain a fu€l gaugetank senderfrom Parts Depart-
ment ancl check it with an accurate ohm-meter
An extra accuratemaster gauge should stay within
th€ followinglimhs:
Upperend position{Fulltank}
40ohmst2ohms
Boftom end position {emptyl
282 ohms a 14 ohms
It mightbe a goodideato bsndths movementlimiter
to obtain correct readings.
Position
Omm 282 t 48 ohms
19?6ModelShorvn
15mm 223 A 26.5ohms
84 mm 98 a 14 ohms
1 9 1m m 40 t 5 ohms
NOTE:Checkvehiclespecilicalions.
A2
Disconnectthe blue(brown)wire at the fu€l gauge
tank senderin the trunk Instead,connectthe master
gaugeand groundit.
1,7mm A2
Swhch ontheignition.
Comparefuelgaugo rsadingwith pictureat leftr show-
ing deviation permitted at €nd of st.okes.
Correct reading:proca€d to A3.
Incorrsct reading:proceed to A4.
Gtoup38
58 lnstruments
Testing fuel gauge
A3
Check connections
Check that the terminal prns(1) have corect conracr
and thal the nuts (2) are tighrened.
Also check temperEturegauge nurs.
0
44
Test operation of voltage stabilizer
To do this,usea new voltageslabiizerto test gauge
A5
lf mis-readingpercistsin spite of operationsaccording
ro 1 and 2 above. re install the ordinaryvoltage sta-
bilizerand replacethe fuel gauge-
A6
Bemove the tank sender.
,72!2
Check thai the tank sender lever operates without
bind ns.
A8
Use an ohrn meter to check resisrance,
urements as shown in il[]srration at left.
ll might be convenientto make a fixilre
c itates a quick sefting.
Group38
59
Testing fuel gauge
VOLVO
112 BB2
li a cusromerstil complainsin spite all specificalions It lakes approx.30 minLrtesto fill ihe expansiontank.
a r e w l h n l i m i t s ,t m u s l b e e x p a i n e dt o h m t h a t t h e This will causethe leve in lhe fuel tank io drop and,
e x p a n s o nt a n ki n s i d ei h e f u e l t a n kc a u s e st h e r e a d i n g in addition to the fuel used, this mght qive the m
olr
to drop fasler al full tank. pressionlhe gauge readingis lower than normal and
The expansiontank capacityis approx. 6 liters (qts). the gauge incorect.
t is slowy fiied with fuel. The p!rcose of the expansiontank is to prevent the
When filling f!el. the expanson tank is srill almost flel tank from releasingfuel in caseswhen lhe tank I
empry when rhe tuel tank has been filled. has been filled whh cod fuel whrch then heats up
Testingtemperaturesensor
Group38
60
Specifrcations
Additional Information
Mainand PumpRelayApplication
1974/1975lrodelg
.1975/192Models
PJr!!-Er&v
!!F.!..d.. Ey r>
Group36
Ralays 61
SpecrTlcadors
Maln& PumpRelays
1978/1979lrodels
!2r5337-l
This relay is located underthe dash n€arthe hood
releasecable.
192/1979Models
gs!g:99!4-e,g
a2
Group36
62 Relays
llatioml
Instihrtetot
AUIOONYT
sElvtGt
EXCEU.EilCE
VOI-VO
SUPPOBTS
VOLUIITARY
rrrEcMt{tc
cEn FtcAfl 0rl
8YTHE lt.t.t.S.t.
(U.s.A.only)