Index ‘Aircooled AFC Accelerator linkage/cable ‘auto. trans. 20.8, 20.9 manual trans. 20,6, 20.7 Fuel fter 20.4 —Fuel gauge sending unit 20.4 —Fuel pump 20.7 —Fuel systom 20.2, 20.3 leak checking 20.5, —Fuel tank 20.4, 20.5 Diesel Accelerator linkagefcable 20.14 —Fuel gauge sending unit 20.13 —Fuel system 20.10, 20.11 leak checking 20.13, Fuel tank 20.12 Water-cooled Digijet Accelerator linkagelcable ‘auto, trans, 20.23, 20.24 rmanwal trans. 20.22 Charcoal fiter valve 20.20 —Fuel fter 20.18, —Fuel gauge sending unit 20:18, —Fuol pump 20:19 —Fuel system 20.16, 20.17 leak checking 20.21 —Fuel tank 20:18, 20.19 Water-cooled Digifant Accelerator linkage/cable adjusting 20.32 auto trans, 20.31 ‘manual trans, 20.30 Charcoal fiter 20.33 —Fuel gauge sending unit 20.29 —Fuel pump 20.29 —Fuel system 20.26, 20.27 leak checking 20.21 —Foel tank 20.28 20 Fuel Supply 20.120 Fuel Supply Note California models, rom 198}, have a: = new fuel-tank filter that i self cleaning and requices NO SERVICING = now an etre finemeth ting acareebenn {ca fe which requlee NO romero 2 i SERVICING foot 6 3 Fuel supply system components, ‘aide Removing and installing oS SO Bele hoon marin ngson Pe et — elvery rate page 207 crecking, elactical page 20.7 roomate heck system for leaks using a soap solution at SbOIs marked with ait". Seal if necessary, Air-cooled ‘| 20.2 sacysonFuel Supply 20 ap teplace gasket it camaged Gravity vont valve ‘checking: when tilted 180°, vaive must close WARNING Charcot titer Disconnect battery when working on fuel system, Never smoke when working with fue oF have anying in area bt can ignite Se ‘Aways pace tea and uel note clamps ome Air-cooled AFC Fuel system 20.320 Fuel Supply Fig. 1 Fuol titer, installing Fuel tank, removing Work sequence WARNING Fire hazard! Do not smoke or have anything in area that can ignite fuel = disconnect battery ground cable = drain fuel tank — install with arrow pointing tawarg fuel pump Fig.2 Fuel gauge sending unit, removing — frat remove fuel tank loosen hose clamp 2 = remaye filer neck 1 — remove vent hose $ = remove vent hoses 1, 2 and 3 Fuel gauge sending unit, installing = coat seal with araphite powder and Position caretully — install sending unit with electrical connector as shown (ar front of vehicle) Ww points to. 20.4 Fuel fitter Ful gauige sending unit remaving Fuel fan Air-cooled AFCFuel Supply 20 = remove vent hoses 4 and § = remove fuel supply hose 1 and fuel ceturn hose 2 trom fuel tank loosen bolts on fuel tank mounting rails white arrows) and remove rails from rear channel — lower fuel tank and disconnect electrical Connector on uel gauge sending unit — remove fue! tank Fuel system, leak checking Refer to illustration on pages 20.2 and 20.3 for location of vent line indicated below _Aftor removal/epairs on fuo! tank, alvays check fuol system for loaks as follows: — romave small hose A from activated charcoal filter and eannoct to leek tester US 4487, ~ bet leak testor sale ta “0” = pressurize system with hand pump to 1.3 i. cof mercury. © systersOK if press after B minutes i 1.0 in or greater 1 syste leaking if pressure drops below 1.0 in. atter 8 minutes, Note Check system for leaks using so9p solution ot spots marked with an *, Seal if neces. Air-cooled AFC | Fuel tank, removing 20. 5 Fuel system leak checking20 Fuel Supply Accelerator linkage/cable Manual transmission Posh rod UUoncate anon inataling Accalaretor peda rele sways epics, a iho ° Aatey vor ——_——_ bnate wen = oP ‘tamping bot Boot check for ora ° \. ‘Accelerator euble ‘dusting Fig. t ? el 20 6 Air-cooled AFC Manual Trans. . ‘Accelerator linkage eableFuel Supply 20 Fig.1 Accelerator cable, adjusting ~ adjust cable so that clearance is. ‘obtained batwaen throttle valve lever {and stop on throttle valve housing 1.0-1.5mmm (©:040-0.060 in.) Fuel pump delivery rate, checking Work sequence WARNING Fire hazard! Never smoke or have anything Inarea that can ignite fuel — disconnect tue! retum line at pressure cegulator = attach hose to return line fitting on pressure Tegulator A and place other end ot nose in ‘one quart messuring container — tum on ignition and open air sensor (or bridge air sensor plug terminals 98 and 39) Fun pump exactly 80 seconds * delivery quantity should be at least 500 co (approx. 1/2 quart) HINO, check fue! filter Is not blocked, ground ‘connections are O.K. and voltage at pump Is. at least 115 volts before replacing pump Fuel pump, checking (electrical) Note Battery must be fully charged — connect ammeter at fuel pump in series with pump and current supply ‘CAUTION. Do not touch positive connection to ground — turn on ignition ang open air sensor flap (or bridge air sensor plug terminals 36 and 39) + ammeter should reac 65-8, amps ‘+ loner reading may indicate pocr ground connections * higher reading usually indicates dragging pump motor and unit must be replaced Air-cooled AFC Manual Trans. ‘Accelerator linkage/cable 2 0 av Fuel pump20 Fuel Supply Accelerator linkage/cable Automatic transmission Push rod lubricate when instating on sa A lubricate when ina Accelerator pod cretip Bae Tube must engage in fever Hove Wire te ‘on transmission 2 0. 8 Accelerator tnkagevcabie |_Aif-c00Ked AFC Auto. Trans.Fuel Supply 20 Accelerator linkage/cable adjustment, checking {automatic ransmission) Work sequence — depress accelerator pedal to full throttle position * throttle valve lever must contact stop, but kickdown lever on transmission must nat be in kickdown position — press accelerator pedal beyond full throttle to tloor * override spring must be tensioned and kickdown fever on trangmisgion must be in kickdown position INO, adjust as tollows: Accelerator linkage/cable, adjusting {automatic transmission) Work sequence loosen nut t — remove override spring 2 —slart engine and let idle — adjust idle speed at screw 5 (a9e Repair Group 24) = shut engine OFF ~ press accelerator rod in direction of arrow to stop — turn adjusting rod 9 with screwdriver until shoulder of adjusting rod just contacts pivot of throttle lever 4 reinstall override spring 2 — start engine and check idle speed * adjust if necessary by turning rod 3 = lock adjusting rod 3 in position with nut 1 = press accelerator pedal to floor * Jeyer B must be in kickdown position (arrow), wath approx, 1-2mm (1/32-3/32 in} free play belween lever and stop — release accelerator pedal lever must be in idle position (out of kickdown} =f necessary, adjusi accelerator cable at clamping bolt (arrow) Air-cooled AFC] [Automatic Trans ico rare] gecantarinagoenns 20D20 Fuel Supply WARNING: Disconnect battery when working on fuel system. Never smoke when working with fuel or have anything in area that can Ignite nt, ‘Always replace seals and fuel hose clamps. Atways clean tual tines before loosening Removing and conte ete checking: valve must lose when tuened 180" stem components, installing =| Fuel return ine ‘hom Injection puin Seat ast with ‘graphite powder Before instaling 1 Injection pump Vent screw ‘open when draining ‘water from titer Fual titer Naage. Fut titer removing: use US 4462 or equivatent nstaling: tighten by nan CAUTION Use only angroved fuel filters for maintenance servies or repairs Not al aftermarket filters meet the filtering, fuel flow, or woter separation requirements of the injeetian system. Fuel tenk vert ines 35 Nm (att) i Fuel gauge sending unit removing Fig, 1 Installing Fig. 2 ving: ‘eplace Wamaged 28 Nm (18 fe 1b) 7 Seal ‘molston with Diese! Yue! ‘tore installing fer -— Water drain plug loosen and drain approx. 100 en» (#102)! fuet 20.10 esntenFue! Supply 20 WARNING. Disconnect battery when warking on fuel system. Never smoke when working with fuol or have anything in area that can ‘ignite it, Always replace seals and fuel hose clamps. Always cloan fuel lines before loosening Fuel tank vant fines, . Filler ep replace gasket imjige it damaged Filer neck removing: two 19 ralease from ide 15 Nm (11M) "Fe een 25m (18 1810} Sst ual tank removing page 20.4 Note Check system for leaks using a soap solution at spots marked with an * Seal if necessary. [8] pen 20.1120 Fuel Supply Fuel tank, removing Work sequence WARNING Fire hazard! Do not smoke or have anything in area that can ignite fuel —disconnect battery ground cable —srain fuel tank Fi —remova vent noses 4 and 5 —pull fue! suction ting to (uel filter en right side) {and fuel retura tine (rom Injection pump, teft side) off fuel tank Fa loosen bolts on fue! tank mounting rails (white arrows) and remove rails {rom rear channel lower fue! tank and gisconnect electricat ‘eannecior on fuel gauge sending unit —remove fuel tank - ‘emove vent hoses 1, 2and 3 20.12 rertan snoreFuel Supply 20 1. Fuel gauge sending unit, removing —first remove fuel tank Fig. 2 Fuel gauge sending unit, installing —coat seal with graphite powder and position carefully install sending unit with electrical con: nector as shown (arrow roints to front ot vehicle) Fuel system, leak checking Refer 0 illustration on pages 20.10 and 20,11 for lacation af vent lines indicated botow. After repaits/removal of fuel tank, always check fuel system for leaks as Fallows: = pinch off all 3 vent hoses & with clamp. ~ remove vent host B from eanister and connect to feak tester US A437, ~ set leak tester tt — pressurize bush system with hand pump te 1.31in. fof mercury. ‘system OK if pressure remains et 1.0 in, Ha oF greater after § minutes, «+ system not OK if pressure drops below 1.0 in. Ha afterS minutes. Now (Check system For laaks using 2 soap solution at spots marked with an *, Seal if necessary, Diesel Felorveccencnent, 20.1320 Fuel Supply Accelerator linkage/cable Manual transmission Push od ivbvicate when instating re sways Acolarator paca replace ‘ Pin Laver lubricate when natating ‘Clamping bolt adjust cable so mat Injection pump lever contacts stop without tension ‘Accelerator eabia __ Pe porter & Dh injection Bump y 20.14 seceerncriniageraic .Fuel Supply 20 THIS PAGE INTENTIONALLY LEFT BLANK as 20.1520 Fuet Supply Fuel supply system components, Removing and installing Fuel system checking fr inks, soe page 20721 uel gauge sending unt 40 Nm (7H ty —_ stating Fig. 4 Fuel expansion tank a ‘coat with graphite powder before instating wo” Fuel tank ‘esmowng, pags 20.18 ~ / Cn a USAuCanada:instaling FIG. 1 Caitornia only: installing Fig. 2 \ roost retire SRT / ttt eum / eal ‘ / (< Roster To ttt vave housing To intake air cietetoutor ™t jet 20.16 nmeFuel Supply 20 WARNING. Disconnect battery when working on fuel system. Never smoks when working with fuel or have anything in area that can ignite it ‘Always replace seals and fuel hose clamps Gravity vent valve checking: valve must close ‘whan titted 180" - go Fue! expansion tank Water-cooled Digijet racism 2001720 Fuel Supply Fact fies instlting (USA and Canada) ‘+ arrow on titer faces toward tuel pump Fig. 4 Fuel gauge sending unit, installing — Soa seal with graphite powder and position carefully — Install sending unit so that electrical connector {s aligned with dotted line * arrow points to front of vehicle Fuel tank, removing Werk sequence — disconnect battery ground strap = drain fuel tank Fig. 2 Fuel filter, installing (California only) + arrow on filter faces toward engine 2A loosen clip 2 0n filler elbow: ller pipe f and pull out breather 99 to next page (35) Fig. 3 Fuel gauge sending unt, removing — before removing unit, remove fuel tank Fuet rier Fuel gauge sending unit - 20.1 Fuel gauge sending Water-cooled DigijetFuel Supply 20 — remove fuel supply hose 1 and fuel return hose 2 from fuel tank — loosen Eoits an fuel tank mounting rails (white arrows} and remove ralls trom ro channel — lower fuel tank and disconnect electrical ‘connector on fuel gauge sending unit — remove fuel tank Fuel pump delivery rate, checking Work sequence WARNING Fire hazard! Never smoke or have anything {In arga that can ignite fut disconnect fuel return line al pressure regulator and block tine attach hose to return ‘ine fitting on pressure regulator and place other end of hose in one quar measuring container remove relay © — connect terminals 30 and 87 with tester us 4480/3 — switeh on for 30 seconds ‘+ minimum fuel delivery rate should be 500. em? me Water-cooled | Ful tank Raster LOAD Digijet20 Fuel Supply Charcoal filter valve, checking = disconnect hose 4 from charcoal filter valve 2 connect vacuum pump to filter valve connection instead of hose 1 — disconnect hose 3 from Tplece 4 — operate vacuum pump and suck with mouth fon hose 3 + filter valve must be open — without operating vacuumn'pump suck with mouth on nose 3 ‘filter valve must be closed IWNOT, replace charcoal filter valve 20.20 crac ate vie Water-cooted DigijetFuel Supply 20 Fuel system, checking for leaks (Vehicles with rear wheel drive ONLY) WARNING Disconnect battery when working on fuel system, Never smoke when working with fuel ‘or have anything in area that can ignite i. Note ‘ter performing repairs on fuel tank, always check ‘uel system for leaks as follows: — US 4487 nA i Work sequence — Remove small hose A at charcoal fiter and connect to leak tester US 4487 — Set leak tester scale to “0° — Pressurize system with hand pump to 3.3 om (1.3 in) of mercury «© system OK if pressure is 2.54 cm (1.0 in) oF greater aftor 5 minutes ‘© system leaking if pressure drops below 254 om (1.0 in) after 5 minutes Note ‘Check system for leaks using soap solution at spots. marked with Seal If necessary. Water-cooled | [_Digitant | [ digiet | .,,.,cereem 20,2120 Fuel Supply Accelerator linkage/cable Manual transmission Accelerator pods Boot: {hock for cracks Accelerator cabla ‘adjust cable 50 that clearance of about 1.0 mm (0,040 In lg obtained cetwaen thottio valve lever end stop on throttle rousing ‘clamping bolts =a) 20 2 Accelerator cable/ | Water-cooled Manual Trans. 5 HokageFuel Supply 20 Aczelerator linkage/cable Automatic transmission Push rod ‘ubcate when inataling wil ‘Accslorator pede! Clamping bots linkage/cabie, -thecking adjusting page 209 Boot ‘cheek for cxache Accelerator eabla Tube Ralay lver lubrleate when instaling ‘must engage in lever (on transmission Hose. Wire sie Aahusting res ‘aqusing page 20.9 As Water-cooled Auto, Trans. | Accelerator cabler 20. 2320 Fuel Supply Accelerator linkage/ca checking {automatle transmission) ‘Work sequence —dopress accelerator pedal fo full throttle position * trroitle valve lever must contact stop, but kickdown lever on transmission must not be In kickdown position — press accelerator pedal beyond full throttle to tloor * override spring must be tensioned and kickdown lever on transmission must be in kickeiown position — press accelerator pedal to floor HNO, adjust as follows: ‘lever 4 must be on stop in kickdown position (arrow A) release accelerator pedal Accelerator linkage/cable, adjusting aver must be in idle position (out of jautomatic transmission) Kickdown) (arrow B) ‘Work sequence — remove override spring 2 — start engine and let idle — adjust idle speed at screw (see Repair Group 24) — shut engine OFF ~ press accelerator rad in direction of arrow to stop j — turn adjusting rod 8 with screwdriver until shoulder of adjusting rod just contacts pivot of throttle lever = reinstall override spring 2 — start engine and check idle speed ‘ adjust If necessary by turning fod 3 — lock adjusting rod 3 in position with nut 1 20.24 sccicserenes [water-cooled Digijet Auto, Trans, . linkageFuel Supply 20 THIS PAGE INTENTIONALLY LEFT BLANKFuel supply system components, Removing and installing WARNING Disconnect vattery ground strap when working (on fuel system. Never smoke wien working wit ust or have anything in area that can igeie i Alwaye replace seals and fuel hose clamps. Alwaya cloan fuel fines botore loosening Fuel pume 1 hacking — page 20.29 ft og —— ce o rataton sow poets Iaretan of ow going to engine . Sram deny tte 300 a0 Torin oe —Fuel Supply 20 '¢ Rules of cleantiness, 20.28 (© Checking for toaks, 20.21 Fler esp. | replace gasket damaged Fal tani vert lines . Gravity vont valve ee neo Ss 180° (connection 25m (18 fib) ranaurousere 20.2720 Fuel Supply Rules of cleanliness: CAUTION wen working on the fuel syetam, the folowing rules of cleaniness must be carefully followed. — Thoroughly elean tonnecting points and ‘surrounding areas before loosening, — Lay pieces tat nave bean removed on & ‘lean surface and cover thert with plaste ‘im or paper — de not uge:cioths with it. Carefully wrap of close parts that have been ‘opened i repair will not be completed, — Use only lean pars ‘© Do not unwrap replacement parts Until immediately betore instalina. '¢ Do not use parts that have been stored ‘unwrapped (i.e. in t20\ boxes). —With system open: ' Avoid the use of compressed air as much 85 possible, ‘© Avoid moving vehicle as much as possible. Fuel tank, removing Vehicles with rear wheel drive only — Disconnect batlery ground strap — Empty fuel tank ~ Remove filler pipe Remove vent jines — Remove feed and return lines fram fuel tani = Unsere splash plate from body anc take out of brackets — Lower tue! tank and remove electieal connector Irom fuel gauge sender Remove fue} tank Syncro vehicles Note Removing and instalng the fuel tank is possibie afler removing the tansmission, For transmission removal and installation: see Flepair Group 34 — Disconnect battery ground strap = Drain fut tare ~— Remove titer pipe ~ Remove vent and tua! ines — Remove restraining straps — When taking out fue! tank, caretully push oF secure coolant pipes and hoses to one side 20.28 Fuel tank, removing DigifantFuel Supply 20 Fuel gauge sender, removing and installing Vehicles with rear wneet drive only = remove fuel tank — page 20.28 — remove and Install Sender with toot 2012 A Note lrstating: electrical connector must fine up with dotted Tne, Ascaw points In driving direction. Synero vehicloe — ctsconniect battery ground strap — empty tuel tank until float fies below level of sender opening — remove sender behind rear whee! house — when instating the sender, make sure that return line is insert into expansion tank inside ot fue! lank (see Fig, 20-549, Page 20.24) Note Aor instalation of sender: Rocker arm must be able to be swung downwards, Fuel pump delivery rate, checking WARNING Fre razard! Never smoke of have anything in ‘ea that can ignite fe! — disconnect fuel ratur tine at pressure regulator and block ting — attach hose to retum line fting on pressure regulator and place other end of hose in one {quart measuring container — remove relay © — connect ferminals 30 and 87 with tester US 4490/3 = switch on far 30 seconds ‘© minimum fuel delivery rate should be $00 em? a7 Digifant Fuel gauge sender, raroratirss 20.2920 Fuel Supply Accelerator linkage/cable Manual transmission a ‘Clamping bots «© adjust accelerator cable in ‘5uch way that the throttle vale lvor lies against the Sop on tattle housing with eppcoximatoly 1.0 mm (0.039 ny pay 20.30 saves LostenFuel Supply 20 Accelerator linkage/cable transmission: Puah rod Gs pecat BR tt nate check an ‘ual supply — Page 2032 on oS (=) “ [_Digtart ] Anveer at toaae sacs 20.3120 Fuel Supply Accelerator linkage/cable, adjusting The accelerator inkage’cable should be adjusted in such a way that with Ihrotla valve closed, (le), the. lever on transmission is against stop in ro-gas, position: otherwise, siting occurs 100 late in middle sooed ranges. ‘The accelerator linkage/cable should be adjusted as follows at ide speed (engine at operating temperature, with throttle vaive closed) — Press gas pedal to floor. Laver ($) must be on slop in kickdewn postion (arrow A) — Release gas pedal. Lever musi be in icle position (ut of kickdown) (arrow B) —Loosen’nut (1) — Remove spring (2) = Pull accelerator rod in rection of arrow — Tum adjusting rod (3) with screwdriver until shoulder of adjusting rod just contacts pivot of throte lover — install spring (2) Start engine and check to 866 i idle rpm Is — It necessary, adjust eecolerator cable at clamping reached. I! necessary, re-adjust by tuming ott adjusting cod (3) lock adjusting rod with nut ¢t) Check gmalustment — Push gas pedal down to ful throtte point. Throttle valve lever must lo against stop (without kickdown) — Push gas pedal past fll thratle point to stop. Spring tmust be compressed. Laver on transmission must be in kicksown position (A. 20.32 rcaieacrinaseeie soning [PitanFuel Supply 20 Charcoal filter assembly on comune sony 2023320 Fuel Supply Fuel supply system, components Synero vehicles Fuel tank ent fee Notes, © Rules of Civaniiness — page 20.28 «© replace seals and spring clamps Feed tne (trom tuo itor to engine ring tine Fuel tank tank (internally located) Ny wih sano, k Fusl ther % A ‘Insialaton locaton: % fron point now econ twergne 9 and Insaing — page 20.29 20 Nim (1518) racket tor 20m fut lines rons) 20.34 Samm | diatom