Scribd Logo
Upload

Welcome to Scribd!

  • 28-Ignition System PDF

    Uploaded by

    brechtfestjens
    10 views46 pages

    Original Title

    28-Ignition_System.pdf

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    10 views46 pages

    28-Ignition System PDF

    Uploaded by

    brechtfestjens

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 46
    28 Ignition System Index Aincooled AFC = Caltforia 28.8 ‘distributor 28.11, 28.12 distributor drive 28.10 Hall control unitgenerator 28.14 Hall ignition troubleshooting 28.17 ile stabilizer 28.16 igriton distrbutor’settings 28.9 ignifon timing 28.11 rotor 28.10 vacuum advancelretard 28.13 ‘vacuum unit 28.12 Wwiresicoll checking 28.10 USA (except Calit) and Canada 282 distributor 28.6, 28.7 distributor drive 28.4, 28.5 ignitonidistibutor setings 28.3 ignition timing 28.5, 28.6 rotor 28.4 vacuum univadvance 28.7 Wiresicoll checking 28.4 Diesel — Glow plug light troubleshooting 2327 — Quick glow troubleshooting 23.24 4H Water-cooled Digijet — Centrifugal advance 28.34 — Distributor driveshatt 28.32, 28.33, — Hall control unit 28.36 — Hall generator 28.37 — Idle stablizer 28.38 — Ignition cable connectors new style 28.308 — Ignition colt 28.92 — Ignition distrbutor!Hall generator 28.29 — Ignition aistbutorsettings 28.29 = Ignition system 28.28 — Ignition wires'connectors 29.31 — Rotor 28.31 = Suppressor connectors 28.32 — Trigger whee! 28.38 = Vacuum unit 28.35 — Vacuum advanceiretard 28.35 Water-cooled Digitant — Distributor, instaling 28.44 — Hall sender checking 28.43 — Ignition distributor 28.40 — Ignition and injection system, repairing 28.39 — Ignition settings 28.41 — Ignition switching function, checking 28.44 — Ignition timing 28.42 wer 2841 28 Ignition System Static siete only on vehicles ‘with radio checking Fig. 3 Terminal 15(+) lanition wiras checking Fig. 2 Distabuter es ‘check for cracks and corroded contacts Carbon brush and spring cheek lor wear end Iree movement i a ee Shechng Fe? >) /—Dust cover Breaker points lubricate cam, patie Dlock ana iva with ‘mult-puroose grease Condanser ‘Spach plug * 30 Wm 22 110) types page 283 Spark plug connector 4000-60000 (wit rh) 00-12008 (thou radio) Distitbutor installing Fg. 6 Checking conttupal avance pages 286 end 207 Vecuum advance unit cenecking leakage page 28.7 vacuum advance checking page 287 Clamping bolt aalusting ignition timing. 8e8 pages 28.5 and 25.6 Spring Distributor dive removing Fig. ¢ installing Fig. 5 Thrust washer uide into position with screwdriver 28.2 ‘si | air-cooled AFC|CAN/USA, not California Ignition System 28 Thine code ter ow ‘Distributor (Part No.) 022 905 2058. | an ii 75" eT0C Timing mah 6ellon: rankehal uly Bee 18.19 fF sean pug conn ecu uit rotor creck aha rrtoa ri sae Pare Sheth Fa. bus cover i Sone ay Tien Se ase Pug fr hat goneratr -oterd connection ‘ehecking retard page 28.12 Soe ND ‘checking centritugal aavance, page 28.11 and 2 always replace Diatebutor dive romoving/instal mt nna then position 2 28.8 seuees.... [air-cooled AFC Cait. Ignition System 28 428.12 iis LLLLEE om cd noes yal ap aes stat 1050-1300 1pm and 21-25" at 3400 rpm Yount ‘start 90-160 mbar (70-120 mm Hg) Sad 240-280 mbar (180-210 mm Hg) anal oa wetcmmnnoentnee 7 Si painie: OSEDTRINT « 11-13" Spark plug gap ‘Spark plug lightening torque 06-0.7 mm (0.029-0.028 In.) 30. Nm (22.111) Firing order =3~2 ‘Tansistorized ignition system cautions 0 not connect any bordlenser suppressor oF test light to terminal 1. De not Ponnect test instruments with a 12 volt supply on terminal 15 of ignition 0)|, Bo not crank engine before high tension wire of distributor cap (terminal 4) is connected to ground with jumper wire (example: compression check etc.) Do not replace installed coil: 211 905 115 C—with conventional type. Oo not leave battery connacted when electric walding ‘on car. Do not start engine after heating up to more than 80°C (176°F), example: paint drying booth, Oo not wash engine when it is running. Do not use battery booster longer than 18 se. nor exceed 165 volta with booster, Allow 1 minute pause between boosting attempts. Do nat discon rect battery while engine is running. Disconnect plug to ignition controt unit when car Nas to be towed. cooled AFC Ignition distributor ‘and settings California 28 Ignition System Note ‘A rough idle oF misfire during partial load could be caused by ignition sparks jumping from the plug wire Connector to the noise suppression shield, or the eylinger head. —temove and inspect the plug connector for white ‘spots or burn marks —0on those vehicles equipped with a suppressor shield on the dfstriutor oap, it Is necessary (0 ‘remove the shield and check for white spots or burn marks on the distributor cap ‘wit spots or bum marks are present, replace the ‘damaged component. Fig. Rotor, checking — check that resistance is approximately 1000 ohms Nate Do not change rotor when instaling radio; rotor must be marked with Fr, -@— == Fig. 2. Ignition wires, checking — check wires between distributor and spark plugs (including connectors} for continuity ' resistanca should not vary greally berwoen wires. — check wire between ignition coil anc istbutor {including connectors) © resistance should not be greater than 12000 ohms: Fig. 4 Distributor drive, installing — set crankshatt 10 TDC on cylinder No. 1 = instal crive shat so thal offen statis at an angle about 12° to engine centecine (smaller segment toward col side) ~ install spacer spring Rotor Ignition wires ir California 28.1 Air-cooled AFC 1 Ignition System 28 ‘CAUTION ‘When working on vehicles with Halt ignition system, observe following precautions to prevent injury or damage to ignition system: do not auch or remove high tension wire when running or eranking engine —| ‘* when temperature controlled preheat period nas ended (glow plug light out) there should still be voltage at glow plugs for additional 6 to 7 seconds. Do not operate starter for this test, Ifo voltage is present at glow plugs, replace relay ‘+ when starter is engaged there should be voltage at glow plugs. If no voltage, repalr wire from glow plug relay terminal 50 to starter or replace glow plug relay + chack Diesel Current Flow Diagram au sow stem -tousesnectng 204d 28 Ignition System Glow plug light—troubleshooting Glow plug light defective Check giow plug light as follows: disconnect glow plug relay ground terminal L in relay socket —tum ignition switch ON Glow plug tight | Glow plug light does lights up. not tight up ‘CAUTION. To avoid glow plug damage from excessive voltage, DO NOT operate glow plug system while charging battery with external battery charger. if using jumper cables to start Diesel ‘equipped vehicles, external power source must not exceed vehicle system voltage (rmax. 13.8 V) ¥ —feplace glow plug light or check wire from ‘olay terminat & to glow plug light ‘The torque specification forall glow plugs is: +90 Nm (22 ft Ib) This torque must NOT be exceeded because increasing the torque beyond the specification wil ‘cause closing of the ring gap, which can lead to Premature failure of the glow plug, f 1 G35) Eng Giow plug relay or engine temperature sensor detective ‘Check operation of relay—see also Note on page 28.26 disconnect glow plug wi — disconnect wire from engine temperature sensor —tum ignition switch ON * glow plug light should light up for 25-30 seconds — ground disconnected wire from engine temperature sensor * glow plug light must go out Glow plug light Glow plug light does lights up. not light up. replace engine —replace glow plug temperature sensor relay End End 1+ Ring gap OK (arrow) approximately 0.5mm (0.02 in) 2.- Ring gap closed (artow) after being over-torqued 28.27 covramnsewsesmains Diesel Ignition System 2 n wil S10 Hal contro unit {ole stabilizer contol uit checking page 28.38, betore adjusting ite, disconnect connectors ‘and plug together checking page 26.38 gation wice hecking Fig. 2 Ignition chocking Fig. 8 and Fig. 6 ‘Suppressor connectors checking Fig. 4 Connector on dietributar Distributor cop ‘oheck for cracks and ‘corroded contacts, Clean before installing ‘check for wear and free movement Ignition wire checking Fig. 2 ‘Spark plug connector checking Fig. 3 Ignition distributor and setings chart page28.30 "ution timing ‘susing page 28.39 Spork plug 20 Nm (14 10) types page 2830 [Water-cooted || Digtiet | puson sym 28.23 28 Ignition System Rotor checking Fig. 1 Dust cover: orcip “enn es ciretps: Es Distributor installing Fig. @ always replace Thrust eves ae {uid0 into position with acrewarivar WARNING. Do not touch or remove ignition coil wire when running or cranking engine, nnect wires of ignition system or remaving/instaling page 26:98 Pin shims adjust cumber of shims until Hall generator tree of play and easy 10 turn Hall generator lighty lubricate bearing surfaces, ‘checking page 28.97 Vacuum unit Distributor ervo shatt comoving Fig. 7 Installing Fig. 8 28.29 ssarezrrnmace Water-cooled Digijet | Ignition System 2 ‘acum hoses connected err a bicoan Paina) meme and mene Timing mark tocatior {20-346} ees am ie stabilizer contrat unit electrical plugs disconnected from unit and connected together Centr fugal advance (crankshaft degrees) start 1050-1180 rpm 16-20" at 2400 rpm end 21-25* at 9800 rpm vacuum advance start 190-290 mbar (14.0-17,0 om Hg) end ‘980 mbar (27.0 om Hg) 12-186" ‘acwum retard start 100-220 mbar (7.5-16.5 em Hg) 260-960 mbar (19.6-27.0 em Hg) end ont Spark slugs: Bosch w7co Beru 14-76 ‘Champion N 268 ‘Soak plug gap 0.7 +0.1 mim (0.028 + 0.004 in.) Soark plug tightening torque 20.Nm (14 fib) Fring order 14-32 Water-cooled non stot and setge 2OWOC 28 Ignition System Ignition cable connectors (ew sive) To assure tight connections, ignition cables now have new style (Mé) connectors, as illustrated below. New syle 4 old aye Connections at distributor cap, ignition coll, Interforonce suppressors and spark plugs have all ‘been changed to new style, Note ‘Components with new style (M4) connectors are ot interchangeable with old style. If replacement is required, install complete set with all connectors of same style. 28.30a zs" [weno Digijet Ignition System 2 ‘CAUTION When working on vehiclas with Hall ignition system, observe following precautions ta prevent injury oF damage to ignition system: —<¢o not touch or remous high tension wire when running or cranking engine disconnect ignition wires onty when lantion is switched oft test instruments should be connected! disconnected only when ignition Is switched off| —do not connect any condenser 10 terminal 1 —do not tow cars without disconnecting plugs on ignition control unit co not crank engine until high tension wire of distributer cap (terminal 4) is connected to ground with jumper wire (example: compression check, etc.) =o not leave battery connected when ‘electric welding on car —d0 not substitute rotor of ignition distributor with one of differant typo —when installing suppressor, use only 1000 ohms for high tension wires and 1000 10 5000 ohms for spark plug connectors ~do not wash engine when it is running —do not use battery booster longer than 1 minute not exceed 18.5 volts with booster Fig. 2 Fig. 1 Rotor, checking — chock that resistance is 1000 +400 ohms Note Rotor must be marked with R 4 for Hall generator equioped cars, Fig. 3 \gnition wires and connectors, checking — chock wire Between ignition coll and distributor including connectors 8) + sistance Should be = 2000 + 800 ohms — check wires 2 botween distributor and ‘spark plugs (including connectors and 9) * resistance should be =6000 = 1400 ohms = i values are not a& specified, check wires and connectors Individually ‘# fesistance of wires (without onnectors) must be=0 ohm Spark plug connectors, checking check connectors resistance + specified value = $000 » 1000 ohms LE Water-cooled | Ignition system cautions Rotor Ignition wires/ Connectors 28.31 28 ignition System Note ‘A rough idle or mistire during para load couid be ‘caused by igrition sparks jumping from the plug wire ‘connector to the noise suppression shield, or the ‘yiinder head. = remove and inspect the piug connector for white spots or burn marks, —on those vehicles equipped with a suppressor shield on the aistriblor cap, itis necessary to remove the shiaid and check for white spots or ‘burr marks on the distributor cap It white spots or burn marks are present, replace the ‘famaged components, = Fig. 4 Suppressor connectors, checking — check resistance of supressor connectors * speciiad value = 1000409 ohms -~ A Fig. 5. Ignition coll primary resistance, checking Note W traces of leakage from ignition colt are visible check HALL control unit and replace ignition coil = disconnect all wires trom cai terminals — connect chmmoter between terminal 1 ) and terminal 18 (+) ' resistance should be = 0.420-0.760 ‘ohms — check secondary resistance (Fig. 6) LE Fig. 6 Ignition coll secondary resistance, checking — connect ohmmeter Between terminal (=) and terminal 4 ‘resistance should be ‘ohms NO, replace ignition colt 400-35 Note W resistance readings are correct, but no high voltage occurs at ignition col, check Hall gonere ‘and Hall control unit. necessary, replace igri call Fig, 7 Distributor drive shaft, removing — use extractor with diameter 14.8-18 (0.589-0.728 in) ‘Suppressor connectors Ignition coll Distributor drive shaft Digiiet 28.32 Water-cooled Ignition System 2 — Fig. 8 Distributor drive shatt, Installing — set crankshaft 10 TOG on No. 1 cylinder — insert drive shaft so that off-set siot in top of drive shatt is pointing toward tapped hole (sirovr) ‘+ smaller segment points to water Fig. 9 Distributog installing — sot crankshaft to TOG on cylinder No. 1 — tum rotor until itis pointing to No. 1 cylinder mark on edge of housing install distributor —

    You might also like