Service Manual

Service Manual 

c Repairs 

and maintenance

Volvos a€ sold in versions adaptecl for different mark€ts. 

Th€se adaptalions depend on many facrorc including le- 

9al, taxation and market requirem€nts, 

This manual may therefore show illustrations and text 

which do nol apply to cars in your country. 

o 

a' 

o 

a 

o

0 

0 

Contents 

Group 34 lgnition system 

Soecia lools 

General nstructions . . 

Specifications: lgnition sFtem with contact br66ket .... ... ... ... ... ... . 

Breake eBB ignitron 3y3lem .......... 

Computerized ignition 3y3lem .... ......... .. .. 

Inspection of lgnition sy3t6m with contact breakeB B 20 A, B 17-A 23 A 

Breakerles. ignilion syltem B 20 F, B 19 E, ET, 

B 21 E, ET, F FT,823e,827128 A.E and F ......................... 

Compurerized ignition sFiem B 21 F-MPG (1981), B 21 F-Cl (1982), 

B 21 F-LH (1982), A 2s F-LH 0983-1984), B 230 F-LH (1985-) .......... 

Index page 79 

Indicates revised informalion: 

Order numbor: TP 30432/2 

We rcserve the right lo make alterations 

withoul prior notilicalion. 

O 1985. VOLVO CAFS OF NORTH AMERICA, 

A Dvson ol Volvo Norlh Am€ica Corporation 

Group 34 lgnition sysLem 

Page 

2 

3 

5 

10 

2-l 

24 

37 

57 

Contents

Specialtools 

,: E-,1-.t 

v!a' - - {' 

-t_*_.- , ,: 

Special tools 

Ohm-Oiode Tesler 

Monole3ter - Owell angle, ignition setting 

Stfoboscop€ - lgnition seliing 

Flywheel Adapter - lgnition setring lvlY 1984-

lgnition system - general instructions 

0 Measuring resistance 

o 

1e8o: VC 244 45 

1981 

: YV1 AX 454X 

19ao: 245 

1981 : YV1 244 

!15 

40 

I 

L 1 0ooooo 

E10OOO0O 

L 1 000000 

18 T1000000 

General instructions 

Before measuring the resistance of a compononl make 

sure that all leads have been disconnected from it. 

Resista nce values specified in thismanualapplyat20"c 

(68'F). 

Electronic ignition systems 

Electronic ignition systems operate at very high vol 

tages - often in excess of 30 000 V. Such hig h volrages 

are a danger to life and special precautions musl be 

laken when working on vehicles so fitted. 

The ? symborused (hroughoutth sTalua Indrcates 

terminals where dangerous high voltages can be ex 

Engine type and model year designation 

11 = 4317 {820 1975 761 

2:819 

24=E 

26 = E Turbo 

4=821 

44=E 

45=F{5} 

46 = E-Turbo 

48=F(8) 

49=F(9) 

6:827 {1975-79) 

64 = E (-1980) 

65=F 

6 = 828 (1980-) 

62=A 

68= E(1981 ) 

69=F 

8 = A23IB23O 

81 

84 E 

88

General instruclions 

0 231 -.... 

JFU 1

t 

i$ 

r0 

tgnition coil 

,0 820 

BI/ B.J 

Ignition system with contact breaker 

Specif ications 

lgnition system with contact breaker 

B20A,817_8234 

Res stance of pr ma.ycoi (acrosslerm na s 1l ) and l5(+) ) 

Resistance of secondary coi lacross rermina s 11 )and HT 

Bollo r'p i5to 

Spark plugs 

T ghlening 

torque 

{uno €d pl!s) 

High tension leads' 

A-engines -1978 

2.8510.r 5 () 

9.512.5 k() 

Bosch W 7B 

Eosch W 7DC 

0.7 0.8 mm 

25-5 Nm (1813.5 

fi.lbs) 

A-€nganes'1979- 

1.910.1 0 

d$ 

a- 

{r 240 240 

1ko 0(ym 1kn 

1976-aO d__r-'- --1 1975-76 

,o-. 

_}.*_ 

+'E--------.------:c+ 

9.51t.5 kO 

1.310.1 O (0.9:t01 

oo 5,6 ko/m oa 1ko g a/m 1k') 

0 c) 5,6 ko/m oo 

_--- 

oo O a/m 1.4 kf) 

-f\}.__ Jr'-1..Jr\ 

!.,2_--.J, 

1ko O Orm 

'Nore: Fes,srance values are gtven in K O perneter af length. (Measure tead in otder ta campute corcct value ) All 

0 vatues have a permEsable tolerance of . 20o/o 

5ka

Specifications 


Rotol 

Resrstance. 

Firing ordel 

lgnition setting 

420 

1 3-4-2 

5r1 ko 

817-823 

'l-3-4-2 

With effectfrom 1976, vehiclesfor Sweden, Australia, USAand Canada {also Switzerland 1983'rnodels)have details of 

ignition setting stamped on a plate lo left of engine compartment. 

SDecial vehicles 

lgnition setting (before T.D.C., vacuum control unit disconnected) 

Engine type Modelyear/Marlet 11.7-13.3 r/s 

700-800 r/min 2500 /min 

B 17A 

'1979 

84 

'12" 

2A 32' 

819A 19'/71t 

1978 ltaly 

1978 80 Other markets 

1981-84 

" Sweden:245wilh 8W35,8W55, M 46andspecialvehr. 10" 

211979-80:Sweden,Overseaswithenginelypes49ST55and49ESllandspecisvehicleswithmanuagearbox.. .. 10" 

Specalvehicleswithaulohatcsearbox.. .. .. ...... .. .. .. 8" 

3r240wiih 

enginetype4gS 528 r5'and32-36' 

') 

lgnilion setting can be retarded lo 5' if, despite uslng 98 ociane f!el, engine is prone lo pre ignition (knockins). 

15' 

15" 

12" 

10' 

Special vehicle refers 1o heavy veh c e rypes slch as 245 GL with auiomatic rransmission. 

32-36' 

32-36' 

2A 32' 

26-30' 

B19K 17 23" 

B20A 1915-76 10" 23-21' 

B21A 1975 

1916 7711 

1978 Sweden3) 

Other markets 

1979-8o'z) 

1981 Scandinavia,Australia 

Olher markets 

'1982-83 Scandinavia,Australia 

Other markets 

1984 Scandinavia,Switzerland 

Auslralia 

Europe 

Canada 

B23A 1981-82 Scandinaviaa) 

1982 Other markets 

1983 84 Europe 

Overseas 

'12' 

'15' 

12" 

15' 

12' 

10" 

12' 

'10" 

12" 

10" 

10" 

7" 

5" 

5' 

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 

0) 

0'

qA 

i0 

i0 

t 

., 

Distributor 

Engine type 

B17A 1979-80 

1981 84 

B19A 1977 

1978 

1979 

1980 

1981-84 

lgnition setting 

nttl 

(App ies io ai markeis un ess otherw se 

Thailand, Malaysia, ndonesia 

Bosch n!mber at bottom 

stamped n disiributor body. 


0 231 176 103 

0 185 

0 185 

0 185 

6 103 

6 103 

0 185 

6 103 

0 185 

Variation of lgnition sening 

Variation of ignition setting 

1 266 478 

I 219 661 

1 219 661 

1 219 661 

1 266 478 

1 266 418 

1 219 661 

1 266 474 

1 219 661 

B19K 1984 0 302 1 332 410 

B20A 1975-76 0 085 462 657 

B21A 1915 

1976 11 

1978 

1979 

1980 

1981 83 

1984 

823 A 1981 82 


H irl 

'.,4 :) 

o2 1 170 08 

Other markets 

Sweden, Australia, Canada, Ove.seas 

Olher markets (inc. Thailand, Indones a) 

Sweden, Australia, Canada, Overseas 

Other markers (inc. Malaysia, Thailand, 

Sweden, Auslralia (1982 

also Switzerland, canada) 

is:t,' 

Oiagram key: 

lsl 

l-r I 

@ 

0 134 

0 173 

0 185 

6 103 

0 185 

6 103 

0 185 

6 103 

0 185 

103 

o 244 

0 185 

0 302 

0 284 

o 247 

0 302 

o 241 

463 692 

1 219 625 

I 219 661 

1 266 414 

1 219 661 

1 266 478 

1 219 661 

1 266 478 

1 219 661 

1 266 474 

1 306 792 

1 219 661 

1 332 410 

1 306 792 

306 872 

332 410 

306 872 

:s3b ""'i;''o 

t: 

Ai L E'H


lgnition setting graphs 

. 

ErN 

o 

o 

Ei za -) 

-T 

I

9 

r-B 

l@; 

o];e 

:@:l ?9 

, LU 

!:" o@ | 

69tsc 

-1;o 

Nl;-l 

3_ 

9 

:*;: 

6P: c +l qU 

: 6

B rea kerless ig n it i o n system 

Frpr rrod. gdo 

T 9h'P1rnq ro qJp rulo: pd o Jqr 

10 


Breakerless ignition system 

B20 F, 8 1 9 E. ET. 8 21 E, ET, F, FT, 8 23 E, 8 27 A, E, F, B 2A A, E' F 

lgnition coil 

Resistance of primarY coi 

acrossterrnlnals l{ )and 15{+) 

Resistance oi secondarY coi 

lern ra lacro55lpr-rndls ll l"ldtTl 

Ballastresistor .. .. 

Spark plugs 

4.cyl engines 

B20F 

1976 

819E, B21E 1975 84 Bosch W6DC 

B 19ET. B 21ET 

Bosch W6 DC 

B21F 1976 79 

Bosch W7 DC 

1980-82 USA 

1980-84 Others 

Bosch WR7 DS 

B2I FT 1981-85 Bosch WR 7 DS 

B23E 

1979 80 

Bosch W5 DC 

1981 -84 

Bosch W6 DC 

E e.rodegdp 

Tightenirg lorque (unoiled pl!g) 

6-cyl engines 

827 A 19J5 l9 Bosch H6D 

a27 E 1975-14 

Bosch H6D 

1979 80 

Bosch H5D 

B27F 1976 79 Bosch H6D 

B28A and E t980 84 Bosch H6D 

B 2AF 

1980-84 USA Bosch HR6DS 

1980 84 Others Bosch H 6 D 

820,819-823 

1.910.1 i) 

9.511.5 kl) 

0.910.1 {} 

827/824 

0.5r0.1 {) 

9.511.5 kl) 

110.1 (l 

0.7 0.8 mm 

2515 Nm (1813.5 

ft.lbs) 

0.6 0.7 mm 

1212 Nm (8.711.5 

ft.lbs) 

0 

0 

O 

0 

0 

I

,0 

,N 

O 

I 

3 

0 

, 

Rotor 

High tension leads. 

- 

\:, 

L---.T i 

260 : 

' ii- 

' 

_, _1. 

lkrr 

0a 0a 

,t-.+-'*.,* 

E 1t O O!) m 

--n 

tok.l 

'Nore: 

F.srslrnce yalires a.e glven n K a permeter ol length. (Measure tead n ardet to compute coftect value ) Al 

vatues have a pe.ntssable tolerance of ! 2A% 

Firing order 

820 

1342 

240 

819 823 

1342 

-'" 

5-1 ka 

ifll 

:_i, 

D 5 lllr- --=_ 

-or, 

5.6 

B rea ke rl ess tg n i ti o n system 

i.J 

24O .=r 

oo m 

260 

i 

5k!) 

: 

-i 

II 

827, 828 

r 6 3 5-2,4 

tt

Breake rl ess ig n iti on system 

lgnition setting (before T.D.C wilh vacuum conlrol unit dlsconnecled) 

Wlth effecl from 1976, vehicles for Sweden, Auslralia, USA and Canada laLso Sw tzer and I983_mocle s) have deta ls oi 

gnition selling stamped on a plate io lefl oi eng ne compa.tment 

4-cyl E-engines 

Engine type Modelyear/market 11.7 13.3 r/s 

700 800 tm n 2 500 nmin 

B19E 1977 83 

1984 

8' 

10' 

28 33' 

24 2A- 

B 19ET 1982 a4 15' 21 26' 

B2I E 1975 82 r 8_ 2a 33' 

B2l ET t98t 84 15' 21 26 

823 E 1979 82 

1983 canada 

Other markets 

'r 

1s76 80:a!stra ia,swedenSpec 6 vehicLes 

4-cyl F-engines 

6-cyl A and E-engines 

r 

1978:Sweden,Audralia,Speca vehcles 


5' 

10 

5' 

25 3A' 

25 29' 

25 3A' 

B20F 1975 5' 20 25', 

B21F 1976 

1977 USA 

Olher rnarkets 

1978 

1979 Calforna, Japan 

Olher markels 

1980 Canada 

Olher markels 

l98l 84 Japan 

1981 USA Adjusr at 15 ris (900 r/min) 

15" 

12' 

15. 

124 

10" 

'10" 

8' 

8' 

25 30' 

2a 32' 

25 30 

2A-32' 

22 26' 

26 30' 

24-24' 

22 26' 

22 26' 

B2t t\ 1981 85 Adjusr at 15 r/s (900 r/min) 12' 25 30' 

a27 A 1975 79 10' 22 25 

B 28A 1980 84 10' 22 25' 

B27E 1975 

1976 Sw€den, Austra a 

Other markels 

1977 lA 

r979 80 

B28E 1981 82 

1983 84 

827 F 1976 

1977 Ca ifornia 

Olher markets 

1979 

828 F 1980 82 Adjlst al 15 rA (900 r/min) 

12 

1981: California, Japan 

1982: All 

10' 

10' 

10' 

t0' 

t0' 

10' 

12' 

10' 

7' 

10' 

10' 

30 34 

22 26', 

30 34 

30 34- 

25 29' 

,25 29 

2t 31' 

27 32' 

20 24' 

27 32' 

20 24' 

l0' 2A 24' 

0 

I 

-I 

a) 

0) 

c 

0 

0t

is 


:e4-cyl F-engines 

r 

I 

I 

0 


827 A 

lB21E 

B 28A 

828 E 

Model year Desc,iption 

197 5 79 

1976 

1911 1A 

1979 80 

r980 84 

1981 84 


1976 

19/7 lA 

1979 

USA 

Distributor 

Eng ine type Bosch P/N 

0 237 00 

B19E 1977 83 

1984 

Bosch P/N 

0 231 44. 

Breake ess ignition system 

2 017 

2 039 

2 006 

001 

005 

001 

005 

007 

013 

2 Q13 

1 219 957 

1 276 403 

Bl9ET r982 84 3 021 1 216101 

B2I E 1975 

1976 

19/7 8Q 

1981 82 

Sweden, Australia (Overseas 1979 ) 

Otlrer markets (lncl. Thaland 1979 ) 

2 001 

2 A1A 

2 401 

2 014 

2 Q17 

2 011 

463 832 

1 219 662 

463 832 

1 219 662 

1 219 951 

1 219 957 

821 ET 1981 84 3 427 1 216 /01 

1979 82 

1983 

1Sa4 

B20 F 1975 BW 35 (Ca iorn:a to engine no 500) 

fvl 40iM 41 {Caifornia: to enq ne no 500) 

Caifornia Blr 35 (engrne no 501 ) 

Ca iornla M 40/N4 41 (engne no 501-) 

B21F 1976 

t3t; 

1979 

r980 8l 

1980 84 

I21 FT 1981 84 

B2-I F 

1980 84 

USA 

Ca io.n a. Canada. Japan 

Ca iornia Japan (Canada 1980) 

USA (Canada 

l98l 82) 

2 All 

2 039 

2 017 

2 039 

2 003 

2 002 

2 009 

2 008 

2 001 

3 003 

2 007 

3 009 

3 003 

2 039 

2 038 

2 039 

2 039 

1 219 957 

1 276 443 

1 219 957 

1 276 4Q3 

462 762 

462 496 

'| 218 672 

1 218 671 

463 694 

1 219 848 

463 694 

1 266 466 

1 219 848 

1 216 403 

1 266 904 

1 276 443 

1 276 443 

3 024 1 276143 

269 

269323 

269565 

269 323 

269 565 

269 733 

1 269191 

269 995 

269 191 

269134 

269 134 

269 739 

1 269 291 

ll

B reakerless ig n iti on system 

lgnition setting graPhs 

Bosch number at bottom left of diagrams !s siamped In 

Legend 

l=l 

l-r I 

@ 

--- 

, €) r 2Jl 

) \@ tru' :=) 

Variation of gnition setting 

Variation oI ignltion settlng 

-'..'-: 

,9 rp 49 5p 

_.!!5r. 

f, 

I 

t)) 

f) 

a 

( 

( 

0, (

\ 

{l 

't 

'e 

I 

I 

c 

,:1. 

o231002411 

-tt'o 

..'.; 

*llr',i 

,t 

: 

//',z 

J. I 

o 237 o )2 o3A 

B reake rl ess i g n i t i a n system 

,/l 

1"..--:"--, "p'.-:*1: 

:I::l] 

s 

:? !! t!1 

t5

Breake rl ess i g n i tio n system 

," ,l- ,,1,,,r., +, 

,","r?"jrjf. 

t6 

I r- :::_::--:--:i:' ::: ; 

o-Fo 

--^-oo0'000 

0\ 

0 

f) 

0 

I \ 

I 

(

.J 

:f 

I 

9 

0 

t 

I 

:';: 

=Fb 

B rea kerl ess I g n i t io n system 

i;-l-ll ,t,_,..-f+_-l 

:0237402017: 1 : l:i: l 

J; io r'l; i;' 

2j 

--


:t-. d 

*l i ii 

96: - 

E-- d 

q.9 

Nti & 

Pio9 - 

9t 

!!N ! '! 

5@: 

r9r 

l]n: 

:i-< 

I 

I 

a 

ci 

>,9 

x3 

Hx-E i 

d+< o 

Rl9 

9r 

!^ 6 .t 

56 e - 

.9: 

-o 

ar 9;3;P 

18 

- 

6 r6q: 

.rfr :;R 

lr9 q 

1_r l3 :81&: E 

:r]9 

:!X=U!9 

1ia :oj:i | ^ 

LdQ 9 

6 

+i LP 

.!5ulo 

qP\:q 

^9 

99 

- -9 V 

^.6 @oo: 

-:9 risil = 

6 9 C9 X\X 

^e 

^ d:on 

^.6 > i5:,ici8'i.> i5:dci:5 

I 

0') 

f) 

0 

0 

0) 

f' 

( 

I 

(

t 

i:0 

I 

c 

0 

a 

lt 

\66 

so: I -38 - ii6i --? - s v RR€ 

:i: f l;E €ilfs-, .r: ;:";lle:r 

- ^9 ! 

3e. ) --i -::- a :_g Ei{ 

.j: i 1:: iA*F:i r:s sEil 

F:; I ;F ii;_ g_i !R{ 

" 

!.c E* 

:Rj g !13 !EF:i3 "arp {€{ 9** ti 

;=:r .?:FiF 

:6' ; ! 3 I X i-: 

s:9 g !iE iEqiSI p=s q : 9:€ s3 

= 6i; F 

H9: I -.rn ::!^ g 3 Re? 

:. ) o {o 6 .:. - -NN 

;^ ! . ro aRo 

j'J 3 ii€ :dri;{ .5[? FE: 

>3: 

ii-O 

I 9! 

09 

>:o-; 

s ;: o; 

+ 39-3 

:> 

:_ 

:o 

ao 

: 

^: 

e "E{:;" 

E !c_-oc 

: ::-:9i' 

:b: 

a aa 4:z! 

.9 < o:= :9 

: ir 6 ! d: 

ci in : > 

I 

-o- 

o iE6 

o io-F 

5 .i i: 

t, E;i 

r! 9!! 

> i5ii 

ooo!oo 

:PO 

:E 

3;,bi 633 

Brcakerless enitton system 

qR 

I I 33 

:S: :E 

E Ee 

E X;E; E 

! ; s:E .; 

i; ; 9;! ;: 

Fs 3 s,6 EF 

*;a E Epi*i; 

ciN> O. i5Edci:-> 

19

Specitications 

Breakerless i g n itio n syste m 

€F! B EE 

^gii : - 

T:5 S ::B 

?.i; s 

\P; 

3:; 3 

*P: 

e3 t 3 

93; 3 

3g; 3 

?R; 3 

l!553!l 

6 96\o 

6 

a 

.1609- 

^9 

oK'U 

:lg 5d&=Br 

^s 

ii N66@ 

.^i o-Fa 

q? 

:^g 

: : :3: - , 

:: o { 

:e&=i"i!J 

6 9G090 

99 

66m:NX 

;q: 6i t dj- d;.1 

i'' ,.i66- 

+r -LP .?P :.?5 

6 

.:-F 

, P 3R9 

3"' R 333 

.33? 

=l 

-NN .: I 

::::.::. I I i : . : 

q - -l 

,,t Ee^r I c o x. 

E 

', ; 6 gp i- 

d', 3xl : 

$c 

E: o;: -- ri E":E I u:i , 

EE ? il; ;.i:= o:66 . :li E 

;= 6;:'; q!:l8i e ieE i E:l 

drE ,:i EHg: 'i3s-4 q;:€i; ':!iH: Ei!s';eEiee''! 

E;:;i 

i'EE€EFE'E!;:q 

E ::t ci=s :u H ElEe;ix E:="-" 

,Is9;fs 3!i= x,l = = >i5;dcj?.b> a.35Ij 

20 

: : 

0) 

t, 

0r 

f) 

I 

0

I 

I 

.N 

0 

0 

0 


Computerized ignition systems 

Computerized ignnion systems 

B 21 F-MPG 1981, B 21 F-Ct 1982, B 21 F-LH 1982, B 23 F 1983-1984 

B 230 F 1985lgnition 

coil 

Bcsstance of prnrary col(across terminas 1( ) and 15(r ) 

Fes slafce ol secondary coil (across lermnals l( ) and HT 

C"pd o - rJl '( ) 

Spark plugs 

B2]F.B 

B23OF 

23F 

sao 

T ghle. na 'o 

oLp Lr o -d Lg 

High tension leads 

R--s sr.rce ol fild belween i!tnil on.or and d srf buror 

Res starce af sDark p !!l s!ppressof 

Res st.nce ol d slfibutor s!ppressor 

Firing order 

I342 

Enqine type 

I210.1 O 

10 6r'1.0 k() 

50 250 nF 

Bosch WB 7 DS 

Eosch 

L2:r 0.1 

07 08mm 

25-5 Nm (18r3 s ft bs) 

5.6 kQ/m 

5ko 

lko 

o 

8.5-0.8ko 

setting (vac!um governor on control unt disconnecied) see Instrucnons on page 6s 

11.7-13.3 4s 

700-800 rimrn 2 500 rim n 

421 F r98r.-82 

12" 

B23F 8230 r983- 

12" 16 ?4" 

21 

=

Specifications 

Com putei zed ign ition systems 

Distributol 

Engine type 

B2'IF 1981 82 1 306 0s9 

a23F 1983 

1984 

1 332 684 

1 336 737 

B23OF T985- 1 332 587 

lgnition advance graphs, control unit 

Legend: 

[=l 

l.l-l 

r- n---t 

l,S)l 

JwF' I 

821 

22 

vdridl'or or ionir'or serrins w lh v.r Lrrr 

Varidtiol ol iglil,or \"lr n9 with ergine rpr 

Max vac!um advance in relation lo 

Example conirol unit P/N 1306057: at 30./s (l 800 r/min) 

vacuum advance cannot be more th.n 90' regardless of 

extent of depression. 

lji.-1: 

f..l 

) 

tLt) I-I 

.:-..'_l - 

:L I 

:1317873 t.: 

$, 

l 

t, ( 

D 

I 

I 

), 

( 

4 I

I 

i0 

I 

L 

0 

I 

I 

821 F-LH 1982 

B23F LH Auto transmission 1983-84 

Manual gearbox 1983 engine P/N 499802 

lchanqed ensine vers on 1983) 

1317295 

.o?r::] l L 

l .L..l 

B23F-LH Manual gearbox 1983 engine piN 499a9O 

Manual gearbox 1984 

t; 

tt 

ido 

C om puteri zed i g n i tt on sett i n g 

..::1. 

23

Contents 

Computerized ignitian systems, lgnitian system with contact breaker assenbly 

B 230 F-LH 1985- 

lgnition system with contact breaker assembly 

Contents 

lgnition coil and HT leads 

Distributor cap and rotor arm 

Replacing contact breaker points 

Checking iqnlioi sFiI 19 

ch"clrrg cP'rtr'f Jgdl advan(e 

Cl'ecling vdcu rr adva..e 

Reconditioning distributol 

Replar ir 9 v.'JJ- cont'olL1r' 

Repid.irg dislribJrol 

Checl rg side p a! 

Distributortest bench 

- 

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 

0 

f, 

ll 

I 

0( 

t) 

I 

); 

(

,{ 

r0 

'0 

'o 

I 

Distribulor 

lgnition svstem with contact breaker assenary 

25

Distributor 

lgnition system wnh contact breaker assemblY 

26 

A. lgnition coil and HT leads 

At 

Testing ignition coil, ballast resistor and HT leads 

Components should be al a temperat!re of aboLrt 20'C 

(68"F). 

All leads must be disconnected from the componenls 

when taking nreasuremenrs 

Measuring resistance oI ballast resistor 

Ballast resistor fitted to 1979 models onwaros 

Resistance:0.9 O (eanY 79) 

1 3 {) {others) 

A3 

Checking ignition coil: 

check outer casing of ignilion coil Io. cracks elc 

measure r€sistance across ternrinas 1( ) and 15 

(+ ). 

Resisrance:2.7 3.0 f! 1978 

1.8-2.01) 1979 84 

- measure resistance across termina 1( ) and h gh 

tension terminal. 

Besist.nce: 7.0-12.0 () -1978 

8.0 11.0 {} 1979 84 

4 

a 

fj 

-t 

( 

r) | 

0 

t' 

|) 

{

0 

'975 

i_, 

240 

Checking resistancet ot HT leads 

MU 

r4,1 

m 

1kf) O ')/m 1kf} 

i0 oc] 5,6kJ)/m oo 

e 

0 

I 

I 

#:n- 1cl6- --1 

,T--- 

o() 5,6 ko/m o.) 

tgnition system with conncr 

Distributor 

breaker assembly 

1k o oQ/m l ko 

-'----- 

Reststance values are given in K Q .per neter af tength. (Measure tead in 

vatues have a petmissabte 

tolerance of ! 20%. 

\,,/- 

. .-

Distributol 

Ignition system with contact brcaker assembly 

2A 

t T 

B3 

Replacing contact breake. points 

crease cams after installing new points. 

Turn crankshaft untilfibre heel on contact breaker is on 

Adjust gap to 0.i10 mm on B 17-823. 

0.35 mm on 820 

Apply 1 2 drops of engine oil to spindle wick 

Adjust dwell to 59-65" 

B4 

Volvo lMonotester or dwell meter' 

neduce points gap to decrease dwellangle and increase 

gap to increase angle, 

Refit rotor and distributor cap, 

Check dwell angle at 42 t/s (2500 r/min) 

B5 

tl dwell angle differs by more than 2" from reading at 

idle, check distributor for wear. 

I 

,1 

't 

{) 

6 

( 

(

'0 

0 

I 

0 

I 

I 

Distributor 


Adlust ignition setting at 11.7 13.3 r/s 

{700-800 r/min) 

Disconnecl hose from vacuum unit on distributor. 

B6 

Adjust ignition tim'ng to value ind caled in tabte betow. 

B7 

Check centritugal advance at 42 r/s {2 500 r/min} 

Check thal iginition advance is according to specifica 

tion, see lable below. lt advance is nol according to 

specificalion, check adv.nce weight assemb y. 

lgnition settinq 

With elfectfrom 1976, vehicles for Sweden, Auslralia, USA and Canada (also Switzertand 1983,modets)have detatts of 

ignition settlng stamped on a plale to lefr of engine compartment. 

lgnition setting (before T.O.C., vacuum contro unit disconnecred) 

Engine type Modelyear/Market 11.7-13.3 r/s 

1700 800 r/min) 12 s00 r/min) 

B17A 1979 -84 12" 2A 32" 

a 19A 9771 

978 taly 

978 80 Other markets 

98',1 84 

Special vehicles 

rr 

Sweden:245w th Bw 35,8W55, M 46 

'' 

1979 80 Sweden, Overseasw lh engin€type498 

755and498 811 andspecia vehicleswih manua gearbox 

'' 

240w theng.clype498 528 

1r gnit on se ng can be rerarded oi 5r if, despite using 9s ocrane foe, engtne s prone ro pre. gniiton lknocktfg) 

Spec a veh c e refers to heavy vehic e lypes such as 245 cLE wilh zulomar c rra.smission 

t5' 

t5' 

12'- 

10' 

32 36' 

32-36' 

2A 32" 

26-32', 

B19K r984 17 22' 

B20A 1975 76 10' 23-2/' 

B21A 1975 

1916 77 ) 

1978 Sweden3r 

Other nrarkets 

1979 80'r 

1981 Scandinavia,Australia 

Other markets 

'1982 83 Scand navia, Auslralla 

Other ma*ers 

1984 Scandinav a, Switz€n€nd 

Auslra la 

I23A 1981 82 Scandinaviaa) 

1942 Olher markets 


Overseas 

12' 

15' 

'12' 

15' 

12' 

10' 

12' 

10' 

12' 

10" 

10" 

1' 

7' 

1' 

5' 

5' 

24 28' 

32 36' 

2A-32', 

32 36' 

28 32' 

26-32', 

28 32' 

26 32' 

24 30' 

28 32' 

20-26' 

27 33' 

17 -23' 

24 3A' 

21 26' 

19-24' 

17 22' 

10' 

t0' 

29

Distributor 


30 

Vacuum advance/retard 

Sonre dislributors are equipped with a vacuum conlrol 

' 

unir wlth 1wo vac!um hoses. In such cases the contro 0 

unil regulales both vacuum advance and retard. 

B8 

B9 

Delay valve 

Because of exhaust emission aws some vehrcles are 

equipped with a de ay valve connected between the 

inlet rnanifold and vacuum control unn 

S€veraldifferent types of va ves are n use Ona ltypes 

"DlST must face distributor. 

Check that it ls possible to suck air throught "DLST" side 

oi valve and that it is verY difflc! t 10 blow a r lhrough 

810 

Checking vacuum advance 

Connect a vacuurn pump to vacuum control unii- R!n 

englne at id e speed and record ignilion advance ln 

ard clerk r1.l rqlir or ddv.rcP ._ 

li ignition advance does not increase check vac!um 

Checking vacuum retard 

Run engine al id e speed. 

811 

Check that ignilion is retarded when vacuum hose is 

lf not, check condition of hose. lf hose is in good condi 

tion check vacuLrm control unrt. 

rlr 

,)) 

| 

F 

I 

I 

( 

I 

(

I 

i.,0 

0 

,r 

0 

I 

{ 

f] 

,?' 

;).. 

.=- 

: rt\ 

E, L 

Disttibutor 


Bl2 

Check vacuum advance with a vacuum pump 

Check dislributor number and iind cotrect ignitlon advance 

graph on pages 7 and 8. 

Selecl a pressure from graph and punrp !p vac!um 

pump to thrs va ue. 

Record ignition advance. 

Subtract basic ignition setting from recorded ignition 

advance and check that va ue conforms to graph. 

813 

Example: Bosch number 0 231 170 287 on B23A 

1981 82 Sweden 

You decide to check vacuum advance at 200 mm Hg. 

Recorded advance al this pressure is found 1o be 

16-21". 

Basic lgnition serting : 7'. 

D fference - 9 14' which ls as specifiecl. 

814 

Check vacuum unit for leakage 

Connect a vacuum pump. ncrease vacuum to 500 mm 

Hg (67 kPa). 

Record pressure for 1 minute. Pressure nrusl not drop 

by more than 100 mm Hg {13.5 kP.). 

Pre-ignition B23A Sweden 1981 82 

815 

lf, despite use of 98 octafe fue, ensine s prone to 

pre-lgnitlon (knocking), igniiion can be retarded to 5'. 

lgnition setting can also be retarded lo 2'before T.D.C if 

vehicle is required for towing purposes. Noie rhat fue 

consumption will increase and that ignit on shou d be 

reset to specificalion cluring normal usage. 

3r

Distri buto r, reconditioni ng 

lgnition system with cantact breaket assembly 

32 

C. Reconditioning distributor 

Replacing vacuum control unit 

C1 

(8 20: distributor must be removed f rom engine before 

vacuum unit can be replaced. See operation C3.) 

- condensation trap 

Mark position ol distributol 

Replacing distributol 

- condensation trap. 

c3 

Turn crankshaft until rotor points towards scribed ine 

in distributor body. 

Remove relaining screw and ift away distributor. 

C2 

Turndistributorto obtain accesslo vacuum unit relain' 

Replace vacuum unit. 

Turn distriburor back 1o mark. 

Fit: 

- condensatLon trap 

ChecUadjust ignition setting. 

To install: 

- turn rotor approx- 60" clockwise away frorn ine in 

distributor body. (Does not apply lo I20) 

- fil distributor 

rotor should now point lowards line. Reconnect 

vacuum hose and wire. Fit condensation lrap and 

reclamp dislributor caP. 

Checuadjust ignilion timins. 

0i a s 

rI 

rul 

r) 

t' 

0 

a 

I 

I 

( 

(

I 

(0 

,0 

t 

(c 

a 

I 

Di stri buto r, recon d it ioni ng 

lgnition system with contact brcaker assembly 

c5 

Checking side play of distributor shaft 

Max side play = 0.2 mm (0.079 in). Fit a new distributor 

if side play is great€r than 0.2 mm. 

Lubrication 

A = distributor grease P/N 1'16 

'1136-7 

or Bosch Ft1v4 

B = distributor Srease P/N 116 1136-7 or Bosch F v26

D i st r i b u to r, reco n d it i o n i ng 

lgnition system with contact breaker assemblY 

t T 

D. Testing distributor on a test bench 

Refer to the manufacturer's instructions at aL times 

when testing distribltors on a test bench 

The number on the side of the dlstributor is the Bosch 

D1 

checking dwell angle 

Conditionr New contact breaker po nls 

Run distributor at 3.5-4.2 revs/sec (200-250 r/m n) 

Adjust dwell angle to 59-65'. (ll is advisable to set dwell 

angle to 59' as angle increases as cam wears ) 

Increase speed to 25 r/s (1 500 r/min). 

Read off dwell anqle. 

Dwell angle musl not varY bY more than 2'from pre_ 

Check distributor for wear, damage elc ii deviatlon is 

Checking firing 

Run distributor at 3-5 revs/sec (200-300 ,min) on test 

Set distributor "0" to position which corresponds lo 

firing oi cylinder 1. 

Firing should be 0 90-180-270"- 

Check shape of atrows (or equivalent symbol depend 

lfdeviation is morethan 2"lhis indicales that side plaY is 

too large or cam is worn. 

D2 

D3 

Checking mechanical advance 

Run distribulor 3t 3.5 r/s (200 r/min) Ca ibrate meter' 

lncrease speed and check that mechanicaLadvance con_ 

forms to specification. 

rl) 

lf not,checkthaibalanceweightsarelubncatedanddo 

Also check spranss. 

0 

I 

I

,1 

i0 

,0 

I 

0 

Dist ributor, recondi tioni ng 

Ignition system with contact brcaker assembly 

D4 


Run distributor at 10 r/s (600 r/min). 

Calibrate meter. 

Increase vacuum and compare vatue to specificarion. 

35

Contents 

Breaketless ignition system 

Contents 


OPeration 

Ignition coil and HT leads .. .... .......... E1 E4 38 

Checking distributor cap and rotot ....... F1-F2 3s 

Checkingimpulsesenderandairgap...... F3-F4 40 

Checking ignition advance 

Basrc-sett;.g 

Mechanical advance . 

.... Fs F1] 

F5 

. . F6 

40 

40 

40 

42 

vacuumadvance 

F7-F1o 

R€tard ... .. .. ... .. ... . . . .. F11 

Reconditioning distributor ... ... .. ... ... ... ... Gl G28 

Replacingvacuumcontro unit ...... . . . . .. . G]-G2 

ReplacingdistrlbutorBlg-E23...... . G3-G4 

ReplacinsimpulsesenderBl9-823.. . . . G5Gll 

ReplacingdistributorB2T/828............... . G12-G21 

Replacins impulsesenderB2T/828 

G22-G21 

Checkingsideplay 

G28 

Lubrication. ... .. ... .. .. . . .. . G29 

Replacingcontrolunit.............. 

G30 

Testing distlibutor on test bench . . . . . . . . . . . . . G31-G34 

Wiring diagram .. 

Faultracing . 

36 

Page 

43 

43 

47 

49 

51 

52 

52 

53 

55 

56 

,0 

I 

0 

0 N 

t. I 

N

c 

0 

F 

(-% 

\.-:zEu 

Brcakerless ignition system 

,-/-]4. 

$# 

,-F...-, 

g

grcakerless ignition system 

38 

E. lgnition coil and HT leads 

E1 

Testing ignition coil. ballast resistorand HT leads 

. lgnition coil and ballast resistor at approximate y 

20"c (68"F) 

. All leads disconnected from components under test. 

Meesuring resistance ot ballast resistor 

B 20, B 19-8 23 

82t,824......... 

{Bolh resistors are connected in series) 

E2 

0.910.',t o 

1.010.1f) 

E3 

Checking ignition coil 

- check outer casing for cracks 

- measure resistance across terminats j ( )and 15(+). 

820,B19 823.. .... .. ... ... t.gio.to 

B27,B2A ... .. .. 0.510.1() 

- measure resistance acrossterminal l(-)and HTter 

All models: 9.5i1.5 k(). 

0' 

,[ 

0 

I 

I 

t I

t 

0 

0 

t 

I 

\,:: 

260 "r ..f 

0(l 

Checking HT leads* 

*A 24o A 

-\ip 

H 

nlj 

-i!- 

lko orvm tko 

reE & dli-, r 

oo 5,6ko/m 

1>#.-_--\] 

oo 

_-^_Ir_--- ',"'-L!4--_\.] 

- 

oo 56ko/h 

ij.i 

q -j:' 

260 

I 

E 

95>:- _rih 

oo 

ffi=FaP* 

l-_ _-,__it> 

lfl--_-----=a|- 

-Oq 

5.6[o/m Oo 

Besistance vatues are given tn K Q -|F.r neter of tength (tvleasure tead ln oder ta 

values have a permssable tolerance of ! 20Va. 

F. Distributor 

,r?5 II]i-- 

!+,-+:l-i- 

oo 

!-+JFqir-3 

Checking distributor cap 

240 

Distributor 

B reakerless ig n ition system 

E4 

oo 

oo 

g 

i? 

U 

1ko 

lko 5ko 

- burnt e edrodes, tracking 

- carbon brush for wear or damase 

compute carrect vatDe.) At 

hpofianrl To prevenl rela n ng sprinss ifom damas hs 

.olor do nol cra.k engine whe. d srr butor cap is ofi 

F2 

Checking rotor 

Rotor shou d be free from cracks and etectrode shoutd 

Measure resistance. Resistance = 5t1 kc]. 

39

Distributor 


40 

F3 

Checking impulse sender 

Measure resistance of s€nder' 

B 20, B 19-8 23 

095-t 25ko 

a21,828 . . . . . . . . . . . . . . . ........ ....0.54-0.66kO 

Check that no arcing io ea(h occurs 

lf meter pointer swings lo far right {ie open circuit) 

removo impulse sender and check if sender or lead rs 

checking air gap 

set rotor and stator tips opposite each other and mea_ 

sure air gaP wilh feeler gauge- 

6 cyl engines: min 0.3 mm (0-012 in) 

4 cyl ensines: min 0.25 mm {0.010 in) 

Adjusi if necessary' 

F5 

Checking/adjusting basic setting at'l 1.7-13.3 r/s 

(700-800 r/min) 

Disconnect hose f.om vacuum conl.ol unit. 

Adiust isnition settins to specificalion. See nexr page. 

F6 

Checking centrifugal advance al 42 r/s 

(2500 r/min) 

Check ihat ignitjon advance is according to speciiica_ 

tion. See next Page. 

lf not, examine centrifugal advance mechanrsm 

0 

( 

\ 

I 

I 

:t 

f 

e 

I 

I 

( 

I

t 

e 

CI 

I 

I 

Dislnbutor 

B reakerl ess i g n it ion system 

lgnilion setting (before T.O.C., disconnected vacuum contro unitl 

With effecl from 1976, vehic es for Sweden, Ausrralia, USA and Canada (also Swilzer and 1983,models)have deraits of 

ignition setting stamped on a plate lo left of engine compartmenr. 


Engine type Model year/Market Description 11.7 13.3 r/s 

(700-800 r/min) (2 500 r/min) 

B19E 1977 -83 

1984 

'10" 

28-33" 

24-24' 

B19ET 1942 a4 15. 21 26' 

a21E 1975-82 rr 

28 33' 

B21ET 1981 84 15" 21-26" 

823 E 1979-82 

1983 Canada 

Olher markeis 

1984 

/ 

1976 S0iAustra ia,SwedenSpecia vehicles 



r978:Sweden,Alsrraiaspecalvehicle. 8. 


10" 

5' 

10' 

25 30" 

25- 29' 

25 30" 

25 30' 

B20F 1975 5' 20 25' 

B21F 1976 

1977 USA, California 

Other markets 

1978 

1979 Californla, Japan 

Olher markets 

1980 Canada 

Olher markels 

1981 84 

A21FT 198r-85 

(900 /min) 

15' 

12' 

15' 

12' 

8' 

10' 

10" 

8' 

I' 

25 30" 

2A 32" 

25 30" 

2A 32" 

22-26' 

26 30" 

24 2A' 

22 26' 

22 26' 

12' 26-30' 

927 A 1917 79 10' 22 25' 

828 A 1980 84 10" 22-25' 

827 E 1975 

r976 Sweden, Ausrralia 

Other markets 

1917 7A ) 

r 979-80 

B28E 1980-82 

1983 84 

B27F 

- 1976 

191/ Ca iiornia 

Othe. markets 

1919 

B28F 1980-82 Adjust at 15 r/s 

1900 r/min)ior 

1981 California 

10" 

10' 

10' 

10' 

t0' 

10" 

12' 

10' 

10' 

10" 

30-34' 

22 26" 

30 34" 

30-34' 

25-29" 

25 29' 

27 3f 

21 32' 

2A 24' 

27 32' 

20 24' 

10' 20 24' 

41

Disttibutor 


42 


Connect a vacuum pump to vacuum unit. 

Run engine al idle speed and record ignition advance. 

Pump vacuum pump and check that ignition setting 

lf ignition se(lng does not advance check vacuum con' 

Check Bosch number on distribuior and turn to 

appropriate graPh on Pages 16-20 

Select pressure from graph and pump up vac'rurn 

pump to this value. Record ignition setting. Subtract 

basic ignition setting and check that value conforms to 

graph- 

Example: Bosch number 0 237 002 038 

B21F 1979- (Excl. California and Japan) 

You selecl d p essure of 200 mm Hg Crankshal de' 

grees al this oressu e 9 14'. Bdsic ignilror senirg rs 

10. whrcn meaas rhal t9-2a' shoL d be recorded dt 

t I 

! 

F8 

F9 

Fl0 

Check vacuum control unit for leakage 

connect a vacuum pump and Increase vacuum to 

67 kPa (500 mm Hs). 

Pressure should not drop by more than 13.5 kPm (l00 

mm Hg) during one minute. 

{ 

{ 

{, 

c 

I 

I

0 

0 

I 

0 

t 

Checking ignition retard 

Distti butot. recond itioni ng 

Brcake ess ignition system 

FI1 

Applies to B 19/2'l E and F-Turbo engines. 

Connect pressure gauge 5230 and pump 5496 to 

vacuum conirol unt, 

Start engine and run at idle. 

Record ignition advance. Increase pressure to 30 kPa 

and read off;gnition setting. 

lsnition se(ins should drop 3 7'. 

Disconnect pump and pressure gauge. Reconnect hose. 

G. Distributor - reconditioning 

Replacing vacuum control unit 

G1 

B 20: Rernove distriburorf rom engine priorto removing 

Mark position of diskibulor. 

Turn distributorto obtain access to vacuum unit retain 

Remove vacuum unit. 

Hook on vacuum unit 

Return distributor to original position. 

Fit: 

Check ignition setting- 

43

D i st ri buto r, rcc o n d i ti o n i n g 


G3 

Replacing distributor on B 19-B 23 

Removing 

Unclip distributor cap and remove dust cover. 

Turn crankshaftunti rotor pointstowards mark in dislri' 

butor body, see fig. 

Remove distribulor retaining screwand lift away distri 

G4 

Installing 

Turn rotor ap prox. 60' clockwise from mark in distribu' 

(Does not apply ro 820.) 

Place distributor in position and fit screw loosely 

Check that rotor points towards mark. 

Refit distrib!tor cap. 

Checuadjust basic ignition timing. 

Replacing impulse sender 

on B 19-B 23 

Removing 

nemove distributor as described in G3. 

Remove/disconnect: 

- retaining clips 

impulse sender screw, 

G5 

i[) 

{' 

i) 

{| 

I 

I 

I 

e

'[ 

JI 

' 

i 

Distri butor, recon d ition i ng 


G6 

Unclip lock ring and remove shims as applicable 

Remove rotor and lock pin 

Use lwo screwdrivers to pry rotor off shaft. 

Remove lock ring and ift oul impu se sender 

Fit new imoulse sender 

Attach lock ring 

GB

Distri butor, tecond itioni ng 

Breakerless ignilion system 

46 

Fit rotor and lock pin 

lf lock pin has a groove lLrn t lo raue Lenlre sl-a'l 

Fit shims and lock rins. 

Fitlconnect: 

rmpurse senoer screw 

retaining clips. 

Turn shaft and check for grinding etc 

G9 

Gl1 

Magnets will give slight resistance to turning action. 

Refit distributor. See G14. 

Check/adjust basic ignition setting. 

G10 

0l 

i 

It 

I 

I 

0. ( 

I

0 

0 

I 

N 

0 

Replacing distributor on 827, B2a 

tr 

D i st ri b uto r, rec o n d it i o n i ng 


827A, B28A start at operation G15 

Other engine typesl 

827 E 1975-74 

Proceed to G15. 

Remove front Dart of inlet manifold 

Disconnect link rod from throtile pullev. 

G12 

G13 

G14 

Remove air-luel control unit retaining screws 

Lift unit up slightly. 

All B 27, 828 models 

Unclip distributor cap and lift o!1 dusi cover. 

G15 

Turn crankshaft until rotor points towards mark in dislri 

Remove/disconnectl 

Remove distributor.

Distributor, recond itio ni ng 

Breake ess ignition system 

48 

v 

lnstalling distributor 

Turn rotor to point towards clip 

Check setting 

Refit inlet manilold 

Tightening torque 10-15 Nm (7 '11 

ft.lbs-). 

G16 

G17 

Rotor should point towards mark in distributor body. 

Fit retaining screw loosely. 

G18 

827A, B28A proceed to G21 

827 E 1975-78 proceed to G20 

Other 827 E modefs and 827 F, B28E and B28F 

lnstall air-fuel control unit 

Reconnect link rod to throttle pulley. Tighten airfuel 

G19 

{) 

t, 

0)l 

0)( 

{. 

{ 

I 

(

t- 

(f 

0 

h 

0 

I 

I 

i:@ 

Fit air filter 

aI827, 528 

ChecVadjust basic ignition setting. 

Replacing impulse sendel 

on B27lB28 

Distribu to r, rccon d ition i ng 

B rea kerless ig nitio n system 

Remove distributor according to G12 G15. 

G20

Di stri buto r, recondition i ng 

Breakerless ig n iti on system 

t^n 

50 

(._, 

-+lL 

a(o)} 

\

0 

(o 

i| 

CI 

0,2 mm 

Refit: 

Di stri butor, reconditio ni ng 


Turn shaft and check for grinding etc 

G26 

G27 

[4agnets wil offer slight resistance to turn]n9 action. 

Refit disrributor. See G16-G21- 

Check distributor shaft side play 

l,.4ax. side play = 0.2 mm (0.008 in). 

G28 

lf side play is greaterthan specifled, replace distributor. 

51

Distributor, recond iti on i ng 


52 

Lubrication 

G29 

Distributor grease (P/N1161136-7) 

or Bosch lubricant 

Ft1v26. 

Replacing control unit 

G30 

Make sLrre that rubber seal remains in bottom of connector 

when disconnecting conlrol unit. 

,f) 

'4) 

f 

a 

I 

I 

t", ( 

f)

''f 

(lt 

'i 

(l 

I 

- 

Cran[shafl degrees 

- D strlblror degrees 

1 

2 

p< 

\s{ 

Zero ser ai (360 th n) 

Testing distlibutor on a test bench 

centrlugal advance begins 

Cenrr iugai advance ends 

Absollte lm r of gn r on advance 

Distributor, testing 

Breakerless i g n i t t o n system 

Refer to the manuiacturer's instruction at 

when testing distributors on a test bench. 

The number on the side of the distributor is ihe Bosch 

''rll:::!= 

;s 

'{f' L .:- 

Calibrate test bench 

6 connecr ng lead to distributor 

7 Power supply (14 V) 

Llohhing (, )symbo s indicale danserous 

hi€h vohage terminals 

G31 

Set zero at distfibutor shaft speed corresponding to 

zero advance. See diagrams on pages 15 lT.Thiscompensates 

for the electronic advarce f.om the impulse

Distributor, testing 

Breake 

+s 

ess ignition syslem 

Checking firing 

G32 

Set distributor "0" ro posltion which coiiesponds lo 

firing oi cyl 1. 

Firing should bei 

4 cyl: 0 90 180-270 

6cy:0-75 120 195 240 315 360 

lMax- deviation = I1.5'. 

Check shape of arrows (or equlvalenl symbol depend 

lfdeviation is morethan 2'this indicates that side play is 

too large. 

G33 

checking centrifugal advance 

Run distributor at 3.5 r/s {200 ,min). Calibrate meter. 

Increase speed and check that cenlrif!gal advance conforms 

to specification. 

lf no1, check thal balance weights are lubricated and do 

Also check springs. 


Run distributor at 10 r/s (600 r/min). 

Calibrate merer. 

G34 

Increase vacuum and compare value to specificat on- 

{, I 

0) I 

I 

f) |

I 

.0 

'.0 

li 

(f 

I 

4 cyl 

6 cyl 

Wiring diagram 

B reakerl ess i g n ition sYstem 

Wiring diagram, breakerless ignition system 

1975 78 

Err 

--t1 

Y 

1s75- ,I,7a l- | 

I 1979 - 

1979 

4BNBN 

a- 

-- 

!-/" E :rl [r: 

fi' fr | ' TTrT i- 

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lf-. I 

l.lt-[U-l !r!,J!LJJtrJ! l.]lil - JJ!u-t 

L-, 

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er.r 

B"|::Q 

-@!u 

-r i- u-, .- I .i4+ 

;r1+ 

--@ 

J 

rmr'rlrl." 

h ." /|1+it .-lr@ 

1975 -1978 

1979 

^'r'a 

C = Balast fesistor 

55

Faull Ttacing 

I reakerl ess ign iti on system 

56 

9 

E 

!3E 

;i; 

o s! ; 

-9 ii o 

E: Ei E B 

ii;.r, 

! 6:9': 

g) 

i!i9i9 

9! 9 - 9 ^ 

-:-:6: 

J: h- 

P :;: 

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e 

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!E !; 

,9iec; 

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I t; 

a +6 

:' :-6 

z 

f:] 

I al 

lHrl 

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I 

Conlents 

General instructions . .. .. 

Connectors and earth points... .. 

Modilications to 1983 models.. ... 

lgnition col and HT leads 

Checking distribuior cap and rotor. .. 

Checking basic ignition setting .... 

Checking/adjusling microswilch 

B 2t L-\,10C r98r, B 2 t--Cr 1982 

B 2r F-LH 1982 

B 23 f LH 1983 1984 

B 230 T-l Ll 1985- 

Checking ignilion advance. 

cenlri'Jgaladvance 

dserl a.gle . 

Recondilioning distribulor 

replaci19 dislr bulor 

Replacing distributor P/N 1332684, 

1336737, 1332587 

replacrg mpLlse se.de. . 

reoldLi19 

dislr bulor 



Fault tracing 

Computerizedignition system 

(P/N 1306059)........ 

Operation 

H1_H4 

J1-J4 

Kl-K8 

L1_14 

t\.i1-t\43 

M4-M10 

M5-1\46 

I\t7 

M8-M9 

M11-M15 

M11 

M12 

M!3 

[,414-M15 

N1_N4 

N1-N2 

N3-N4 

N5-N14 

N5-N8 

Ng-N14 

N15 

Page 

58 

59 

60 

62 

63 

63 

64 

64 

65 

65 

65 

66 

66 

66 

67 

67 

67 

68 

68 

69 

70 

71 

5l

General instructions 

Computeri zed ign ition system s 

58 

H. General instructions 

Always switch ofi the ignition when disconnecnng/con 

necling ignition system terminals 

H2 

Begin by€hecking all relevantterminals 3nd conneclors 

before carrying out extensive faull lraclng procedures 

H3 

Never let spark iengthexceed 

5 mm when checking 

ignirion system circuitsor 

contro unit may be damaged. 

Consequendy, connect spark plug to HT ead and earth 

plug via engine. 

CAUTION: 

To avoid damaging the conneclor sleeves DO NOT DIS- 

CONNECT CONNECTOR lrom conlrol unil when checking 

vollage. The volt-/ohm-meler should be connecled 

direclly lo the wires. 

o 

.{ 

0, 1 

ol 

rl)

! 

0 

0 

I 

(o 

,I 

I 

J. Gonnectors and earth points 

Control unit 

Distributor 

Bulkhead 

Control unit earth 

Connectors 

Com pute i zed ig n ition systems 

JI 

J2 

J4 

59

Guide sleeves 

Com putenzed i g n it ion syste ms 

60 

].. 

K. Modif ications 

Connecting guide sleeves 

2mm 

+tt-tr 

K1 

With eifeci from 1983 models lhe dislributor connector is 

equipped with gulde sleeves. These sleeves can also be 

fitted to eadier models and to the conlrol unit conneclor. 

Guide sleeves P/N 1 324 909-9. 

Note: From modelyear 1984. the guide sleeves are 

installed in the control unit at lhe taclory. 

Note: The wiing harness for lhe control unil musl be 

rcplaced il the connector has been disconnected 

or when replacing the control unrt. 

K2 

Orill lor connecling guide sleeves 

P/N 999 5268-1. 

To install guide sleeve, place sleeve in the drift and check 

that it protrudes 2 mm (0.08 in.) 

f nol, shone. loollo drrenson sl'own adacenl 

Easier lo insert guide sleeve it opening s countersunk. 

K3 

Caretully clean connector on distribulor and control 

unit 

Withdraw connector from distribulor. Scrape off PVC 

and oxide deposits from all lhree pins. 

Use tool 9549. 

Apply grease to pin. 

Clean female connector with a tapered file. 

Withdraw connector from control unit. Scrape off oxide 

from around pins 3, 5 and L 

Place guide sleevein 

tool 5268 

Pack (A) with grease. Repeat for each sleve 

Inse( sleeve in tool, 

K4 

o 

j 

I 

I

I 

3 

,I 

I 

- 

_= 

_::) 

-f 

-- 

- 

_:) 

_l 

::l 

- 

1o 1Oo 

3a-80 

40 70 

Guide sleeves 

Com puterized ig n iti on system s 

Install guide sleeves on connectors 

Distributor: 

On all pins. 

Control unit 

On pins 3,5 and 9. 

Check 

Replacing sleeve insulators 

K5 

K6 

K7 

Press on guide sleeves so that at Least 2 mm (0.08 in) of 

pin is visible above sleeves. 

Reconnect terminais and check function. 

Withdmw connector 

Detach rubber cover and remove insulator. 

Fit new insulator P/N 949597'9. 

Reconnect connector. 

K8 

61

Com puterized ig n ition systems 

- 

iesi- ll l+-r+ 

'--n 

oa 5,6 ko/m oo u 

iE6 -r1 _ i r-€< 

1ko 

L. lgnition coil and HT leads 

5ko 

L1 

Test conditions: 

. lsnilion coil and leads should be ai a lenrperature of 

about 20'c {68'F). 

. All ieads must be disconnected trom components 

when taking measurenrenls. 

Checking ignition coil 

check outer casing for cracks etc 

- measure resistance acrossrerminals I (-)and 151+). 

Aesistance = 1.1-1.3 Q. 

L2 

L3 

measure resistance acrossterminal 

1( ) and the 

high tension te.mina. 

Reslstance : 9.6 '11.6 

kO. 

Checking HT leads 

Resistance of HT lead between distriburor and ignition 

coa shou d be 2 3.5 kohms which is equivalent to 5.6 

L4 

l:L) 

Spd.l p ugs supp esso|esisldlce - 5 kol_ns 

c 

Resistance of cable connector on distriburor cap = 1

l" 

i 

I 

(f 

j 

,I 

M. Distributor, general 

Checking distributor cap 

tracking, burnr terminals. 

Distributor, general 

Computerized ig n hio n systems 

Noter Centfe terminal is not spring loaded. 

Checking rotor 

Two types of rotor are in 

checking Hall pick-up wire 

M1 

M2 

use. Use only new type for 

M3 

lMake sure that the wires cannotbe 

damaged by the 

M4 

Checking/adiusting basic ignition setting 

Eefore checking ignition setting check function of 

| 

_- 

Noie: see p"ge 65 for co'tect ao.:slmerr orol1f_l

Distributor, general 

Cofiputelized ignition systems 

R*...q*5to' 

64 

M5 

Checking microswitch on 821 F-MPG 1981 and 

821 F-Cr '1982 

Connect a test lamp between battery (+) and terminal2 

(yellow wire) on microswitch. 

I amp snoulo be off when engrne is idl,ng. l' lamo is on, 

adjust microswitch as described below. 

Turn throttie pulley and check that lamp lights- 

Adjusting microswitch 

M6 

Pl6ce a 0.4 mmfeelergauge between adjustment screw 

Unscrew microswitch retaining screws and turn switch 

unlil lamp lights. 

Checking 

Place a 0,2 mm feelergauge between adjustnrent screw 

Lamp should light. 

Remove feeler qauge and insert a 0.4 mm feeler gauge. 

Lamp should be off. 

Checking microswitch on 821 F-LH 1982 

M7 

Disconnect connector from vacuum switch. Connecr a 

test lemp behveen batre-y ( ) a.ld orange wi'e o. 

Start engine. 

Test lamp should light with engine idling. 

Increase engine rpm and check that lighl goes oul. 

lf not, check hose to vacuum switch. lf intact, rep ace 

CI) 

o

il 

0 

\A. 

q. rl 

€ 

DisLtibutor, general 

Com puterized i g n iti on systems 

Checking microswilch on B 23F-LH 1983-1984; 

B 230 F-LH 1385- 

M8 

With engine ofl, turn throttle puLley slowy and isten to 

mlcroswitch. A cick should be heard when throltle valve 

Adjusting microswitch 

M9 

Unscrew relaining screws. 

Turn switch clockwise slightly. Then turn swilch back 

until it contacts slop, but no funher as throttle valve wi 

Tighten retaining screws. 

M10 

Check lhat basic signition setting is 12oa2'at 

12.5 r/s (750 r/min) 

Air condiioning disconnected as applicabLe. 

Adlust ignilon selling by turning dstributor. 

Increase engine speed to 2000 rpm for 5 seconds. 

Lel the englne idle and check idle quality. 

Make sure the dle is slable and wthin specifications as 

variations coud afiect the liming. 

Check centrilugal advance 

Dsconnect vacuum hose lrom distributor. 

M11 

Run engine at 42 r/s (2 500 r/rnin) and check that ignition 

advance is l6-24c belore T D.C. ior B 23 F, B 230 F and 

22-30o before T.D C. tor other models. 

ll incorrect, replace conlrol unit 

65

Checking, control unit 

Com puterized ign ition system s 

66 

Mt2 

Check vacuum advance 

Run engine at 25 /s (1500 r/min). 

Disconnectvacuum hose. Becord ignition advance. Re_ 

connect hose and check that advance allers. 

lf not, check for vacuurn at control unil {check suction at 

lf vacuum, but no advance, replace control unit 

Check dwell angle 

Read off dwell angle at idle. 

M13 

Dwell angle = 36 38'. 

Increase engine rpm and check that dwell angLe increases. 

if no increase is recorded, replace control I'nit, 

B23F 

Checking knock sensor 

M14 

connect a volvo Monotesrer or equivalenl test nreter. 

Srart engine (AC disconnected). 

Increase engine speed and mainlain al sel leve by e.g. 

pLacing screwdriver across throttle pulley. 

M15 

Tap plug on rishtside on cylinder blockwith a hammer' 

lgnition should retard by max6'and return aulomatrcal 

t';

0 

(0 

il 

rl 

I 

Distri buto r, recon d i ti o n i n g 

Com puterized i g n iti on system s 

N. Distributor (Ghrysler), 

reconditioning 

1 (P/N 1306059) 

Replacing Hall pick-up 

Remove: 

springs retaining Hall pick-up 

- drsconnect connector 

remove Hall pick-up. 

lnstall: 

- Hall pick,up 

springs 

Check that wires cannot be damaged by rotor. 

Refrl disrributor cap and reconneLr co.lreclor. 

See p€ges 60-61 for installins gu de steeves on connectors. 


Remove: 

- HT leads from distributor cap 

N2 

N3 

Tu.n crankshaft until rotor points towards rubber 

Disconnect connector. 

Remove distributor. 

Install distributor 

Tubularpinprotrudesmoreononesidethanlheother. 

Turn shaft until pin is opposite groove in distribLrto. 

Fit: 

distributor cap and reconnect HT leads. 

Reconnect connector. 

Checvadjust basic isnition timing. See operation M4. 

See pages 60 61 foi instal ing quide sleeves on connectors. 

67

Djst rj b u to r, recondjtion i ng 

Computerized ignitton sYstems 

68 

Distributor (Bosch), reconditioning 

Type 2 (P/N 1332684, 1336737,1332587) 


Remove/disconnect 

HT leads iiom cap 

N6 

Set cyl 1 ro T.D.C. 

Turncrankshaftunti rotor po nls towards mark in distri 

Dlsconned connector. 

Remove distribulor 

lnstall distributor 

N5 

Check that cyl 1 is at T D-C 

Turn rotor approx. 60' c ockwise from rnark ln 'listrib! 

Rotor should now point towards mark n distributor 

ChecUadlusl basic igniiion t ming. Se€ l!14. 

S€e pages 60 61 ror nsla I ng suide s ecves on conneclors 

CI 

r:l 

f) 

o 

r

,) 

I 

Replacing Hall pick-up 

D i stributor, recondition i ng 

Computerized ig n itio n systems 

Nole: hp trd Sr.tL1 >-oJld -or be epla Fd on 

irbutors wilhii the lirst year oi warranty. 

cornpete disiributor must be replaced 

Bemove dstr butor according lo operauons N5-N6 

Mount dlstrbulor in a vise (NOT SOFT VICE JAWS TO 

PREVENT DAI\,iAGE). 

Reease crc p retaining lrgger whee. 

NlA 

Pry oii trgger whee wiih two screwdrvers (use roundshalt 

screwdrvers 5mm diameler) 

Place tips ol screwdrve.s on sleel hub. as shown. 

Take care not lo damage trigger wheel 

lfvqger whee s benlduring removal ir m'rsr be 

Take care not lo lose ock p n 

Remove 

- Hal pick up retaning screws 

- plaslic p n (A) lor connector 

ru9 

69

Dist ributor, recond itioni ng 

I sa-4 

" a-, 

a 

Remove HaLl swtch and connector. 

lnstall: 

- New HalL switch and connector 

circlip 

- retainng screws and plastic pin (1) 

lnstall: 

- trgqer wheel (2) 

- Lockpin (3) 

- circlip (4) 

- condensation trap 

Instal diskbulor accordtngto operations N7-N8. 

Control unit 

N13 

N15 


Check centrifugal and vacuum advance accordrng to 

operalions M11-M13 after instal ing control 'rnil 

See pages 60-61 lor lnsla ling g!ide s eeves o' conne'rors

9 

0 

I 

I 

I 

I 

BL 

CN 

BN 

SB 

Wiring diagram, computerized ignition systems 

B 2'I F_LH, B 23 F_LH 

t"'," 

Llllru rn!8 


Com puterized ig n itio n systems 

D = Microswnch a2r F I 

H = Mlcroswtch B2l F LH Jerronic 

J - lvl cr;swiich 823 F 

K = Knock sensor B23F 

_,,rxrt]x-D 

-l 

_ 

! _rl-lfD 

71


C om puteri zed ignition sy stem 

/2 

Wiring diagram, computerized ignilion system 

B 230 F-LH, 198s- 

I lgnition switch 

C Breaker unit 

F lgnition coil 

G oistributor 

214 Control Unit 

LH Jetronic 0 

Heated reaf w ndow 

Overdrive

NOIES 

Oi 

'D( 

0( 

o 

t). 

t' 

o

o 

-E 

Fault tracing chart 

B 21 F-MPG/LH B 23 F-LH

o 

0 

Adllsl advance by lurn ng dlstr 

I 

Check that ign tion advance s 12' 

al r2.5 r/s (750 r/min). 

Checl conlrol !nil earth 

T!rn ofi ignition. Disconnect conneclor 

Check for vo tase €t biue wire. Voltage? 

i 

I 

i

) 

? 

,.,., 

D sconnect 3 pole conneclor 

8r dge pi.s B and Cwth piece 

L_". 

olsconnecl HT leads irom disrri 

C5p.l fo' ,ohage ar rorn ral A or 3-poie Lorne' tor 

Check ior vo lage at termi.al 15(+) on igni- 

.5p.r wtrc( bdrwear g1t on rwrt a dnd ro ,o. r 

Notei Nol 12 V. Lamp dim. 

gnilioh shou d be ofi when 

d sconnecrn9 conneclors. 

Check thal each pl!g sparks 

Repace Fallpick !p in d srriboror. 

Che.l wrre lo dr5hburor.

o 

0 

o 

o 

{D 

0 

C

o 

-E 

1o 

o 

Fault tracing chart 

B 230 F_LH

o 

Adjust gnrlon advance by turn.9 

I 

check lhal ign tior advance is 12" 

ar 12 5 r/s (750 rpm) 

Reler ro SB 34:105 for selting 

f. /42.4 

€?. 

ll 

A{i 

ca 

' 

Posh lest lamp probe through b ue w.e covero. 

rconlro unt. Check tor vollage 

Nole: Oo nol disconnect connecror lrom con- 

t 

I 

check control unrt ground connecto. 

i 

"-

D sconnect 3 poe connector 

Nolei Check lype olconneclor. 

Bosch (1) Chryslef (2) 

Co..ect a br dgew re across B 

Dsconneci HT ead irom dslri 

Check ror vollageatierminal 1 5(+)on gnil on 

Check wires connected between anilon switch and conirol unt 

Che.l lor vo lage ar terhrnal A on 3-pole connecror 

Nole. Nol 12 V Lamp d m 

gntion sholld be oil when discon- 

Check lhal each Pug sparks 

Push testrampproberhrough green w re cov 

oK- 

Nole: Also repLace cabe harnes 

Check conlro uni connector

€ 

0 

o 

o 

D 

e 

0

7 

if 

'l 

Dwell angle 

Checking. A €fg nes (4 cyt) 

Checking B 2l F-MPG, B 21 F-LH, 

B23F LH.823OF-LH, ., 

A eng nes {4 cy) . . 

EIF efg fes A-enqines 

(6 cy) 

Operation 

83 84 

84 85 

Mt3 

Cenlrirugal advance 

B 17A-B 23 A. B 19 K, 

87 

B]9EB23E ., 

F6 

a 2/A B28F 

F6 

821 MPG B23F LH.B23OF-LH M8 

821 F MPG, B21F LH. B23F-LH. 

B23OF LH 

Repacement . 

Check ng dwell ang e 

Delay valve 

Oist buror {B 17 A-B 23 A) 

Remov ng-nstallng . 

Sde pay 

Testing on lesl bench 

Lubrcation 

. . . . 

Disrriburof (B 19 E-B 23 E) 

Bemoving- n sta ling . . 

Bepacemenl oi impLr se sender 

Side play 

Testing on tesl bench . . 

A2 

E2 

J1-J3 

B3 

B4 

B19B23E.B27AB28F 

B2] F MPG.B21 F-LH,B23F LH, 

G30 

B23OF LH 

N16 

B9 

c3 c4 

c5 

D1-D4 

c6 

G3 G4 

G5 G11 

G28 

G31-G34 

lndex 

Page 

28 

28 

66 

26 

38 

29 

40 

40 

65 

59 

2A 

28 

52 

70 

30 

33 

34 

33 

53 

Dislributor (B 21 F-MPG-B 23 F,LH, I 230 F-LH) 

Removing nstaing. .. .. .. N3-N4 67 

Fep acenrenlof Ha lsender, type 1 N1-N2 67 

B epiacernenl of Hall sender, type 2 Ng-N I 4 69 

Distriburor (B 27A-B 28 F) 

Rernovlng-insta ing. c12 c21 47 

Bepacement ol mpulse sender c22-c27 49 

Side play G28 51 

Tesling of lest bench ..... G31-G34 53 

Earlh points . . 

Engine speed control 

B21 F.MPG, B21 F LH, 823 F-LH. 

8230F-1H... .. .. .. 

Fault lracing 

E/Fengines.... 

B 21 F.MPG/LH 2] F-LH 

B 230 F-LH 

Firingorder..... 

Groundpoints... 

lgnition coilg 

B17AB23A 

BlgE B23E.B27A-828F. 

821 F.MPG 821 F_LH 823 F-LH, 

8230F-1H.......... 

lgnilion retard 

B 19/21 E and F,Turbo...... 

Knock 3en30r 

Lubicalion, dBtributo. 

B17A-823A....... 

B 19 E B 23 E. A27 A-A 27 F . 

rvl l 

A]-A3 

E1_E4 

Ll L4 

F11 

59 

65 

56 

75 

77 

26 

38 

62 

M14-t\,415 66 

c6 

G29 

B 21 F-MPG, B 21 F-Ct 1982... M5 t\46 

B 2l F-LH 1982 

M7 

B 23 F,LH 1383 1985, B 230F-LH M8 M9 

B17A_823A 

B]9E-.823E.827A-B2AF. 

B2] F.I!IPG,821 F LH, B23F-LH. 

8230F-1H......... 

Wiring diag16m 

821 F MPG,B2] F-LH,B23F LH. 

8230F-1H.... 

8230F-1H..... 

Olher E/F engines.......... 

K7 

B8-Br4 

M9 

33 

52 

64 

64 

65 

30 

71 

72 

55

Service Manual

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