Service Manual
Service Manual
Service Manual
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<strong>Service</strong> <strong>Manual</strong><br />
c Repairs<br />
and maintenance
Volvos a€ sold in versions adaptecl for different mark€ts.<br />
Th€se adaptalions depend on many facrorc including le-<br />
9al, taxation and market requirem€nts,<br />
This manual may therefore show illustrations and text<br />
which do nol apply to cars in your country.<br />
o<br />
a'<br />
o<br />
a<br />
o
0<br />
0<br />
Contents<br />
Group 34 lgnition system<br />
Soecia lools<br />
General nstructions . .<br />
Specifications: lgnition sFtem with contact br66ket .... ... ... ... ... ... .<br />
Breake eBB ignitron 3y3lem ..........<br />
Computerized ignition 3y3lem .... ......... .. ..<br />
Inspection of lgnition sy3t6m with contact breakeB B 20 A, B 17-A 23 A<br />
Breakerles. ignilion syltem B 20 F, B 19 E, ET,<br />
B 21 E, ET, F FT,823e,827128 A.E and F .........................<br />
Compurerized ignition sFiem B 21 F-MPG (1981), B 21 F-Cl (1982),<br />
B 21 F-LH (1982), A 2s F-LH 0983-1984), B 230 F-LH (1985-) ..........<br />
Index page 79<br />
Indicates revised informalion:<br />
Order numbor: TP 30432/2<br />
We rcserve the right lo make alterations<br />
withoul prior notilicalion.<br />
O 1985. VOLVO CAFS OF NORTH AMERICA,<br />
A Dvson ol Volvo Norlh Am€ica Corporation<br />
Group 34 lgnition sysLem<br />
Page<br />
2<br />
3<br />
5<br />
10<br />
2-l<br />
24<br />
37<br />
57<br />
Contents
Specialtools<br />
,: E-,1-.t<br />
v!a' - - {'<br />
-t_*_.- , ,:<br />
Special tools<br />
Ohm-Oiode Tesler<br />
Monole3ter - Owell angle, ignition setting<br />
Stfoboscop€ - lgnition seliing<br />
Flywheel Adapter - lgnition setring lvlY 1984-
lgnition system - general instructions<br />
0 Measuring resistance<br />
o<br />
1e8o: VC 244 45<br />
1981<br />
: YV1 AX 454X<br />
19ao: 245<br />
1981 : YV1 244<br />
!15<br />
40<br />
I<br />
L 1 0ooooo<br />
E10OOO0O<br />
L 1 000000<br />
18 T1000000<br />
General instructions<br />
Before measuring the resistance of a compononl make<br />
sure that all leads have been disconnected from it.<br />
Resista nce values specified in thismanualapplyat20"c<br />
(68'F).<br />
Electronic ignition systems<br />
Electronic ignition systems operate at very high vol<br />
tages - often in excess of 30 000 V. Such hig h volrages<br />
are a danger to life and special precautions musl be<br />
laken when working on vehicles so fitted.<br />
The ? symborused (hroughoutth sTalua Indrcates<br />
terminals where dangerous high voltages can be ex<br />
Engine type and model year designation<br />
11 = 4317 {820 1975 761<br />
2:819<br />
24=E<br />
26 = E Turbo<br />
4=821<br />
44=E<br />
45=F{5}<br />
46 = E-Turbo<br />
48=F(8)<br />
49=F(9)<br />
6:827 {1975-79)<br />
64 = E (-1980)<br />
65=F<br />
6 = 828 (1980-)<br />
62=A<br />
68= E(1981 )<br />
69=F<br />
8 = A23IB23O<br />
81<br />
84 E<br />
88
General instruclions<br />
0 231 -....<br />
JFU 1
t<br />
i$<br />
r0<br />
tgnition coil<br />
,0 820<br />
BI/ B.J<br />
Ignition system with contact breaker<br />
Specif ications<br />
lgnition system with contact breaker<br />
B20A,817_8234<br />
Res stance of pr ma.ycoi (acrosslerm na s 1l ) and l5(+) )<br />
Resistance of secondary coi lacross rermina s 11 )and HT<br />
Bollo r'p i5to<br />
Spark plugs<br />
T ghlening<br />
torque<br />
{uno €d pl!s)<br />
High tension leads'<br />
A-engines -1978<br />
2.8510.r 5 ()<br />
9.512.5 k()<br />
Bosch W 7B<br />
Eosch W 7DC<br />
0.7 0.8 mm<br />
25-5 Nm (1813.5<br />
fi.lbs)<br />
A-€nganes'1979-<br />
1.910.1 0<br />
d$<br />
a-<br />
{r 240 240<br />
1ko 0(ym 1kn<br />
1976-aO d__r-'- --1 1975-76<br />
,o-.<br />
_}.*_<br />
+'E--------.------:c+<br />
9.51t.5 kO<br />
1.310.1 O (0.9:t01<br />
oo 5,6 ko/m oa 1ko g a/m 1k')<br />
0 c) 5,6 ko/m oo<br />
_---<br />
oo O a/m 1.4 kf)<br />
-f\}.__ Jr'-1..Jr\<br />
!.,2_--.J,<br />
1ko O Orm<br />
'Nore: Fes,srance values are gtven in K O perneter af length. (Measure tead in otder ta campute corcct value ) All<br />
0 vatues have a permEsable tolerance of . 20o/o<br />
5ka
Specifications<br />
lgnition system with contact breaker<br />
Rotol<br />
Resrstance.<br />
Firing ordel<br />
lgnition setting<br />
420<br />
1 3-4-2<br />
5r1 ko<br />
817-823<br />
'l-3-4-2<br />
With effectfrom 1976, vehiclesfor Sweden, Australia, USAand Canada {also Switzerland 1983'rnodels)have details of<br />
ignition setting stamped on a plate lo left of engine compartment.<br />
SDecial vehicles<br />
lgnition setting (before T.D.C., vacuum control unit disconnected)<br />
Engine type Modelyear/Marlet 11.7-13.3 r/s<br />
700-800 r/min 2500 /min<br />
B 17A<br />
'1979<br />
84<br />
'12"<br />
2A 32'<br />
819A 19'/71t<br />
1978 ltaly<br />
1978 80 Other markets<br />
1981-84<br />
" Sweden:245wilh 8W35,8W55, M 46andspecialvehr. 10"<br />
211979-80:Sweden,Overseaswithenginelypes49ST55and49ESllandspecisvehicleswithmanuagearbox.. .. 10"<br />
Specalvehicleswithaulohatcsearbox.. .. .. ...... .. .. .. 8"<br />
3r240wiih<br />
enginetype4gS 528 r5'and32-36'<br />
')<br />
lgnilion setting can be retarded lo 5' if, despite uslng 98 ociane f!el, engine is prone lo pre ignition (knockins).<br />
15'<br />
15"<br />
12"<br />
10'<br />
Special vehicle refers 1o heavy veh c e rypes slch as 245 GL with auiomatic rransmission.<br />
32-36'<br />
32-36'<br />
2A 32'<br />
26-30'<br />
B19K 17 23"<br />
B20A 1915-76 10" 23-21'<br />
B21A 1975<br />
1916 7711<br />
1978 Sweden3)<br />
Other markets<br />
1979-8o'z)<br />
1981 Scandinavia,Australia<br />
Olher markets<br />
'1982-83 Scandinavia,Australia<br />
Other markets<br />
1984 Scandinavia,Switzerland<br />
Auslralia<br />
Europe<br />
Canada<br />
B23A 1981-82 Scandinaviaa)<br />
1982 Other markets<br />
1983 84 Europe<br />
Overseas<br />
'12'<br />
'15'<br />
12"<br />
15'<br />
12'<br />
10"<br />
12'<br />
'10"<br />
12"<br />
10"<br />
10"<br />
7"<br />
5"<br />
5'<br />
24 24"<br />
32 36"<br />
2a-32'<br />
32 36"<br />
28 32"<br />
26 32'<br />
2A 32'<br />
26 32'<br />
24-30"<br />
2A-32'<br />
20 26"<br />
26-32"<br />
17 23"<br />
24-30'<br />
2t 26"<br />
19-2{<br />
17-22"<br />
19 2q<br />
0)<br />
0'
qA<br />
i0<br />
i0<br />
t<br />
.,<br />
Distributor<br />
Engine type<br />
B17A 1979-80<br />
1981 84<br />
B19A 1977<br />
1978<br />
1979<br />
1980<br />
1981-84<br />
lgnition setting<br />
nttl<br />
(App ies io ai markeis un ess otherw se<br />
Thailand, Malaysia, ndonesia<br />
Bosch n!mber at bottom<br />
stamped n disiributor body.<br />
lgnition system with contact breaker<br />
0 231 176 103<br />
0 185<br />
0 185<br />
0 185<br />
6 103<br />
6 103<br />
0 185<br />
6 103<br />
0 185<br />
Variation of lgnition sening<br />
Variation of ignition setting<br />
1 266 478<br />
I 219 661<br />
1 219 661<br />
1 219 661<br />
1 266 478<br />
1 266 418<br />
1 219 661<br />
1 266 474<br />
1 219 661<br />
B19K 1984 0 302 1 332 410<br />
B20A 1975-76 0 085 462 657<br />
B21A 1915<br />
1976 11<br />
1978<br />
1979<br />
1980<br />
1981 83<br />
1984<br />
823 A 1981 82<br />
1983 84 Europe<br />
H irl<br />
'.,4 :)<br />
o2 1 170 08<br />
Other markets<br />
Sweden, Australia, Canada, Ove.seas<br />
Olher markets (inc. Thailand, Indones a)<br />
Sweden, Australia, Canada, Overseas<br />
Other markers (inc. Malaysia, Thailand,<br />
Sweden, Auslralia (1982<br />
also Switzerland, canada)<br />
is:t,'<br />
Oiagram key:<br />
lsl<br />
l-r I<br />
@<br />
0 134<br />
0 173<br />
0 185<br />
6 103<br />
0 185<br />
6 103<br />
0 185<br />
6 103<br />
0 185<br />
103<br />
o 244<br />
0 185<br />
0 302<br />
0 284<br />
o 247<br />
0 302<br />
o 241<br />
463 692<br />
1 219 625<br />
I 219 661<br />
1 266 414<br />
1 219 661<br />
1 266 478<br />
1 219 661<br />
1 266 478<br />
1 219 661<br />
1 266 474<br />
1 306 792<br />
1 219 661<br />
1 332 410<br />
1 306 792<br />
306 872<br />
332 410<br />
306 872<br />
:s3b ""'i;''o<br />
t:<br />
Ai L E'H
lgnition system with contact breaker<br />
lgnition setting graphs<br />
.<br />
ErN<br />
o<br />
o<br />
Ei za -)<br />
-T<br />
I
9<br />
r-B<br />
l@;<br />
o];e<br />
:@:l ?9<br />
, LU<br />
!:" o@ |<br />
69tsc<br />
-1;o<br />
Nl;-l<br />
3_<br />
9<br />
:*;:<br />
6P: c +l qU<br />
: 6
B rea kerless ig n it i o n system<br />
Frpr rrod. gdo<br />
T 9h'P1rnq ro qJp rulo: pd o Jqr<br />
10<br />
Specif ications<br />
Breakerless ignition system<br />
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<br />
lgnition coil<br />
Resistance of primarY coi<br />
acrossterrnlnals l{ )and 15{+)<br />
Resistance oi secondarY coi<br />
lern ra lacro55lpr-rndls ll l"ldtTl<br />
Ballastresistor .. ..<br />
Spark plugs<br />
4.cyl engines<br />
B20F<br />
1976<br />
819E, B21E 1975 84 Bosch W6DC<br />
B 19ET. B 21ET<br />
Bosch W6 DC<br />
B21F 1976 79<br />
Bosch W7 DC<br />
1980-82 USA<br />
1980-84 Others<br />
Bosch WR7 DS<br />
B2I FT 1981-85 Bosch WR 7 DS<br />
B23E<br />
1979 80<br />
Bosch W5 DC<br />
1981 -84<br />
Bosch W6 DC<br />
E e.rodegdp<br />
Tightenirg lorque (unoiled pl!g)<br />
6-cyl engines<br />
827 A 19J5 l9 Bosch H6D<br />
a27 E 1975-14<br />
Bosch H6D<br />
1979 80<br />
Bosch H5D<br />
B27F 1976 79 Bosch H6D<br />
B28A and E t980 84 Bosch H6D<br />
B 2AF<br />
1980-84 USA Bosch HR6DS<br />
1980 84 Others Bosch H 6 D<br />
820,819-823<br />
1.910.1 i)<br />
9.511.5 kl)<br />
0.910.1 {}<br />
827/824<br />
0.5r0.1 {)<br />
9.511.5 kl)<br />
110.1 (l<br />
0.7 0.8 mm<br />
2515 Nm (1813.5<br />
ft.lbs)<br />
0.6 0.7 mm<br />
1212 Nm (8.711.5<br />
ft.lbs)<br />
0<br />
0<br />
O<br />
0<br />
0<br />
I
,0<br />
,N<br />
O<br />
I<br />
3<br />
0<br />
,<br />
Rotor<br />
High tension leads.<br />
-<br />
\:,<br />
L---.T i<br />
260 :<br />
' ii-<br />
'<br />
_, _1.<br />
lkrr<br />
0a 0a<br />
,t-.+-'*.,*<br />
E 1t O O!) m<br />
--n<br />
tok.l<br />
'Nore:<br />
F.srslrnce yalires a.e glven n K a permeter ol length. (Measure tead n ardet to compute coftect value ) Al<br />
vatues have a pe.ntssable tolerance of ! 2A%<br />
Firing order<br />
820<br />
1342<br />
240<br />
819 823<br />
1342<br />
-'"<br />
5-1 ka<br />
ifll<br />
:_i,<br />
D 5 lllr- --=_<br />
-or,<br />
5.6<br />
B rea ke rl ess tg n i ti o n system<br />
i.J<br />
24O .=r<br />
oo m<br />
260<br />
i<br />
5k!)<br />
:<br />
-i<br />
II<br />
827, 828<br />
r 6 3 5-2,4<br />
tt
Breake rl ess ig n iti on system<br />
lgnition setting (before T.D.C wilh vacuum conlrol unit dlsconnecled)<br />
Wlth effecl from 1976, vehicles for Sweden, Auslralia, USA and Canada laLso Sw tzer and I983_mocle s) have deta ls oi<br />
gnition selling stamped on a plate io lefl oi eng ne compa.tment<br />
4-cyl E-engines<br />
Engine type Modelyear/market 11.7 13.3 r/s<br />
700 800 tm n 2 500 nmin<br />
B19E 1977 83<br />
1984<br />
8'<br />
10'<br />
28 33'<br />
24 2A-<br />
B 19ET 1982 a4 15' 21 26'<br />
B2I E 1975 82 r 8_ 2a 33'<br />
B2l ET t98t 84 15' 21 26<br />
823 E 1979 82<br />
1983 canada<br />
Other markets<br />
'r<br />
1s76 80:a!stra ia,swedenSpec 6 vehicLes<br />
4-cyl F-engines<br />
6-cyl A and E-engines<br />
r<br />
1978:Sweden,Audralia,Speca vehcles<br />
6-cyl F-engines<br />
5'<br />
10<br />
5'<br />
25 3A'<br />
25 29'<br />
25 3A'<br />
B20F 1975 5' 20 25',<br />
B21F 1976<br />
1977 USA<br />
Olher rnarkets<br />
1978<br />
1979 Calforna, Japan<br />
Olher markels<br />
1980 Canada<br />
Olher markels<br />
l98l 84 Japan<br />
1981 USA Adjusr at 15 ris (900 r/min)<br />
15"<br />
12'<br />
15.<br />
124<br />
10"<br />
'10"<br />
8'<br />
8'<br />
25 30'<br />
2a 32'<br />
25 30<br />
2A-32'<br />
22 26'<br />
26 30'<br />
24-24'<br />
22 26'<br />
22 26'<br />
B2t t\ 1981 85 Adjusr at 15 r/s (900 r/min) 12' 25 30'<br />
a27 A 1975 79 10' 22 25<br />
B 28A 1980 84 10' 22 25'<br />
B27E 1975<br />
1976 Sw€den, Austra a<br />
Other markels<br />
1977 lA<br />
r979 80<br />
B28E 1981 82<br />
1983 84<br />
827 F 1976<br />
1977 Ca ifornia<br />
Olher markets<br />
1979<br />
828 F 1980 82 Adjlst al 15 rA (900 r/min)<br />
12<br />
1981: California, Japan<br />
1982: All<br />
10'<br />
10'<br />
10'<br />
t0'<br />
t0'<br />
10'<br />
12'<br />
10'<br />
7'<br />
10'<br />
10'<br />
30 34<br />
22 26',<br />
30 34<br />
30 34-<br />
25 29'<br />
,25 29<br />
2t 31'<br />
27 32'<br />
20 24'<br />
27 32'<br />
20 24'<br />
l0' 2A 24'<br />
0<br />
I<br />
-I<br />
a)<br />
0)<br />
c<br />
0<br />
0t
is<br />
4-cyl E-engines<br />
:e4-cyl F-engines<br />
r<br />
I<br />
I<br />
0<br />
6-cyl A and E-engines<br />
827 A<br />
lB21E<br />
B 28A<br />
828 E<br />
Model year Desc,iption<br />
197 5 79<br />
1976<br />
1911 1A<br />
1979 80<br />
r980 84<br />
1981 84<br />
6-cyl F-engines<br />
1976<br />
19/7 lA<br />
1979<br />
USA<br />
Distributor<br />
Eng ine type Bosch P/N<br />
0 237 00<br />
B19E 1977 83<br />
1984<br />
Bosch P/N<br />
0 231 44.<br />
Breake ess ignition system<br />
2 017<br />
2 039<br />
2 006<br />
001<br />
005<br />
001<br />
005<br />
007<br />
013<br />
2 Q13<br />
1 219 957<br />
1 276 403<br />
Bl9ET r982 84 3 021 1 216101<br />
B2I E 1975<br />
1976<br />
19/7 8Q<br />
1981 82<br />
Sweden, Australia (Overseas 1979 )<br />
Otlrer markets (lncl. Thaland 1979 )<br />
2 001<br />
2 A1A<br />
2 401<br />
2 014<br />
2 Q17<br />
2 011<br />
463 832<br />
1 219 662<br />
463 832<br />
1 219 662<br />
1 219 951<br />
1 219 957<br />
821 ET 1981 84 3 427 1 216 /01<br />
1979 82<br />
1983<br />
1Sa4<br />
B20 F 1975 BW 35 (Ca iorn:a to engine no 500)<br />
fvl 40iM 41 {Caifornia: to enq ne no 500)<br />
Caifornia Blr 35 (engrne no 501 )<br />
Ca iornla M 40/N4 41 (engne no 501-)<br />
B21F 1976<br />
t3t;<br />
1979<br />
r980 8l<br />
1980 84<br />
I21 FT 1981 84<br />
B2-I F<br />
1980 84<br />
USA<br />
Ca io.n a. Canada. Japan<br />
Ca iornia Japan (Canada 1980)<br />
USA (Canada<br />
l98l 82)<br />
2 All<br />
2 039<br />
2 017<br />
2 039<br />
2 003<br />
2 002<br />
2 009<br />
2 008<br />
2 001<br />
3 003<br />
2 007<br />
3 009<br />
3 003<br />
2 039<br />
2 038<br />
2 039<br />
2 039<br />
1 219 957<br />
1 276 443<br />
1 219 957<br />
1 276 4Q3<br />
462 762<br />
462 496<br />
'| 218 672<br />
1 218 671<br />
463 694<br />
1 219 848<br />
463 694<br />
1 266 466<br />
1 219 848<br />
1 216 403<br />
1 266 904<br />
1 276 443<br />
1 276 443<br />
3 024 1 276143<br />
269<br />
269323<br />
269565<br />
269 323<br />
269 565<br />
269 733<br />
1 269191<br />
269 995<br />
269 191<br />
269134<br />
269 134<br />
269 739<br />
1 269 291<br />
ll
B reakerless ig n iti on system<br />
lgnition setting graPhs<br />
Bosch number at bottom left of diagrams !s siamped In<br />
Legend<br />
l=l<br />
l-r I<br />
@<br />
---<br />
, €) r 2Jl<br />
) \@ tru' :=)<br />
Variation of gnition setting<br />
Variation oI ignltion settlng<br />
-'..'-:<br />
,9 rp 49 5p<br />
_.!!5r.<br />
f,<br />
I<br />
t))<br />
f)<br />
a<br />
(<br />
(<br />
0, (
\<br />
{l<br />
't<br />
'e<br />
I<br />
I<br />
c<br />
,:1.<br />
o231002411<br />
-tt'o<br />
..'.;<br />
*llr',i<br />
,t<br />
:<br />
//',z<br />
J. I<br />
o 237 o )2 o3A<br />
B reake rl ess i g n i t i a n system<br />
,/l<br />
1"..--:"--, "p'.-:*1:<br />
:I::l]<br />
s<br />
:? !! t!1<br />
t5
Breake rl ess i g n i tio n system<br />
," ,l- ,,1,,,r., +,<br />
,","r?"jrjf.<br />
t6<br />
I r- :::_::--:--:i:' ::: ;<br />
o-Fo<br />
--^-oo0'000<br />
0\<br />
0<br />
f)<br />
0<br />
I \<br />
I<br />
(
.J<br />
:f<br />
I<br />
9<br />
0<br />
t<br />
I<br />
:';:<br />
=Fb<br />
B rea kerl ess I g n i t io n system<br />
i;-l-ll ,t,_,..-f+_-l<br />
:0237402017: 1 : l:i: l<br />
J; io r'l; i;'<br />
2j<br />
--
Breakerless ignition system<br />
:t-. d<br />
*l i ii<br />
96: -<br />
E-- d<br />
q.9<br />
Nti &<br />
Pio9 -<br />
9t<br />
!!N ! '!<br />
5@:<br />
r9r<br />
l]n:<br />
:i-<<br />
I<br />
I<br />
a<br />
ci<br />
>,9<br />
x3<br />
Hx-E i<br />
d+< o<br />
Rl9<br />
9r<br />
!^ 6 .t<br />
56 e -<br />
.9:<br />
-o<br />
ar 9;3;P<br />
18<br />
-<br />
6 r6q:<br />
.rfr :;R<br />
lr9 q<br />
1_r l3 :81&: E<br />
:r]9<br />
:!X=U!9<br />
1ia :oj:i | ^<br />
LdQ 9<br />
6<br />
+i LP<br />
.!5ulo<br />
qP\:q<br />
^9<br />
99<br />
- -9 V<br />
^.6 @oo:<br />
-:9 risil =<br />
6 9 C9 X\X<br />
^e<br />
^ d:on<br />
^.6 > i5:,ici8'i.> i5:dci:5<br />
I<br />
0')<br />
f)<br />
0<br />
0<br />
0)<br />
f'<br />
(<br />
I<br />
(
t<br />
i:0<br />
I<br />
c<br />
0<br />
a<br />
lt<br />
\66<br />
so: I -38 - ii6i --? - s v RR€<br />
:i: f l;E €ilfs-, .r: ;:";lle:r<br />
- ^9 !<br />
3e. ) --i -::- a :_g Ei{<br />
.j: i 1:: iA*F:i r:s sEil<br />
F:; I ;F ii;_ g_i !R{<br />
"<br />
!.c E*<br />
:Rj g !13 !EF:i3 "arp {€{ 9** ti<br />
;=:r .?:FiF<br />
:6' ; ! 3 I X i-:<br />
s:9 g !iE iEqiSI p=s q : 9:€ s3<br />
= 6i; F<br />
H9: I -.rn ::!^ g 3 Re?<br />
:. ) o {o 6 .:. - -NN<br />
;^ ! . ro aRo<br />
j'J 3 ii€ :dri;{ .5[? FE:<br />
>3:<br />
ii-O<br />
I 9!<br />
09<br />
>:o-;<br />
s ;: o;<br />
+ 39-3<br />
:><br />
:_<br />
:o<br />
ao<br />
:<br />
^:<br />
e "E{:;"<br />
E !c_-oc<br />
: ::-:9i'<br />
:b:<br />
a aa 4:z!<br />
.9 < o:= :9<br />
: ir 6 ! d:<br />
ci in : ><br />
I<br />
-o-<br />
o iE6<br />
o io-F<br />
5 .i i:<br />
t, E;i<br />
r! 9!!<br />
> i5ii<br />
ooo!oo<br />
:PO<br />
:E<br />
3;,bi 633<br />
Brcakerless enitton system<br />
qR<br />
I I 33<br />
:S: :E<br />
E Ee<br />
E X;E; E<br />
! ; s:E .;<br />
i; ; 9;! ;:<br />
Fs 3 s,6 EF<br />
*;a E Epi*i;<br />
ciN> O. i5Edci:-><br />
19
Specitications<br />
Breakerless i g n itio n syste m<br />
€F! B EE<br />
^gii : -<br />
T:5 S ::B<br />
?.i; s<br />
\P;<br />
3:; 3<br />
*P:<br />
e3 t 3<br />
93; 3<br />
3g; 3<br />
?R; 3<br />
l!553!l<br />
6 96\o<br />
6<br />
a<br />
.1609-<br />
^9<br />
oK'U<br />
:lg 5d&=Br<br />
^s<br />
ii N66@<br />
.^i o-Fa<br />
q?<br />
:^g<br />
: : :3: - ,<br />
:: o {<br />
:e&=i"i!J<br />
6 9G090<br />
99<br />
66m:NX<br />
;q: 6i t dj- d;.1<br />
i'' ,.i66-<br />
+r -LP .?P :.?5<br />
6<br />
.:-F<br />
, P 3R9<br />
3"' R 333<br />
.33?<br />
=l<br />
-NN .: I<br />
::::.::. I I i : . :<br />
q - -l<br />
,,t Ee^r I c o x.<br />
E<br />
', ; 6 gp i-<br />
d', 3xl :<br />
$c<br />
E: o;: -- ri E":E I u:i ,<br />
EE ? il; ;.i:= o:66 . :li E<br />
;= 6;:'; q!:l8i e ieE i E:l<br />
drE ,:i EHg: 'i3s-4 q;:€i; ':!iH: Ei!s';eEiee''!<br />
E;:;i<br />
i'EE€EFE'E!;:q<br />
E ::t ci=s :u H ElEe;ix E:="-"<br />
,Is9;fs 3!i= x,l = = >i5;dcj?.b> a.35Ij<br />
20<br />
: :<br />
0)<br />
t,<br />
0r<br />
f)<br />
I<br />
0
I<br />
I<br />
.N<br />
0<br />
0<br />
0<br />
Specif ications<br />
Computerized ignition systems<br />
Computerized ignnion systems<br />
B 21 F-MPG 1981, B 21 F-Ct 1982, B 21 F-LH 1982, B 23 F 1983-1984<br />
B 230 F 1985lgnition<br />
coil<br />
Bcsstance of prnrary col(across terminas 1( ) and 15(r )<br />
Fes slafce ol secondary coil (across lermnals l( ) and HT<br />
C"pd o - rJl '( )<br />
Spark plugs<br />
B2]F.B<br />
B23OF<br />
23F<br />
sao<br />
T ghle. na 'o<br />
oLp Lr o -d Lg<br />
High tension leads<br />
R--s sr.rce ol fild belween i!tnil on.or and d srf buror<br />
Res starce af sDark p !!l s!ppressof<br />
Res st.nce ol d slfibutor s!ppressor<br />
Firing order<br />
I342<br />
Enqine type<br />
I210.1 O<br />
10 6r'1.0 k()<br />
50 250 nF<br />
Bosch WB 7 DS<br />
Eosch<br />
L2:r 0.1<br />
07 08mm<br />
25-5 Nm (18r3 s ft bs)<br />
5.6 kQ/m<br />
5ko<br />
lko<br />
o<br />
8.5-0.8ko<br />
setting (vac!um governor on control unt disconnecied) see Instrucnons on page 6s<br />
11.7-13.3 4s<br />
700-800 rimrn 2 500 rim n<br />
421 F r98r.-82<br />
12"<br />
B23F 8230 r983-<br />
12" 16 ?4"<br />
21<br />
=
Specifications<br />
Com putei zed ign ition systems<br />
Distributol<br />
Engine type<br />
B2'IF 1981 82 1 306 0s9<br />
a23F 1983<br />
1984<br />
1 332 684<br />
1 336 737<br />
B23OF T985- 1 332 587<br />
lgnition advance graphs, control unit<br />
Legend:<br />
[=l<br />
l.l-l<br />
r- n---t<br />
l,S)l<br />
JwF' I<br />
821<br />
22<br />
vdridl'or or ionir'or serrins w lh v.r Lrrr<br />
Varidtiol ol iglil,or \"lr n9 with ergine rpr<br />
Max vac!um advance in relation lo<br />
Example conirol unit P/N 1306057: at 30./s (l 800 r/min)<br />
vacuum advance cannot be more th.n 90' regardless of<br />
extent of depression.<br />
lji.-1:<br />
f..l<br />
)<br />
tLt) I-I<br />
.:-..'_l -<br />
:L I<br />
:1317873 t.:<br />
$,<br />
l<br />
t, (<br />
D<br />
I<br />
I<br />
),<br />
(<br />
4 I
I<br />
i0<br />
I<br />
L<br />
0<br />
I<br />
I<br />
821 F-LH 1982<br />
B23F LH Auto transmission 1983-84<br />
<strong>Manual</strong> gearbox 1983 engine P/N 499802<br />
lchanqed ensine vers on 1983)<br />
1317295<br />
.o?r::] l L<br />
l .L..l<br />
B23F-LH <strong>Manual</strong> gearbox 1983 engine piN 499a9O<br />
<strong>Manual</strong> gearbox 1984<br />
t;<br />
tt<br />
ido<br />
C om puteri zed i g n i tt on sett i n g<br />
..::1.<br />
23
Contents<br />
Computerized ignitian systems, lgnitian system with contact breaker assenbly<br />
B 230 F-LH 1985-<br />
lgnition system with contact breaker assembly<br />
Contents<br />
lgnition coil and HT leads<br />
Distributor cap and rotor arm<br />
Replacing contact breaker points<br />
Checking iqnlioi sFiI 19<br />
ch"clrrg cP'rtr'f Jgdl advan(e<br />
Cl'ecling vdcu rr adva..e<br />
Reconditioning distributol<br />
Replar ir 9 v.'JJ- cont'olL1r'<br />
Repid.irg dislribJrol<br />
Checl rg side p a!<br />
Distributortest bench<br />
-<br />
B1-82<br />
83-815<br />
B6<br />
B1<br />
B8 814<br />
ct -c6<br />
c1 c2<br />
c3-c4<br />
C5<br />
c6<br />
Dl D4<br />
26<br />
27<br />
2A<br />
29<br />
29<br />
30<br />
32<br />
32<br />
32<br />
33<br />
33<br />
0<br />
f,<br />
ll<br />
I<br />
0(<br />
t)<br />
I<br />
);<br />
(
,{<br />
r0<br />
'0<br />
'o<br />
I<br />
Distribulor<br />
lgnition svstem with contact breaker assenary<br />
25
Distributor<br />
lgnition system wnh contact breaker assemblY<br />
26<br />
A. lgnition coil and HT leads<br />
At<br />
Testing ignition coil, ballast resistor and HT leads<br />
Components should be al a temperat!re of aboLrt 20'C<br />
(68"F).<br />
All leads must be disconnected from the componenls<br />
when taking nreasuremenrs<br />
Measuring resistance oI ballast resistor<br />
Ballast resistor fitted to 1979 models onwaros<br />
Resistance:0.9 O (eanY 79)<br />
1 3 {) {others)<br />
A3<br />
Checking ignition coil:<br />
check outer casing of ignilion coil Io. cracks elc<br />
measure r€sistance across ternrinas 1( ) and 15<br />
(+ ).<br />
Resisrance:2.7 3.0 f! 1978<br />
1.8-2.01) 1979 84<br />
- measure resistance across termina 1( ) and h gh<br />
tension terminal.<br />
Besist.nce: 7.0-12.0 () -1978<br />
8.0 11.0 {} 1979 84<br />
4<br />
a<br />
fj<br />
-t<br />
(<br />
r) |<br />
0<br />
t'<br />
|)<br />
{
0<br />
'975<br />
i_,<br />
240<br />
Checking resistancet ot HT leads<br />
MU<br />
r4,1<br />
m<br />
1kf) O ')/m 1kf}<br />
i0 oc] 5,6kJ)/m oo<br />
e<br />
0<br />
I<br />
I<br />
#:n- 1cl6- --1<br />
,T---<br />
o() 5,6 ko/m o.)<br />
tgnition system with conncr<br />
Distributor<br />
breaker assembly<br />
1k o oQ/m l ko<br />
-'-----<br />
Reststance values are given in K Q .per neter af tength. (Measure tead in<br />
vatues have a petmissabte<br />
tolerance of ! 20%.<br />
\,,/-<br />
. .-
Distributol<br />
Ignition system with contact brcaker assembly<br />
2A<br />
t T<br />
B3<br />
Replacing contact breake. points<br />
crease cams after installing new points.<br />
Turn crankshaft untilfibre heel on contact breaker is on<br />
Adjust gap to 0.i10 mm on B 17-823.<br />
0.35 mm on 820<br />
Apply 1 2 drops of engine oil to spindle wick<br />
Adjust dwell to 59-65"<br />
B4<br />
Volvo lMonotester or dwell meter'<br />
neduce points gap to decrease dwellangle and increase<br />
gap to increase angle,<br />
Refit rotor and distributor cap,<br />
Check dwell angle at 42 t/s (2500 r/min)<br />
B5<br />
tl dwell angle differs by more than 2" from reading at<br />
idle, check distributor for wear.<br />
I<br />
,1<br />
't<br />
{)<br />
6<br />
(<br />
(
'0<br />
0<br />
I<br />
0<br />
I<br />
I<br />
Distributor<br />
lgnition system with contact breaker assembly<br />
Adlust ignition setting at 11.7 13.3 r/s<br />
{700-800 r/min)<br />
Disconnecl hose from vacuum unit on distributor.<br />
B6<br />
Adjust ignition tim'ng to value ind caled in tabte betow.<br />
B7<br />
Check centritugal advance at 42 r/s {2 500 r/min}<br />
Check thal iginition advance is according to specifica<br />
tion, see lable below. lt advance is nol according to<br />
specificalion, check adv.nce weight assemb y.<br />
lgnition settinq<br />
With elfectfrom 1976, vehicles for Sweden, Auslralia, USA and Canada (also Switzertand 1983,modets)have detatts of<br />
ignition settlng stamped on a plale to lefr of engine compartment.<br />
lgnition setting (before T.O.C., vacuum contro unit disconnecred)<br />
Engine type Modelyear/Market 11.7-13.3 r/s<br />
1700 800 r/min) 12 s00 r/min)<br />
B17A 1979 -84 12" 2A 32"<br />
a 19A 9771<br />
978 taly<br />
978 80 Other markets<br />
98',1 84<br />
Special vehicles<br />
rr<br />
Sweden:245w th Bw 35,8W55, M 46<br />
''<br />
1979 80 Sweden, Overseasw lh engin€type498<br />
755and498 811 andspecia vehicleswih manua gearbox<br />
''<br />
240w theng.clype498 528<br />
1r gnit on se ng can be rerarded oi 5r if, despite using 9s ocrane foe, engtne s prone ro pre. gniiton lknocktfg)<br />
Spec a veh c e refers to heavy vehic e lypes such as 245 cLE wilh zulomar c rra.smission<br />
t5'<br />
t5'<br />
12'-<br />
10'<br />
32 36'<br />
32-36'<br />
2A 32"<br />
26-32',<br />
B19K r984 17 22'<br />
B20A 1975 76 10' 23-2/'<br />
B21A 1975<br />
1916 77 )<br />
1978 Sweden3r<br />
Other nrarkets<br />
1979 80'r<br />
1981 Scandinavia,Australia<br />
Other markets<br />
'1982 83 Scand navia, Auslralla<br />
Other ma*ers<br />
1984 Scandinav a, Switz€n€nd<br />
Auslra la<br />
I23A 1981 82 Scandinaviaa)<br />
1942 Olher markets<br />
1983 84 Europe<br />
Overseas<br />
12'<br />
15'<br />
'12'<br />
15'<br />
12'<br />
10'<br />
12'<br />
10'<br />
12'<br />
10"<br />
10"<br />
1'<br />
7'<br />
1'<br />
5'<br />
5'<br />
24 28'<br />
32 36'<br />
2A-32',<br />
32 36'<br />
28 32'<br />
26-32',<br />
28 32'<br />
26 32'<br />
24 30'<br />
28 32'<br />
20-26'<br />
27 33'<br />
17 -23'<br />
24 3A'<br />
21 26'<br />
19-24'<br />
17 22'<br />
10'<br />
t0'<br />
29
Distributor<br />
lgnition system with contact breaker assembly<br />
30<br />
Vacuum advance/retard<br />
Sonre dislributors are equipped with a vacuum conlrol<br />
'<br />
unir wlth 1wo vac!um hoses. In such cases the contro 0<br />
unil regulales both vacuum advance and retard.<br />
B8<br />
B9<br />
Delay valve<br />
Because of exhaust emission aws some vehrcles are<br />
equipped with a de ay valve connected between the<br />
inlet rnanifold and vacuum control unn<br />
S€veraldifferent types of va ves are n use Ona ltypes<br />
"DlST must face distributor.<br />
Check that it ls possible to suck air throught "DLST" side<br />
oi valve and that it is verY difflc! t 10 blow a r lhrough<br />
810<br />
Checking vacuum advance<br />
Connect a vacuurn pump to vacuum control unii- R!n<br />
englne at id e speed and record ignilion advance ln<br />
ard clerk r1.l rqlir or ddv.rcP ._<br />
li ignition advance does not increase check vac!um<br />
Checking vacuum retard<br />
Run engine al id e speed.<br />
811<br />
Check that ignilion is retarded when vacuum hose is<br />
lf not, check condition of hose. lf hose is in good condi<br />
tion check vacuLrm control unrt.<br />
rlr<br />
,))<br />
|<br />
F<br />
I<br />
I<br />
(<br />
I<br />
(
I<br />
i.,0<br />
0<br />
,r<br />
0<br />
I<br />
{<br />
f]<br />
,?'<br />
;)..<br />
.=-<br />
: rt\<br />
E, L<br />
Disttibutor<br />
lgnition system with contact breaker assembly<br />
Bl2<br />
Check vacuum advance with a vacuum pump<br />
Check dislributor number and iind cotrect ignitlon advance<br />
graph on pages 7 and 8.<br />
Selecl a pressure from graph and punrp !p vac!um<br />
pump to thrs va ue.<br />
Record ignition advance.<br />
Subtract basic ignition setting from recorded ignition<br />
advance and check that va ue conforms to graph.<br />
813<br />
Example: Bosch number 0 231 170 287 on B23A<br />
1981 82 Sweden<br />
You decide to check vacuum advance at 200 mm Hg.<br />
Recorded advance al this pressure is found 1o be<br />
16-21".<br />
Basic lgnition serting : 7'.<br />
D fference - 9 14' which ls as specifiecl.<br />
814<br />
Check vacuum unit for leakage<br />
Connect a vacuum pump. ncrease vacuum to 500 mm<br />
Hg (67 kPa).<br />
Record pressure for 1 minute. Pressure nrusl not drop<br />
by more than 100 mm Hg {13.5 kP.).<br />
Pre-ignition B23A Sweden 1981 82<br />
815<br />
lf, despite use of 98 octafe fue, ensine s prone to<br />
pre-lgnitlon (knocking), igniiion can be retarded to 5'.<br />
lgnition setting can also be retarded lo 2'before T.D.C if<br />
vehicle is required for towing purposes. Noie rhat fue<br />
consumption will increase and that ignit on shou d be<br />
reset to specificalion cluring normal usage.<br />
3r
Distri buto r, reconditioni ng<br />
lgnition system with cantact breaket assembly<br />
32<br />
C. Reconditioning distributor<br />
Replacing vacuum control unit<br />
C1<br />
(8 20: distributor must be removed f rom engine before<br />
vacuum unit can be replaced. See operation C3.)<br />
- condensation trap<br />
Mark position ol distributol<br />
Replacing distributol<br />
- condensation trap.<br />
c3<br />
Turn crankshaft until rotor points towards scribed ine<br />
in distributor body.<br />
Remove relaining screw and ift away distributor.<br />
C2<br />
Turndistributorto obtain accesslo vacuum unit relain'<br />
Replace vacuum unit.<br />
Turn distriburor back 1o mark.<br />
Fit:<br />
- condensatLon trap<br />
ChecUadjust ignition setting.<br />
To install:<br />
- turn rotor approx- 60" clockwise away frorn ine in<br />
distributor body. (Does not apply lo I20)<br />
- fil distributor<br />
rotor should now point lowards line. Reconnect<br />
vacuum hose and wire. Fit condensation lrap and<br />
reclamp dislributor caP.<br />
Checuadjust ignilion timins.<br />
0i a s<br />
rI<br />
rul<br />
r)<br />
t'<br />
0<br />
a<br />
I<br />
I<br />
(<br />
(
I<br />
(0<br />
,0<br />
t<br />
(c<br />
a<br />
I<br />
Di stri buto r, recon d it ioni ng<br />
lgnition system with contact brcaker assembly<br />
c5<br />
Checking side play of distributor shaft<br />
Max side play = 0.2 mm (0.079 in). Fit a new distributor<br />
if side play is great€r than 0.2 mm.<br />
Lubrication<br />
A = distributor grease P/N 1'16<br />
'1136-7<br />
or Bosch Ft1v4<br />
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<br />
lgnition system with contact breaker assemblY<br />
t T<br />
D. Testing distributor on a test bench<br />
Refer to the manufacturer's instructions at aL times<br />
when testing distribltors on a test bench<br />
The number on the side of the dlstributor is the Bosch<br />
D1<br />
checking dwell angle<br />
Conditionr New contact breaker po nls<br />
Run distributor at 3.5-4.2 revs/sec (200-250 r/m n)<br />
Adjust dwell angle to 59-65'. (ll is advisable to set dwell<br />
angle to 59' as angle increases as cam wears )<br />
Increase speed to 25 r/s (1 500 r/min).<br />
Read off dwell anqle.<br />
Dwell angle musl not varY bY more than 2'from pre_<br />
Check distributor for wear, damage elc ii deviatlon is<br />
Checking firing<br />
Run distributor at 3-5 revs/sec (200-300 ,min) on test<br />
Set distributor "0" to position which corresponds lo<br />
firing oi cylinder 1.<br />
Firing should be 0 90-180-270"-<br />
Check shape of atrows (or equivalent symbol depend<br />
lfdeviation is morethan 2"lhis indicales that side plaY is<br />
too large or cam is worn.<br />
D2<br />
D3<br />
Checking mechanical advance<br />
Run distribulor 3t 3.5 r/s (200 r/min) Ca ibrate meter'<br />
lncrease speed and check that mechanicaLadvance con_<br />
forms to specification.<br />
rl)<br />
lf not,checkthaibalanceweightsarelubncatedanddo<br />
Also check spranss.<br />
0<br />
I<br />
I
,1<br />
i0<br />
,0<br />
I<br />
0<br />
Dist ributor, recondi tioni ng<br />
Ignition system with contact brcaker assembly<br />
D4<br />
Checking vacuum advance<br />
Run distributor at 10 r/s (600 r/min).<br />
Calibrate meter.<br />
Increase vacuum and compare vatue to specificarion.<br />
35
Contents<br />
Breaketless ignition system<br />
Contents<br />
Breakerless ignition system<br />
OPeration<br />
Ignition coil and HT leads .. .... .......... E1 E4 38<br />
Checking distributor cap and rotot ....... F1-F2 3s<br />
Checkingimpulsesenderandairgap...... F3-F4 40<br />
Checking ignition advance<br />
Basrc-sett;.g<br />
Mechanical advance .<br />
.... Fs F1]<br />
F5<br />
. . F6<br />
40<br />
40<br />
40<br />
42<br />
vacuumadvance<br />
F7-F1o<br />
R€tard ... .. .. ... .. ... . . . .. F11<br />
Reconditioning distributor ... ... .. ... ... ... ... Gl G28<br />
Replacingvacuumcontro unit ...... . . . . .. . G]-G2<br />
ReplacingdistrlbutorBlg-E23...... . G3-G4<br />
ReplacinsimpulsesenderBl9-823.. . . . G5Gll<br />
ReplacingdistributorB2T/828............... . G12-G21<br />
Replacins impulsesenderB2T/828<br />
G22-G21<br />
Checkingsideplay<br />
G28<br />
Lubrication. ... .. ... .. .. . . .. . G29<br />
Replacingcontrolunit..............<br />
G30<br />
Testing distlibutor on test bench . . . . . . . . . . . . . G31-G34<br />
Wiring diagram ..<br />
Faultracing .<br />
36<br />
Page<br />
43<br />
43<br />
47<br />
49<br />
51<br />
52<br />
52<br />
53<br />
55<br />
56<br />
,0<br />
I<br />
0<br />
0 N<br />
t. I<br />
N
c<br />
0<br />
F<br />
(-%<br />
\.-:zEu<br />
Brcakerless ignition system<br />
,-/-]4.<br />
$#<br />
,-F...-,<br />
g
grcakerless ignition system<br />
38<br />
E. lgnition coil and HT leads<br />
E1<br />
Testing ignition coil. ballast resistorand HT leads<br />
. lgnition coil and ballast resistor at approximate y<br />
20"c (68"F)<br />
. All leads disconnected from components under test.<br />
Meesuring resistance ot ballast resistor<br />
B 20, B 19-8 23<br />
82t,824.........<br />
{Bolh resistors are connected in series)<br />
E2<br />
0.910.',t o<br />
1.010.1f)<br />
E3<br />
Checking ignition coil<br />
- check outer casing for cracks<br />
- measure resistance across terminats j ( )and 15(+).<br />
820,B19 823.. .... .. ... ... t.gio.to<br />
B27,B2A ... .. .. 0.510.1()<br />
- measure resistance acrossterminal l(-)and HTter<br />
All models: 9.5i1.5 k().<br />
0'<br />
,[<br />
0<br />
I<br />
I<br />
t I
t<br />
0<br />
0<br />
t<br />
I<br />
\,::<br />
260 "r ..f<br />
0(l<br />
Checking HT leads*<br />
*A 24o A<br />
-\ip<br />
H<br />
nlj<br />
-i!-<br />
lko orvm tko<br />
reE & dli-, r<br />
oo 5,6ko/m<br />
1>#.-_--\]<br />
oo<br />
_-^_Ir_--- ',"'-L!4--_\.]<br />
-<br />
oo 56ko/h<br />
ij.i<br />
q -j:'<br />
260<br />
I<br />
E<br />
95>:- _rih<br />
oo<br />
ffi=FaP*<br />
l-_ _-,__it><br />
lfl--_-----=a|-<br />
-Oq<br />
5.6[o/m Oo<br />
Besistance vatues are given tn K Q -|F.r neter of tength (tvleasure tead ln oder ta<br />
values have a permssable tolerance of ! 20Va.<br />
F. Distributor<br />
,r?5 II]i--<br />
!+,-+:l-i-<br />
oo<br />
!-+JFqir-3<br />
Checking distributor cap<br />
240<br />
Distributor<br />
B reakerless ig n ition system<br />
E4<br />
oo<br />
oo<br />
g<br />
i?<br />
U<br />
1ko<br />
lko 5ko<br />
- burnt e edrodes, tracking<br />
- carbon brush for wear or damase<br />
compute carrect vatDe.) At<br />
hpofianrl To prevenl rela n ng sprinss ifom damas hs<br />
.olor do nol cra.k engine whe. d srr butor cap is ofi<br />
F2<br />
Checking rotor<br />
Rotor shou d be free from cracks and etectrode shoutd<br />
Measure resistance. Resistance = 5t1 kc].<br />
39
Distributor<br />
Brcakerless ignition system<br />
40<br />
F3<br />
Checking impulse sender<br />
Measure resistance of s€nder'<br />
B 20, B 19-8 23<br />
095-t 25ko<br />
a21,828 . . . . . . . . . . . . . . . ........ ....0.54-0.66kO<br />
Check that no arcing io ea(h occurs<br />
lf meter pointer swings lo far right {ie open circuit)<br />
removo impulse sender and check if sender or lead rs<br />
checking air gap<br />
set rotor and stator tips opposite each other and mea_<br />
sure air gaP wilh feeler gauge-<br />
6 cyl engines: min 0.3 mm (0-012 in)<br />
4 cyl ensines: min 0.25 mm {0.010 in)<br />
Adjusi if necessary'<br />
F5<br />
Checking/adjusting basic setting at'l 1.7-13.3 r/s<br />
(700-800 r/min)<br />
Disconnect hose f.om vacuum conl.ol unit.<br />
Adiust isnition settins to specificalion. See nexr page.<br />
F6<br />
Checking centrifugal advance al 42 r/s<br />
(2500 r/min)<br />
Check ihat ignitjon advance is according to speciiica_<br />
tion. See next Page.<br />
lf not, examine centrifugal advance mechanrsm<br />
0<br />
(<br />
\<br />
I<br />
I<br />
:t<br />
f<br />
e<br />
I<br />
I<br />
(<br />
I
t<br />
e<br />
CI<br />
I<br />
I<br />
Dislnbutor<br />
B reakerl ess i g n it ion system<br />
lgnilion setting (before T.O.C., disconnected vacuum contro unitl<br />
With effecl from 1976, vehic es for Sweden, Ausrralia, USA and Canada (also Swilzer and 1983,models)have deraits of<br />
ignition setting stamped on a plate lo left of engine compartmenr.<br />
4-cyl E-engines<br />
Engine type Model year/Market Description 11.7 13.3 r/s<br />
(700-800 r/min) (2 500 r/min)<br />
B19E 1977 -83<br />
1984<br />
'10"<br />
28-33"<br />
24-24'<br />
B19ET 1942 a4 15. 21 26'<br />
a21E 1975-82 rr<br />
28 33'<br />
B21ET 1981 84 15" 21-26"<br />
823 E 1979-82<br />
1983 Canada<br />
Olher markeis<br />
1984<br />
/<br />
1976 S0iAustra ia,SwedenSpecia vehicles<br />
4-cyl F-engines<br />
6-cyl A and E-engines<br />
r978:Sweden,Alsrraiaspecalvehicle. 8.<br />
6-cyl F-engines<br />
10"<br />
5'<br />
10'<br />
25 30"<br />
25- 29'<br />
25 30"<br />
25 30'<br />
B20F 1975 5' 20 25'<br />
B21F 1976<br />
1977 USA, California<br />
Other markets<br />
1978<br />
1979 Californla, Japan<br />
Olher markets<br />
1980 Canada<br />
Olher markels<br />
1981 84<br />
A21FT 198r-85<br />
(900 /min)<br />
15'<br />
12'<br />
15'<br />
12'<br />
8'<br />
10'<br />
10"<br />
8'<br />
I'<br />
25 30"<br />
2A 32"<br />
25 30"<br />
2A 32"<br />
22-26'<br />
26 30"<br />
24 2A'<br />
22 26'<br />
22 26'<br />
12' 26-30'<br />
927 A 1917 79 10' 22 25'<br />
828 A 1980 84 10" 22-25'<br />
827 E 1975<br />
r976 Sweden, Ausrralia<br />
Other markets<br />
1917 7A )<br />
r 979-80<br />
B28E 1980-82<br />
1983 84<br />
B27F<br />
- 1976<br />
191/ Ca iiornia<br />
Othe. markets<br />
1919<br />
B28F 1980-82 Adjust at 15 r/s<br />
1900 r/min)ior<br />
1981 California<br />
10"<br />
10'<br />
10'<br />
10'<br />
t0'<br />
10"<br />
12'<br />
10'<br />
10'<br />
10"<br />
30-34'<br />
22 26"<br />
30 34"<br />
30-34'<br />
25-29"<br />
25 29'<br />
27 3f<br />
21 32'<br />
2A 24'<br />
27 32'<br />
20 24'<br />
10' 20 24'<br />
41
Disttibutor<br />
Brcakerless ignition system<br />
42<br />
Checking vacuum advance<br />
Connect a vacuum pump to vacuum unit.<br />
Run engine al idle speed and record ignition advance.<br />
Pump vacuum pump and check that ignition setting<br />
lf ignition se(lng does not advance check vacuum con'<br />
Check Bosch number on distribuior and turn to<br />
appropriate graPh on Pages 16-20<br />
Select pressure from graph and pump up vac'rurn<br />
pump to this value. Record ignition setting. Subtract<br />
basic ignition setting and check that value conforms to<br />
graph-<br />
Example: Bosch number 0 237 002 038<br />
B21F 1979- (Excl. California and Japan)<br />
You selecl d p essure of 200 mm Hg Crankshal de'<br />
grees al this oressu e 9 14'. Bdsic ignilror senirg rs<br />
10. whrcn meaas rhal t9-2a' shoL d be recorded dt<br />
t I<br />
!<br />
F8<br />
F9<br />
Fl0<br />
Check vacuum control unit for leakage<br />
connect a vacuum pump and Increase vacuum to<br />
67 kPa (500 mm Hs).<br />
Pressure should not drop by more than 13.5 kPm (l00<br />
mm Hg) during one minute.<br />
{<br />
{<br />
{,<br />
c<br />
I<br />
I
0<br />
0<br />
I<br />
0<br />
t<br />
Checking ignition retard<br />
Distti butot. recond itioni ng<br />
Brcake ess ignition system<br />
FI1<br />
Applies to B 19/2'l E and F-Turbo engines.<br />
Connect pressure gauge 5230 and pump 5496 to<br />
vacuum conirol unt,<br />
Start engine and run at idle.<br />
Record ignition advance. Increase pressure to 30 kPa<br />
and read off;gnition setting.<br />
lsnition se(ins should drop 3 7'.<br />
Disconnect pump and pressure gauge. Reconnect hose.<br />
G. Distributor - reconditioning<br />
Replacing vacuum control unit<br />
G1<br />
B 20: Rernove distriburorf rom engine priorto removing<br />
Mark position of diskibulor.<br />
Turn distributorto obtain access to vacuum unit retain<br />
Remove vacuum unit.<br />
Hook on vacuum unit<br />
Return distributor to original position.<br />
Fit:<br />
Check ignition setting-<br />
43
D i st ri buto r, rcc o n d i ti o n i n g<br />
B reakerless ig n ition system<br />
G3<br />
Replacing distributor on B 19-B 23<br />
Removing<br />
Unclip distributor cap and remove dust cover.<br />
Turn crankshaftunti rotor pointstowards mark in dislri'<br />
butor body, see fig.<br />
Remove distribulor retaining screwand lift away distri<br />
G4<br />
Installing<br />
Turn rotor ap prox. 60' clockwise from mark in distribu'<br />
(Does not apply ro 820.)<br />
Place distributor in position and fit screw loosely<br />
Check that rotor points towards mark.<br />
Refit distrib!tor cap.<br />
Checuadjust basic ignition timing.<br />
Replacing impulse sender<br />
on B 19-B 23<br />
Removing<br />
nemove distributor as described in G3.<br />
Remove/disconnect:<br />
- retaining clips<br />
impulse sender screw,<br />
G5<br />
i[)<br />
{'<br />
i)<br />
{|<br />
I<br />
I<br />
I<br />
e
'[<br />
JI<br />
'<br />
i<br />
Distri butor, recon d ition i ng<br />
B reakerless ig n ition system<br />
G6<br />
Unclip lock ring and remove shims as applicable<br />
Remove rotor and lock pin<br />
Use lwo screwdrivers to pry rotor off shaft.<br />
Remove lock ring and ift oul impu se sender<br />
Fit new imoulse sender<br />
Attach lock ring<br />
GB
Distri butor, tecond itioni ng<br />
Breakerless ignilion system<br />
46<br />
Fit rotor and lock pin<br />
lf lock pin has a groove lLrn t lo raue Lenlre sl-a'l<br />
Fit shims and lock rins.<br />
Fitlconnect:<br />
rmpurse senoer screw<br />
retaining clips.<br />
Turn shaft and check for grinding etc<br />
G9<br />
Gl1<br />
Magnets will give slight resistance to turning action.<br />
Refit distributor. See G14.<br />
Check/adjust basic ignition setting.<br />
G10<br />
0l<br />
i<br />
It<br />
I<br />
I<br />
0. (<br />
I
0<br />
0<br />
I<br />
N<br />
0<br />
Replacing distributor on 827, B2a<br />
tr<br />
D i st ri b uto r, rec o n d it i o n i ng<br />
Brcakerless ignition system<br />
827A, B28A start at operation G15<br />
Other engine typesl<br />
827 E 1975-74<br />
Proceed to G15.<br />
Remove front Dart of inlet manifold<br />
Disconnect link rod from throtile pullev.<br />
G12<br />
G13<br />
G14<br />
Remove air-luel control unit retaining screws<br />
Lift unit up slightly.<br />
All B 27, 828 models<br />
Unclip distributor cap and lift o!1 dusi cover.<br />
G15<br />
Turn crankshaft until rotor points towards mark in dislri<br />
Remove/disconnectl<br />
Remove distributor.
Distributor, recond itio ni ng<br />
Breake ess ignition system<br />
48<br />
v<br />
lnstalling distributor<br />
Turn rotor to point towards clip<br />
Check setting<br />
Refit inlet manilold<br />
Tightening torque 10-15 Nm (7 '11<br />
ft.lbs-).<br />
G16<br />
G17<br />
Rotor should point towards mark in distributor body.<br />
Fit retaining screw loosely.<br />
G18<br />
827A, B28A proceed to G21<br />
827 E 1975-78 proceed to G20<br />
Other 827 E modefs and 827 F, B28E and B28F<br />
lnstall air-fuel control unit<br />
Reconnect link rod to throttle pulley. Tighten airfuel<br />
G19<br />
{)<br />
t,<br />
0)l<br />
0)(<br />
{.<br />
{<br />
I<br />
(
t-<br />
(f<br />
0<br />
h<br />
0<br />
I<br />
I<br />
i:@<br />
Fit air filter<br />
aI827, 528<br />
ChecVadjust basic ignition setting.<br />
Replacing impulse sendel<br />
on B27lB28<br />
Distribu to r, rccon d ition i ng<br />
B rea kerless ig nitio n system<br />
Remove distributor according to G12 G15.<br />
G20
Di stri buto r, recondition i ng<br />
Breakerless ig n iti on system<br />
t^n<br />
50<br />
(._,<br />
-+lL<br />
a(o)}<br />
\
0<br />
(o<br />
i|<br />
CI<br />
0,2 mm<br />
Refit:<br />
Di stri butor, reconditio ni ng<br />
Breakerless ignition system<br />
Turn shaft and check for grinding etc<br />
G26<br />
G27<br />
[4agnets wil offer slight resistance to turn]n9 action.<br />
Refit disrributor. See G16-G21-<br />
Check distributor shaft side play<br />
l,.4ax. side play = 0.2 mm (0.008 in).<br />
G28<br />
lf side play is greaterthan specifled, replace distributor.<br />
51
Distributor, recond iti on i ng<br />
Brcakerless ignition system<br />
52<br />
Lubrication<br />
G29<br />
Distributor grease (P/N1161136-7)<br />
or Bosch lubricant<br />
Ft1v26.<br />
Replacing control unit<br />
G30<br />
Make sLrre that rubber seal remains in bottom of connector<br />
when disconnecting conlrol unit.<br />
,f)<br />
'4)<br />
f<br />
a<br />
I<br />
I<br />
t", (<br />
f)
''f<br />
(lt<br />
'i<br />
(l<br />
I<br />
-<br />
Cran[shafl degrees<br />
- D strlblror degrees<br />
1<br />
2<br />
p<<br />
\s{<br />
Zero ser ai (360 th n)<br />
Testing distlibutor on a test bench<br />
centrlugal advance begins<br />
Cenrr iugai advance ends<br />
Absollte lm r of gn r on advance<br />
Distributor, testing<br />
Breakerless i g n i t t o n system<br />
Refer to the manuiacturer's instruction at<br />
when testing distributors on a test bench.<br />
The number on the side of the distributor is ihe Bosch<br />
''rll:::!=<br />
;s<br />
'{f' L .:-<br />
Calibrate test bench<br />
6 connecr ng lead to distributor<br />
7 Power supply (14 V)<br />
Llohhing (, )symbo s indicale danserous<br />
hi€h vohage terminals<br />
G31<br />
Set zero at distfibutor shaft speed corresponding to<br />
zero advance. See diagrams on pages 15 lT.Thiscompensates<br />
for the electronic advarce f.om the impulse
Distributor, testing<br />
Breake<br />
+s<br />
ess ignition syslem<br />
Checking firing<br />
G32<br />
Set distributor "0" ro posltion which coiiesponds lo<br />
firing oi cyl 1.<br />
Firing should bei<br />
4 cyl: 0 90 180-270<br />
6cy:0-75 120 195 240 315 360<br />
lMax- deviation = I1.5'.<br />
Check shape of arrows (or equlvalenl symbol depend<br />
lfdeviation is morethan 2'this indicates that side play is<br />
too large.<br />
G33<br />
checking centrifugal advance<br />
Run distributor at 3.5 r/s {200 ,min). Calibrate meter.<br />
Increase speed and check that cenlrif!gal advance conforms<br />
to specification.<br />
lf no1, check thal balance weights are lubricated and do<br />
Also check springs.<br />
Checking vacuum advance<br />
Run distributor at 10 r/s (600 r/min).<br />
Calibrate merer.<br />
G34<br />
Increase vacuum and compare value to specificat on-<br />
{, I<br />
0) I<br />
I<br />
f) |
I<br />
.0<br />
'.0<br />
li<br />
(f<br />
I<br />
4 cyl<br />
6 cyl<br />
Wiring diagram<br />
B reakerl ess i g n ition sYstem<br />
Wiring diagram, breakerless ignition system<br />
1975 78<br />
Err<br />
--t1<br />
Y<br />
1s75- ,I,7a l- |<br />
I 1979 -<br />
1979<br />
4BNBN<br />
a-<br />
--<br />
!-/" E :rl [r:<br />
fi' fr | ' TTrT i-<br />
',t<br />
lf-. I<br />
l.lt-[U-l !r!,J!LJJtrJ! l.]lil - JJ!u-t<br />
L-,<br />
'<br />
er.r<br />
B"|::Q<br />
-@!u<br />
-r i- u-, .- I .i4+<br />
;r1+<br />
--@<br />
J<br />
rmr'rlrl."<br />
h ." /|1+it .-lr@<br />
1975 -1978<br />
1979<br />
^'r'a<br />
C = Balast fesistor<br />
55
Faull Ttacing<br />
I reakerl ess ign iti on system<br />
56<br />
9<br />
E<br />
!3E<br />
;i;<br />
o s! ;<br />
-9 ii o<br />
E: Ei E B<br />
ii;.r,<br />
! 6:9':<br />
g)<br />
i!i9i9<br />
9! 9 - 9 ^<br />
-:-:6:<br />
J: h-<br />
P :;:<br />
G<br />
.! E<br />
e<br />
:<br />
.E E<br />
.! E<br />
I<br />
6<br />
E *g<br />
iJ<br />
!E E<br />
!E !;<br />
,9iec;<br />
.E E<br />
I t;<br />
a +6<br />
:' :-6<br />
z<br />
f:]<br />
I al<br />
lHrl<br />
,--]p"6I<br />
t-<br />
I<br />
lrr<br />
tg I<br />
l: I<br />
l-E I<br />
J: l-3<br />
t; | ><br />
li I<br />
tE I<br />
I: I<br />
l; E I<br />
t9 t I<br />
l- i I<br />
t;.<br />
I<br />
I<br />
f ., (
I<br />
0<br />
(t<br />
,n<br />
0<br />
I<br />
I<br />
Conlents<br />
General instructions . .. ..<br />
Connectors and earth points... ..<br />
Modilications to 1983 models.. ...<br />
lgnition col and HT leads<br />
Checking distribuior cap and rotor. ..<br />
Checking basic ignition setting ....<br />
Checking/adjusling microswilch<br />
B 2t L-\,10C r98r, B 2 t--Cr 1982<br />
B 2r F-LH 1982<br />
B 23 f LH 1983 1984<br />
B 230 T-l Ll 1985-<br />
Checking ignilion advance.<br />
cenlri'Jgaladvance<br />
dserl a.gle .<br />
Recondilioning distribulor<br />
replaci19 dislr bulor<br />
Replacing distributor P/N 1332684,<br />
1336737, 1332587<br />
replacrg mpLlse se.de. .<br />
reoldLi19<br />
dislr bulor<br />
Replacing control unit<br />
Wiring diagram<br />
Fault tracing<br />
Computerizedignition system<br />
(P/N 1306059)........<br />
Operation<br />
H1_H4<br />
J1-J4<br />
Kl-K8<br />
L1_14<br />
t\.i1-t\43<br />
M4-M10<br />
M5-1\46<br />
I\t7<br />
M8-M9<br />
M11-M15<br />
M11<br />
M12<br />
M!3<br />
[,414-M15<br />
N1_N4<br />
N1-N2<br />
N3-N4<br />
N5-N14<br />
N5-N8<br />
Ng-N14<br />
N15<br />
Page<br />
58<br />
59<br />
60<br />
62<br />
63<br />
63<br />
64<br />
64<br />
65<br />
65<br />
65<br />
66<br />
66<br />
66<br />
67<br />
67<br />
67<br />
68<br />
68<br />
69<br />
70<br />
71<br />
5l
General instructions<br />
Computeri zed ign ition system s<br />
58<br />
H. General instructions<br />
Always switch ofi the ignition when disconnecnng/con<br />
necling ignition system terminals<br />
H2<br />
Begin by€hecking all relevantterminals 3nd conneclors<br />
before carrying out extensive faull lraclng procedures<br />
H3<br />
Never let spark iengthexceed<br />
5 mm when checking<br />
ignirion system circuitsor<br />
contro unit may be damaged.<br />
Consequendy, connect spark plug to HT ead and earth<br />
plug via engine.<br />
CAUTION:<br />
To avoid damaging the conneclor sleeves DO NOT DIS-<br />
CONNECT CONNECTOR lrom conlrol unil when checking<br />
vollage. The volt-/ohm-meler should be connecled<br />
direclly lo the wires.<br />
o<br />
.{<br />
0, 1<br />
ol<br />
rl)
!<br />
0<br />
0<br />
I<br />
(o<br />
,I<br />
I<br />
J. Gonnectors and earth points<br />
Control unit<br />
Distributor<br />
Bulkhead<br />
Control unit earth<br />
Connectors<br />
Com pute i zed ig n ition systems<br />
JI<br />
J2<br />
J4<br />
59
Guide sleeves<br />
Com putenzed i g n it ion syste ms<br />
60<br />
]..<br />
K. Modif ications<br />
Connecting guide sleeves<br />
2mm<br />
+tt-tr<br />
K1<br />
With eifeci from 1983 models lhe dislributor connector is<br />
equipped with gulde sleeves. These sleeves can also be<br />
fitted to eadier models and to the conlrol unit conneclor.<br />
Guide sleeves P/N 1 324 909-9.<br />
Note: From modelyear 1984. the guide sleeves are<br />
installed in the control unit at lhe taclory.<br />
Note: The wiing harness for lhe control unil musl be<br />
rcplaced il the connector has been disconnected<br />
or when replacing the control unrt.<br />
K2<br />
Orill lor connecling guide sleeves<br />
P/N 999 5268-1.<br />
To install guide sleeve, place sleeve in the drift and check<br />
that it protrudes 2 mm (0.08 in.)<br />
f nol, shone. loollo drrenson sl'own adacenl<br />
Easier lo insert guide sleeve it opening s countersunk.<br />
K3<br />
Caretully clean connector on distribulor and control<br />
unit<br />
Withdraw connector from distribulor. Scrape off PVC<br />
and oxide deposits from all lhree pins.<br />
Use tool 9549.<br />
Apply grease to pin.<br />
Clean female connector with a tapered file.<br />
Withdraw connector from control unit. Scrape off oxide<br />
from around pins 3, 5 and L<br />
Place guide sleevein<br />
tool 5268<br />
Pack (A) with grease. Repeat for each sleve<br />
Inse( sleeve in tool,<br />
K4<br />
o<br />
j<br />
I<br />
I
I<br />
3<br />
,I<br />
I<br />
-<br />
_=<br />
_::)<br />
-f<br />
--<br />
-<br />
_:)<br />
_l<br />
::l<br />
-<br />
1o 1Oo<br />
3a-80<br />
40 70<br />
Guide sleeves<br />
Com puterized ig n iti on system s<br />
Install guide sleeves on connectors<br />
Distributor:<br />
On all pins.<br />
Control unit<br />
On pins 3,5 and 9.<br />
Check<br />
Replacing sleeve insulators<br />
K5<br />
K6<br />
K7<br />
Press on guide sleeves so that at Least 2 mm (0.08 in) of<br />
pin is visible above sleeves.<br />
Reconnect terminais and check function.<br />
Withdmw connector<br />
Detach rubber cover and remove insulator.<br />
Fit new insulator P/N 949597'9.<br />
Reconnect connector.<br />
K8<br />
61
Com puterized ig n ition systems<br />
-<br />
iesi- ll l+-r+<br />
'--n<br />
oa 5,6 ko/m oo u<br />
iE6 -r1 _ i r-€<<br />
1ko<br />
L. lgnition coil and HT leads<br />
5ko<br />
L1<br />
Test conditions:<br />
. lsnilion coil and leads should be ai a lenrperature of<br />
about 20'c {68'F).<br />
. All ieads must be disconnected trom components<br />
when taking measurenrenls.<br />
Checking ignition coil<br />
check outer casing for cracks etc<br />
- measure resistance acrossrerminals I (-)and 151+).<br />
Aesistance = 1.1-1.3 Q.<br />
L2<br />
L3<br />
measure resistance acrossterminal<br />
1( ) and the<br />
high tension te.mina.<br />
Reslstance : 9.6 '11.6<br />
kO.<br />
Checking HT leads<br />
Resistance of HT lead between distriburor and ignition<br />
coa shou d be 2 3.5 kohms which is equivalent to 5.6<br />
L4<br />
l:L)<br />
Spd.l p ugs supp esso|esisldlce - 5 kol_ns<br />
c<br />
Resistance of cable connector on distriburor cap = 1
l"<br />
i<br />
I<br />
(f<br />
j<br />
,I<br />
M. Distributor, general<br />
Checking distributor cap<br />
tracking, burnr terminals.<br />
Distributor, general<br />
Computerized ig n hio n systems<br />
Noter Centfe terminal is not spring loaded.<br />
Checking rotor<br />
Two types of rotor are in<br />
checking Hall pick-up wire<br />
M1<br />
M2<br />
use. Use only new type for<br />
M3<br />
lMake sure that the wires cannotbe<br />
damaged by the<br />
M4<br />
Checking/adiusting basic ignition setting<br />
Eefore checking ignition setting check function of<br />
|<br />
_-<br />
Noie: see p"ge 65 for co'tect ao.:slmerr orol1f_l
Distributor, general<br />
Cofiputelized ignition systems<br />
R*...q*5to'<br />
64<br />
M5<br />
Checking microswitch on 821 F-MPG 1981 and<br />
821 F-Cr '1982<br />
Connect a test lamp between battery (+) and terminal2<br />
(yellow wire) on microswitch.<br />
I amp snoulo be off when engrne is idl,ng. l' lamo is on,<br />
adjust microswitch as described below.<br />
Turn throttie pulley and check that lamp lights-<br />
Adjusting microswitch<br />
M6<br />
Pl6ce a 0.4 mmfeelergauge between adjustment screw<br />
Unscrew microswitch retaining screws and turn switch<br />
unlil lamp lights.<br />
Checking<br />
Place a 0,2 mm feelergauge between adjustnrent screw<br />
Lamp should light.<br />
Remove feeler qauge and insert a 0.4 mm feeler gauge.<br />
Lamp should be off.<br />
Checking microswitch on 821 F-LH 1982<br />
M7<br />
Disconnect connector from vacuum switch. Connecr a<br />
test lemp behveen batre-y ( ) a.ld orange wi'e o.<br />
Start engine.<br />
Test lamp should light with engine idling.<br />
Increase engine rpm and check that lighl goes oul.<br />
lf not, check hose to vacuum switch. lf intact, rep ace<br />
CI)<br />
o
il<br />
0<br />
\A.<br />
q. rl<br />
€<br />
DisLtibutor, general<br />
Com puterized i g n iti on systems<br />
Checking microswilch on B 23F-LH 1983-1984;<br />
B 230 F-LH 1385-<br />
M8<br />
With engine ofl, turn throttle puLley slowy and isten to<br />
mlcroswitch. A cick should be heard when throltle valve<br />
Adjusting microswitch<br />
M9<br />
Unscrew relaining screws.<br />
Turn switch clockwise slightly. Then turn swilch back<br />
until it contacts slop, but no funher as throttle valve wi<br />
Tighten retaining screws.<br />
M10<br />
Check lhat basic signition setting is 12oa2'at<br />
12.5 r/s (750 r/min)<br />
Air condiioning disconnected as applicabLe.<br />
Adlust ignilon selling by turning dstributor.<br />
Increase engine speed to 2000 rpm for 5 seconds.<br />
Lel the englne idle and check idle quality.<br />
Make sure the dle is slable and wthin specifications as<br />
variations coud afiect the liming.<br />
Check centrilugal advance<br />
Dsconnect vacuum hose lrom distributor.<br />
M11<br />
Run engine at 42 r/s (2 500 r/rnin) and check that ignition<br />
advance is l6-24c belore T D.C. ior B 23 F, B 230 F and<br />
22-30o before T.D C. tor other models.<br />
ll incorrect, replace conlrol unit<br />
65
Checking, control unit<br />
Com puterized ign ition system s<br />
66<br />
Mt2<br />
Check vacuum advance<br />
Run engine at 25 /s (1500 r/min).<br />
Disconnectvacuum hose. Becord ignition advance. Re_<br />
connect hose and check that advance allers.<br />
lf not, check for vacuurn at control unil {check suction at<br />
lf vacuum, but no advance, replace control unit<br />
Check dwell angle<br />
Read off dwell angle at idle.<br />
M13<br />
Dwell angle = 36 38'.<br />
Increase engine rpm and check that dwell angLe increases.<br />
if no increase is recorded, replace control I'nit,<br />
B23F<br />
Checking knock sensor<br />
M14<br />
connect a volvo Monotesrer or equivalenl test nreter.<br />
Srart engine (AC disconnected).<br />
Increase engine speed and mainlain al sel leve by e.g.<br />
pLacing screwdriver across throttle pulley.<br />
M15<br />
Tap plug on rishtside on cylinder blockwith a hammer'<br />
lgnition should retard by max6'and return aulomatrcal<br />
t';
0<br />
(0<br />
il<br />
rl<br />
I<br />
Distri buto r, recon d i ti o n i n g<br />
Com puterized i g n iti on system s<br />
N. Distributor (Ghrysler),<br />
reconditioning<br />
1 (P/N 1306059)<br />
Replacing Hall pick-up<br />
Remove:<br />
springs retaining Hall pick-up<br />
- drsconnect connector<br />
remove Hall pick-up.<br />
lnstall:<br />
- Hall pick,up<br />
springs<br />
Check that wires cannot be damaged by rotor.<br />
Refrl disrributor cap and reconneLr co.lreclor.<br />
See p€ges 60-61 for installins gu de steeves on connectors.<br />
Replacing distributol<br />
Remove:<br />
- HT leads from distributor cap<br />
N2<br />
N3<br />
Tu.n crankshaft until rotor points towards rubber<br />
Disconnect connector.<br />
Remove distributor.<br />
Install distributor<br />
Tubularpinprotrudesmoreononesidethanlheother.<br />
Turn shaft until pin is opposite groove in distribLrto.<br />
Fit:<br />
distributor cap and reconnect HT leads.<br />
Reconnect connector.<br />
Checvadjust basic isnition timing. See operation M4.<br />
See pages 60 61 foi instal ing quide sleeves on connectors.<br />
67
Djst rj b u to r, recondjtion i ng<br />
Computerized ignitton sYstems<br />
68<br />
Distributor (Bosch), reconditioning<br />
Type 2 (P/N 1332684, 1336737,1332587)<br />
Replacing distributol<br />
Remove/disconnect<br />
HT leads iiom cap<br />
N6<br />
Set cyl 1 ro T.D.C.<br />
Turncrankshaftunti rotor po nls towards mark in distri<br />
Dlsconned connector.<br />
Remove distribulor<br />
lnstall distributor<br />
N5<br />
Check that cyl 1 is at T D-C<br />
Turn rotor approx. 60' c ockwise from rnark ln 'listrib!<br />
Rotor should now point towards mark n distributor<br />
ChecUadlusl basic igniiion t ming. Se€ l!14.<br />
S€e pages 60 61 ror nsla I ng suide s ecves on conneclors<br />
CI<br />
r:l<br />
f)<br />
o<br />
r
,)<br />
I<br />
Replacing Hall pick-up<br />
D i stributor, recondition i ng<br />
Computerized ig n itio n systems<br />
Nole: hp trd Sr.tL1 >-oJld -or be epla Fd on<br />
irbutors wilhii the lirst year oi warranty.<br />
cornpete disiributor must be replaced<br />
Bemove dstr butor according lo operauons N5-N6<br />
Mount dlstrbulor in a vise (NOT SOFT VICE JAWS TO<br />
PREVENT DAI\,iAGE).<br />
Reease crc p retaining lrgger whee.<br />
NlA<br />
Pry oii trgger whee wiih two screwdrvers (use roundshalt<br />
screwdrvers 5mm diameler)<br />
Place tips ol screwdrve.s on sleel hub. as shown.<br />
Take care not lo damage trigger wheel<br />
lfvqger whee s benlduring removal ir m'rsr be<br />
Take care not lo lose ock p n<br />
Remove<br />
- Hal pick up retaning screws<br />
- plaslic p n (A) lor connector<br />
ru9<br />
69
Dist ributor, recond itioni ng<br />
I sa-4<br />
" a-,<br />
a<br />
Remove HaLl swtch and connector.<br />
lnstall:<br />
- New HalL switch and connector<br />
circlip<br />
- retainng screws and plastic pin (1)<br />
lnstall:<br />
- trgqer wheel (2)<br />
- Lockpin (3)<br />
- circlip (4)<br />
- condensation trap<br />
Instal diskbulor accordtngto operations N7-N8.<br />
Control unit<br />
N13<br />
N15<br />
Replacing control unit<br />
Check centrifugal and vacuum advance accordrng to<br />
operalions M11-M13 after instal ing control 'rnil<br />
See pages 60-61 lor lnsla ling g!ide s eeves o' conne'rors
9<br />
0<br />
I<br />
I<br />
I<br />
I<br />
BL<br />
CN<br />
BN<br />
SB<br />
Wiring diagram, computerized ignition systems<br />
B 2'I F_LH, B 23 F_LH<br />
t"',"<br />
Llllru rn!8<br />
Wiring diagram<br />
Com puterized ig n itio n systems<br />
D = Microswnch a2r F I<br />
H = Mlcroswtch B2l F LH Jerronic<br />
J - lvl cr;swiich 823 F<br />
K = Knock sensor B23F<br />
_,,rxrt]x-D<br />
-l<br />
_<br />
! _rl-lfD<br />
71
Wiring diagram<br />
C om puteri zed ignition sy stem<br />
/2<br />
Wiring diagram, computerized ignilion system<br />
B 230 F-LH, 198s-<br />
I lgnition switch<br />
C Breaker unit<br />
F lgnition coil<br />
G oistributor<br />
214 Control Unit<br />
LH Jetronic 0<br />
Heated reaf w ndow<br />
Overdrive
NOIES<br />
Oi<br />
'D(<br />
0(<br />
o<br />
t).<br />
t'<br />
o
o<br />
-E<br />
Fault tracing chart<br />
B 21 F-MPG/LH B 23 F-LH
o<br />
0<br />
Adllsl advance by lurn ng dlstr<br />
I<br />
Check that ign tion advance s 12'<br />
al r2.5 r/s (750 r/min).<br />
Checl conlrol !nil earth<br />
T!rn ofi ignition. Disconnect conneclor<br />
Check for vo tase €t biue wire. Voltage?<br />
i<br />
I<br />
i
)<br />
?<br />
,.,.,<br />
D sconnect 3 pole conneclor<br />
8r dge pi.s B and Cwth piece<br />
L_".<br />
olsconnecl HT leads irom disrri<br />
C5p.l fo' ,ohage ar rorn ral A or 3-poie Lorne' tor<br />
Check ior vo lage at termi.al 15(+) on igni-<br />
.5p.r wtrc( bdrwear g1t on rwrt a dnd ro ,o. r<br />
Notei Nol 12 V. Lamp dim.<br />
gnilioh shou d be ofi when<br />
d sconnecrn9 conneclors.<br />
Check thal each pl!g sparks<br />
Repace Fallpick !p in d srriboror.<br />
Che.l wrre lo dr5hburor.
o<br />
0<br />
o<br />
o<br />
{D<br />
0<br />
C
o<br />
-E<br />
1o<br />
o<br />
Fault tracing chart<br />
B 230 F_LH
o<br />
Adjust gnrlon advance by turn.9<br />
I<br />
check lhal ign tior advance is 12"<br />
ar 12 5 r/s (750 rpm)<br />
Reler ro SB 34:105 for selting<br />
f. /42.4<br />
€?.<br />
ll<br />
A{i<br />
ca<br />
'<br />
Posh lest lamp probe through b ue w.e covero.<br />
rconlro unt. Check tor vollage<br />
Nole: Oo nol disconnect connecror lrom con-<br />
t<br />
I<br />
check control unrt ground connecto.<br />
i<br />
"-
D sconnect 3 poe connector<br />
Nolei Check lype olconneclor.<br />
Bosch (1) Chryslef (2)<br />
Co..ect a br dgew re across B<br />
Dsconneci HT ead irom dslri<br />
Check ror vollageatierminal 1 5(+)on gnil on<br />
Check wires connected between anilon switch and conirol unt<br />
Che.l lor vo lage ar terhrnal A on 3-pole connecror<br />
Nole. Nol 12 V Lamp d m<br />
gntion sholld be oil when discon-<br />
Check lhal each Pug sparks<br />
Push testrampproberhrough green w re cov<br />
oK-<br />
Nole: Also repLace cabe harnes<br />
Check conlro uni connector
€<br />
0<br />
o<br />
o<br />
D<br />
e<br />
0
7<br />
if<br />
'l<br />
Dwell angle<br />
Checking. A €fg nes (4 cyt)<br />
Checking B 2l F-MPG, B 21 F-LH,<br />
B23F LH.823OF-LH, .,<br />
A eng nes {4 cy) . .<br />
EIF efg fes A-enqines<br />
(6 cy)<br />
Operation<br />
83 84<br />
84 85<br />
Mt3<br />
Cenlrirugal advance<br />
B 17A-B 23 A. B 19 K,<br />
87<br />
B]9EB23E .,<br />
F6<br />
a 2/A B28F<br />
F6<br />
821 MPG B23F LH.B23OF-LH M8<br />
821 F MPG, B21F LH. B23F-LH.<br />
B23OF LH<br />
Repacement .<br />
Check ng dwell ang e<br />
Delay valve<br />
Oist buror {B 17 A-B 23 A)<br />
Remov ng-nstallng .<br />
Sde pay<br />
Testing on lesl bench<br />
Lubrcation<br />
. . . .<br />
Disrriburof (B 19 E-B 23 E)<br />
Bemoving- n sta ling . .<br />
Bepacemenl oi impLr se sender<br />
Side play<br />
Testing on tesl bench . .<br />
A2<br />
E2<br />
J1-J3<br />
B3<br />
B4<br />
B19B23E.B27AB28F<br />
B2] F MPG.B21 F-LH,B23F LH,<br />
G30<br />
B23OF LH<br />
N16<br />
B9<br />
c3 c4<br />
c5<br />
D1-D4<br />
c6<br />
G3 G4<br />
G5 G11<br />
G28<br />
G31-G34<br />
lndex<br />
Page<br />
28<br />
28<br />
66<br />
26<br />
38<br />
29<br />
40<br />
40<br />
65<br />
59<br />
2A<br />
28<br />
52<br />
70<br />
30<br />
33<br />
34<br />
33<br />
53<br />
Dislributor (B 21 F-MPG-B 23 F,LH, I 230 F-LH)<br />
Removing nstaing. .. .. .. N3-N4 67<br />
Fep acenrenlof Ha lsender, type 1 N1-N2 67<br />
B epiacernenl of Hall sender, type 2 Ng-N I 4 69<br />
Distriburor (B 27A-B 28 F)<br />
Rernovlng-insta ing. c12 c21 47<br />
Bepacement ol mpulse sender c22-c27 49<br />
Side play G28 51<br />
Tesling of lest bench ..... G31-G34 53<br />
Earlh points . .<br />
Engine speed control<br />
B21 F.MPG, B21 F LH, 823 F-LH.<br />
8230F-1H... .. .. ..<br />
Fault lracing<br />
E/Fengines....<br />
B 21 F.MPG/LH 2] F-LH<br />
B 230 F-LH<br />
Firingorder.....<br />
Groundpoints...<br />
lgnition coilg<br />
B17AB23A<br />
BlgE B23E.B27A-828F.<br />
821 F.MPG 821 F_LH 823 F-LH,<br />
8230F-1H..........<br />
lgnilion retard<br />
B 19/21 E and F,Turbo......<br />
Knock 3en30r<br />
Lubicalion, dBtributo.<br />
B17A-823A.......<br />
B 19 E B 23 E. A27 A-A 27 F .<br />
rvl l<br />
A]-A3<br />
E1_E4<br />
Ll L4<br />
F11<br />
59<br />
65<br />
56<br />
75<br />
77<br />
26<br />
38<br />
62<br />
M14-t\,415 66<br />
c6<br />
G29<br />
B 21 F-MPG, B 21 F-Ct 1982... M5 t\46<br />
B 2l F-LH 1982<br />
M7<br />
B 23 F,LH 1383 1985, B 230F-LH M8 M9<br />
B17A_823A<br />
B]9E-.823E.827A-B2AF.<br />
B2] F.I!IPG,821 F LH, B23F-LH.<br />
8230F-1H.........<br />
Wiring diag16m<br />
821 F MPG,B2] F-LH,B23F LH.<br />
8230F-1H....<br />
8230F-1H.....<br />
Olher E/F engines..........<br />
K7<br />
B8-Br4<br />
M9<br />
33<br />
52<br />
64<br />
64<br />
65<br />
30<br />
71<br />
72<br />
55