Engine OF DG EV SP

+-
Service. code - -
•
- ....
l ~ .

Workshop
Manual
Volkswagen
Transporter 1980...,
34 PICT, 2E3, 2E4 carburettor/ignition system
(1.9 litre engine)

July 1991 Edition

VW Service Department.
Service.
List of Workshop Manual Repair Groups
Volkswagen Transporter 1980 ..._
Engine
code I DF I DG I EV I SP I I I I I I
8 kl t 34 PICT, 2E3, 2E4 carburettor/ignition system
00 e (1.9 ltr. engine) Edition July 1991

When filing a Technical Bulletin enter the Bulletin No. in the adjacent column. When using the Workshop
Manual you can then see at a glance whether Technical Bulletins have been published in respect of the
particular Repair Group in which you are looking.

Repair Group Technical Bulletins

01 Self diagnosis. Electrical check
22 Mixture preparation, Carburettor
28 Ignition system
I

Technical Information should always be available to all foremen and mechanics, because their
compliance with the instructions given is essential to ensure vehicle roadworthiness and safety.
In addition, the normal safety precautions to be observed when working on motor vehicles are also
applicable.
This Workshop Manual is only intended for use within the Volkswagen
and Audi organisation, passing on to third parties is not permitted. Printed in Germany
© 1991 Volkswagen AG 000.5381.41.20
 Contents

01 Self-diagnosis, electrical check Page

Electrical check 01-1
- Checking of wiring and components with test box V.A.G 1598 01-1

22 Fuel system, carburetor Page

Air cleaner and vacuum connections 22-1
- 34 PICT carburetor 22-1
- 2E3 and 2E4 carburetor 22-3
- Checking intake air preheating 22-5
Removing and installing carburetor and intake manifold 22-7
- 34 PICT carburetor 22-7
- 2E3 and 2E4 carburetor 22-9
- Removing and installing intake manifold preheater 22-12
Servicing 34 PICT carburetor 22-14
- Top part of carburetor 22-15
- Bottom part of carburetor 22-17
- Carburetor adjustment data 22-20
- Jets and settings 22-21
- Adjusting idling speed 22-22
- Checking and adjusting amount injected by accelerator pump 22-25
- Adjusting choke valve gap 22-26
Checking and adjusting cold idle speed 22-26
- Checking and adjusting throttle damper and delay valve 22-27
Servicing 2E3 and 2E4 carburetor 22-28
- Top part of carburetor 22-29
- Bottom part of carburetor 22-31
- Servicing components of idling speed stabilisation system 22-33
- Carburetor adjustment data 22-38
- Jets and settings 22-40
- Adjusting idling speed 22-45
- Checking and adjusting cold idle speed 22-49
- Checking and adjusting pull-down unit 22-51
-Checking operation of throttle·valve, stage II 22-53
- Checking and adjusting accelerator pump injection rate 22-56
- Checking part-load duct heating 22-57
- Basic adjustment of throttle valve, stage II 22-58
- Basic adjustment of throttle valve, stage I 22-60
Checking throttle valve positioner 22-61

28 Ignition system Page

Repairing TCI-H ignition system 28-1
- Safety precautions for TCI-H ignition system 28-7
- Adjustment data 28-8
- Spark plugs 28-9
- Distributor data 28-10
- Removing and installing distributor drive shaft 28-11
- Installing distributor 28-12
- Removing and installing rotor plate 28-13
- Checking and adjusting ignition timing 28-14
- Checking distributor 28-16
Checking TCI-H ignition system 28-23
- Checking TCI-H switch unit 28-24
- Checking Hall sender 28-27
- Checking DIS switch unit 28-28
Repairing breaker-triggered ignitJon system 28-30
- Adjustment d~ta 28-34
- Spark plugs 28-35
- Distributor data 28-36
- Removing and installing distributor drive shaft 28-37
- Installing distributor 28-38
- Adjusting ignition timing 28-39
- Checking distributor 28-40

•
Electrical check

Checking of wiring and eo•ponents with test

box.V.A.G 1598

Idling speed stabilisation (2E4 carburetor)

Note:
o Use is to be made for test purposes of the hand
multimeter V.A.G 1526 and the diode test lamp
V.A.G 1527.
o The specified values stated apply to an ambient
temperature range of between 0 and + 40° C.

o If the measured values differ from the specifi-

cations, locate fault ~sing current flow diagram.

o If the measured values only diff·er slightly from

the specifications, clean sockets and plugs of
testers and test leads, and then repeat the test.
Before renewing the respective components, check
wires and ~onnections and - particularly in the
case of specifications less than 10 ohms - repeat
resistance measurement on component.

o Use is to be made for connecting up the testers

of the test box V.A.G 1598 with the adapter cable
V.A.G 1598-1 and the auxiliary cables from the
auxiliary test,set V.l.G 1594.

01-1

o The contact numbers of the connector and the socket

numbers of the test box V.A.G 1598 are identical.

Attention:
•
The respect.ive •easurina; rana;e is to he selected prior
to connection. of the test ~eads. so as not to destroy
electronic components.

Test prerequisites:

o Battery voltage OK.

o Earth connections OK.

Checks at connector of wiring loo•

- With ignition switched off, pull connector off control

unit for ~dling speed stabilisation (Jl42). (The control
unit is installed in front of the left-hand taillight).

Only connect test box V.A.G 1598 with the adapter cable
V.A.G 1598/1 -1- to connector of wiring loom -2-. (The
control unit remains unused).

- Perform testing in accordance with table --- page 01-3.

01-2
Test table

- Measuring range: Select voltage measurement -V-

Test V.A.G Test itea o Test conditions Specifications
step 1598 Add. operations
sockets

10 + 2 Voltage supply, control - Switch on ignition approx. battery voltage

unit (J142) (Term. 15)

2 Bridge Actuation for current Relay heard to energize

2 + 3 supply relay

3 5 + 2 Voltage supply for the o 2 + 3 bridged, approx. b~ttery voltage

control unit via relay relay energized
J 16 (Term. 30)

Measuring range: Select resistance measurement -ohms-

4 5 + 9 Vacuum valve max. 1.5 ohms

5 5 + Breather valve max. 1. 5 ohms

6 12 + 13
Potentiometer max. 1.5 ohms
13 + 14

01-3

Test V.A.G Test itea o Test conditions Specifications

step 1598 Add. operations
sockets.

7 2 + 4 Throttle valve switch Operating lever

- pressed off swit~h max. 1.5 ohms

- pressed against the infinity ohms

switch

8 2 + 6 Thermoswitch - Bridge plugs at th~ max. 1.5 ohms

thermoswitch

9 2 + 7 Air conditioner compressor max. 1. 5 ohms

10 2 + 8 Selector lever switch Selector lever position

N and P max. 1. 5 ohms

1, 2, 3 and R infinity ohms

11 2 + 15 Pressure switch for PAS - Bridge plugs at the max. 1.5 ohms
pressure switch

12 11 + Wire for engine speed max. 1.5 ohms

term. 7 signal from the TCI-H
at plug switch unit
of TCI-H
switch
unit

01-4
 Air cleaner and Tacuum connect i ons

34 PICT carburet or

Note:
2E3 and 2 E4 car bure to r
pa g e 22 - 3.

1 - 7 Na
0 Ren ew self -l oc kin g n ut

2 - Teaperature regulator
0 Bra s s h o s e con nectio n t o
vac uum un i t

-
0 Che c kin g
- pa g e 22- 5

-
3 Vacuo• unit
0 Ch ec k ing page 22- 5
4 - Control box
0 Che c kin g
- pa ge 22 -5

7 6 5 4
22-1'

I 22-10461

5 - Delay yalTe
0 White connect i on to ca r-
buret o r
2 3 6 - Vacuo• unit -Adyance-

7 - Vacuua unit -Retard- ·

Engine c ode let t e r s
0 DF
on l y

7 6 5 4
22- 2

I 22-10461 I

I
 2E3 and 2E4 carburetor
1 1 - Teaperature regulator
o Brass hose connection to
vacuum unit
0 Checking - page 22-5
,2
2 - Vacuua unit
o Checking - page 22-5

3 Control box
3 o Checking page 22-5

4 - 7 Nm
0 Renew self-locking nut

5 - Valve for intake air preheating

o syncro only
o Valve open: handle turned to
left and pulled upwards
o Valve closed (for driving
through water): handle turned
to right and pressed downwards

22-3

6 Pull-down unit
1
1 Vacuua unit -Advance-

8 Vacuua hose
2 o syncro: positioned above
fuel reservoir

. 9 - Vacuua unit
Stage I I
3 '

22-4
Checkins intake air preheating

(34 PICT, 2E3 and 2E4 carburetor)

Checking control box/vaeuua unit

o Intake air temperature at least 20° C.

o syncro: valve for intake air preheating open.

- Pull hoses -1- and -2- off temperature regul-

ator ~3- and join together.
Pull hose -2- off ~acuum unit -4- w~th engine
idling. The flap in the control·box must be
heard to close.
Renew control box if this is'not the case.

Checking teaperature regulator

o Intake air temperature at least 20° C.

o syncro: valve for intake air preheating open.

o Control box/vacuum unit OK.

o Hoses -1- and -2- fitted to temperature regu-
lator -3-.
o Before checking, run engine for not longer than
five minutes.

22-5

- Pull. hose -2- off vacuum unit -4- with engine

idling. The flap in the control box must be
heard to close•
Renew temperature regulator -3- if this is not
the case.

22-6
 • Removing and ·installing carburetor
1 2 3 4 5 6 7 and intake •anifold

Note:
Secure all hoses with hose clamps
such that spring clips can also be
removed using pliers with engine in
situ.

34 PICT carburetor

1 - Ther•osvitch, 10 Nm
o For intake manifol~ preheater
o ~ 07,85 as illustrated
o 08,85 ~ Modified design in
thermostat housing
o Check resistance:
Below 55° C = 0 ohms
Above 65° C = infinity ohms

2 - Seal
o Renew

3 - Coolant pipe
0 ~ 07.85

22-7

1 2 4'- Carburetor
3 4 5 6 7 o Removing and installing
- Fig. 1
o Vacuum connections
- page 22-l

5 - Inter•ediate flange
o Check for cracks and dis-
tortion

6 20 II•

1 - 7 lla
8 - Gasket
o Renew

9 - Intake •anifold preheater

o Checking - F i g . 2
o Removing and installing
- page 22-12

10 - 0-ring
o Renew

11 - Intake aanifold

22:..8
 2E3 and 2E4 ca~bu~eto~
1 2 3 4 5
1 - The~aosvitch. 10 Nm
o For intake manifold pre-
heater and automatic choke
o J> 07.85 as illustrated
o 08.85 J> Modified design in
thermostat housing
o Check resistance:
Below 55° C 0 ohms
Above 65° C = infinity ohms

2 - Seal
o Renew

3 Coolant pipe
0 ... 07.85

4 - Carburetor
o Vacuum connections
page 22-3

6 - Intermediate flange
o Renew if damaged
o syncro 02.85 J>
Flange thickness 50 mm

22-9

122-1061 I

1 2 3 4 5' 7 - Gasket
o Renew

8 - 20 ••
9 - Intake aanifold preheater
o Checking - Fig. 2
o Removing and installing
- page 22-12

10 - o-~ins
c:i Renew

11 - Intake •anifold

22-10

8 l22-1o61 I
Fig. 1 Reaoving and installing 34 PICT carburetor

- Loosen front fastening nuts -arrow-.

- Unscrew rear fastening nuts.
- Lift carburetor together with flange and pull
to rear.

fig. 2 Checking in~ake aanifold preheater

o Engine cold

- Measure resistan~e between. connecting cable -l-

and earth.
Specificati~n: 0.25 ••• 0.50 ohms
t;.old resistance
Measure volt~ge supply between connecting cable -2-
and earth.
Specification:.«t least ll.:S V

22-11

Reaoviilg and installi_ng intake aanifold preheater /

34 PICT carburetor

- Remove air· cleaner and carburetor.

- ~ 07.85: Unscrew rtut -1- and bolt -2-.
- Remove bolts securing intake manifold to cylinder
head.
- Lift intake manifold and unscrew the 3 bolts from
the intake manifold jlreheater. ~
- Place wooden blocks underneath intake manifold.
- Carefully drive intake manifold preheater out of
intake manifold using plastic hammer -arrow-.

Installation takes place in the reverse order.

- Renew gaskets.
To make fitting easier, coat rubber ring for the
intake manifold preheater with coolant.

22-12
 2E3 and 2E4 carburetor

Unscrew bracket for accelerator cable.

- Remove air cleaner and carburetor.

- • 07.85: Unscrew securing nuts for coolant

pipe -1- at crankcase.

- Remove bolts fasten~ng intake manifold to

cylinder head.

- Lift intake manifold and unscrew the 3 bolts

from the intake manifold preheater.

- Place wooden blocks under intake manifold.

Carefully drive intake manifold preheater out

of intake manifold usini plastic hammer -arrow-.

Installation takes pla~e ,in the reverse order.

Renew gaskets.

To make fitting easier~ coat rubber ring for the

intake manifold preheater with. coolant.

22-13

SerYieins 34 PICT carburetor

(Engine code letters DF, EY)

Rote:
o Always renew seals and gaskets
on assembly.

o Hose connections are secured

with screw-type or spring clip~.

o Adjusting screws are secured with

caps, plugs and sealing paint so
that adjustment is not possible
without destroying the securing
element. Always renew the securing
element after carrying out repairs
or adjustment.

o Lubricate all carburetor joints

with G 000 100.

o Carburetor adjustment data

page 22-20

o Jets and settings

page 22-21

12 11 10 9

22-14

122- 16761
 Top part of carburetor

1 - To fuel tank

2 - Check valve
o Arrow must be towards
fuel tank

3 - Screws
o Tighten uniformly

4 - Froa fuel pu•p

5 - Choke shaft
o Check for ease of moveme,pt

6 - Gasket

7 - Choke cover
o Marks must be aligned

8 - 5 N•
9 - Pull-down unit
o Adjusting choke gap
- page 22-26

12 11 10 9
22-15

122- 16761

10 - Gasket
o Renew
o Use gasket with same hole
pattern

11 - Float needle valve

12 - Washer
o Check thickness - specified
value - page 22-21

12 11 10 9

22-16

122- 16761
 Bottom part of carburetor

1 - Screw plug

1 2 3 4 5 6 7 8 9 10 2 - Main jet

3 - Seal
o Renew

4 - CO adjusting screw
o Adjusting idling speed
- page 22-22
o Check 0-ring for damage
5 - Pin

6 - Float
o Watch weight
- page 22-21
7 - Air correction jet with
emulsion tube

8 Pilot jet

18 17 16 15 14 13 12 11
22-17

122. 16771

9 - Mushrooa.valve

10 - Adjusting screw
1 2 3 4 5 6 7 8 9 10 o Adjusting injection cap-
a c i t y - page 22-25

11 - Delay Yalve
o White connection to car-
buretor

12 - Throttle damper
o Checking and adjusting
- page 22-27
13 - Screw plug
o For auxiliary fuel jet

14 - Auxiliary fuel jet

15 - Injection tube
o Checking and adjusting
injection capacity
- page 22-25
o Fuel jet must strike collar
on discharge arm; bend with
normal tools if necessary

18 17 16 15 14 13 12 11
22-18

122. 16771
 16 - Adjusting screw
o Checking and adjusting
cold idle speed
page 22-26
1 2 3 4 5 6 7 8 9 10 17 - Bypass cut-off valve
o Should click when ignition
is switched on
o When ~alve is removed, the
plunger must first be pushed
in about 3 ••• 4 mm

18 - Idle adjusting screw

o Adjusting idle speed
- page 22-22
o Check 0-ring for damage

18 17. 16 15 14 13 12 11
22-19

122- 16771

Carburetor adjustaent da~a

Engine code letters DF EY

Carburetor Type 34 PICT-5 34 PICT-5

Part No. 025 129 027 025 129 027 A
025 129 027 B*}
Modification status 138-1 156-1
. *)157-1

Test: specs.
and settings Injection capacity cm'/stroke 1.3 +I- 0.15 • 1.3 +I- 0.15

Choke valve gap mm 2.8 +I- 0.2 2.8 +I- 0.2

Cold idle speed rpm 1900 +/- 100 1900 +/- 100

Test specification rpm 800 +I- 50 850 +I- 50

(DIS connected)
Setting 2 ) rpm 750 +I- 50 850 +I- 50
(DIS disconnected 3 ))
CO content 2 ) % by vol. 1.5 +I- 0.5 2.0 +I- 1.0

1) Pay attention to checking and adj~stment conditions page 22-22

2) Current values - "Exhaust gas and idling speed test" binder
3) Plugs pulled off DIS switch unit and joined together

22-20
Jets and settings

Engine code letters DF EY

Carburetor Type 34 PICT-5 34 PICT-5
Part No. 025 129 027 025 129 027 A
025 129 027 B*
Modification status 138-1 156-1
*)157-1

Jets and settings

Venturi mm dia. 26 26
Main jet 127.5 132.5
Air correction jet 60 z 60 z
Pilot jet so 55
Pilot air jet 1 ) 140 140
Auxiliary fuel jet 45 45
Auxiliary air jet 1 ) 90 90
Float needle valve mm dia. 1.5 1.5
Float weight g 11 +/- 0.5 11 +/- 0.5
Washer under float
needle valve mm ,0. 5 0.5

1) Jet cannot be exchanged

22-21

Adjusting idling. speed

Checking and adjustment conditions

o Minimum'engine oil temperature 60° C.

0 cranktase breather hose pulled off and sealed

on air cleanet end.

o Radiator fan must not be in operation.

o Electrica~ loads switched off.

o Choke valve fully open.

0 No leaks in exhaust system.

o Ignition timing point adjustment OK; checking

page 28-14 for code letters DF and page 28-39
for code letters EY.

Checking and adjusting idling speed and CO content

-Connect up ignition tester V.A.G 1367.

-Connect CO tester V.A.G 1363A to tailpipe.

V.A.G 1367/9 l2a- 10211

22-22
Attention:
Switch off ignition before connecting up test
appliances.

- Check idle speed and CO content. '

Test specification:

Code letters Engine speed CO content

rpm % by vol.

DF 750 8501) 1.0 2.0

EY 800 900 1.0 3.0

1) DIS connected

In the event of deviation'from the specified value:

- Pull plugs off DIS switch unit and join together

(DF only).

- Adjust idle speed and CO content to setting by

alternately turni,ng· a.;ijusting screws.

22-23

Setting:l)

Code letters Engine speed co content

rpm % by vol,

DF 750 +/- 50 1.5 +I- 0.5

EY 850 +/-, 50 2.0 +I- 1.0

1) Current values ---'- "Exhaust gas and idling speed

test" binder

Adjust idling speed -arrow-.

I

- Adjust CO content -arrow-.

-Connect up DIS and re-check CO content.'Correct

if necessary.

- Fit new anti-tamper cap on CO adjusting screw.

Rote:
The crankcase breather hose must be re-connected
after the CO content has been adjusted. If the
CO level rises afterwards, this does not mean the
adjustment is incorrect, but is due to enrichment
from oil dilution in the crankcase resulting from
frequent stop/start operation.
A long fast drive will reduce the amount of fuel
in the oil and the CO content will return to the
normal level.· At short notice, this can also be
done by way of an oil change.

22-24
Checking and adjusting aaonnt injected by accelerator
puap

Run engine to fill the float chamber.

Open choke valve and fix in position with ret.ainer.

- Push tube over end of injection pipe of carburetor.

- Operate throttle until fuel emerges from tube.

- Hold measuring glass under tube and slowly open the

throttle fully 5 times (at least 3 seconds per stroke).

- Divide injected quantity by 5.

Compare result with specified value and correct where
necessary.
Specification: 1.3 +/- 0.15 cm'/stroke

- Adjusting injec.ted quantity:

+ - more
- • less

- The jet of fuel must strike the collar in the discharge

arm, ()therwise injection tube must be aligned.

22-25

Adjnstin& cheke Ya1ye &ap

- Partially dismantle automatic choke.

- Close choke vain~.

- Press .pul,l rod for vacuum diaphragm with screw-

driver in. direction of .. arrow as far as stop.
Measur~ gap with twist drill in this P?Sition.
Specification: 2.8 +!- 0.2 mm

- If necessary, adjust choke valve gap at the ad-

justing screw -a.trow-.

Checking and adjusting cold idle speed

o Minimum engine oil temperature 60° C.

o Ignition timing adjustment OK.

o Idle adjustment OK.

- Set adjusting screw to third step -arrow- with

engine running.

- Set speed with adjusting screw -1-.

Specification: 190Q +/- 100 rpm

!'

22-26
 Checking and adjusting throttle daaper and delay
valve

o Minimum eng~ne oil temperature 60° C.

- Run engine at idling speed.

- Press lever against adjusting screw by hand

-arrow A-,

- Check speed and, ~f necessary, remove cap from

adjusting screw -arrow B- and adjust speed.
Specification: 1300 +/- 100 rpm

- When speed is correct, fit new anti-tamper cap

on adjusting screw.

Increase engin• speed to approx. 3000 rpm such

that the lever of the throttle damper is pulled
against the adjusting screw -arrow-.

- Release throttle valve lever.

Damper lever shouli.now lift slowly off adjusting
screw and the th~ottle valve should be completely
closed after approximately 3 seconds.

22-27

Servicing 2K3 and 2K4 carburetor

(Engine code letters DG, SP)

lfote:
1
o Always renew gaskets and seals
on assembly.

o Hose connections are secured

with screw-type or spring clips.

o Adjusting screws are secured with

caps, plugs and sealing paint so
that adjustment is not possible
without destroying the securing
element •. Always renew the securing
element after carrying out repairs
or adjustment.

o Lubricate all carburetor joints

with MoS2 grease.

o Idling speed stabilisation comp-

onents, 2E4 carburetor
- page 22-33

o Carburetor adjustment data

page 22-38

o Jets and settings

page 22-40

o Jet layout --. Figs. 1 and 2

10 9 8 7 6

22-28

122. 16781
 o Fuel reservoir on syncro
Fig. 5

o Basic adjustment of throttle

valve, stage II --. page 22-58

1 Top part of carburetor ij

1 - Screen
o Remove ~ith standard puller
for anti-tamper caps (e.g.
Hazet 4518-1)

2 - Pilot fuel/air jet

o - Fig. 1
3 - Breather pipe
o For float chamber

4 - Pull-down unit
o Checking operation
--. page 22-51
o Checking for leaks
- page 22-51
o Checking and adjusting the
choke valve gap
- page 22-52

10 9 8 7 6
22-29

122- 16781

5 - Choke coYer
o Adjusting - Fig. 4
o Checking: Switch on igni-
tion and connect up test
lamp between separated
1 connector.
Test lamp must light
(coolant temperature below
55° C)

6 - Main jet, stage I I

0 -Fig. 2

7 - Main jet, stage I

0 -Fig. 2

8 - Gasket
0 Renew

9 - Float

10 - Float needle

10 9 8 7 6

22-30

122" 16781
 Bottoa part of carburetor

1 - Part-load enrichaent valve

o Do not re-use valve after
removal (renew)
1 2 3 4 2 - Injection tube
o Installing --. Fig. 3
o Renew 0-ring if damaged
3 - Adjusting screw
o Checking and adjusting
co:J,d idle speed
---+ page 22-49

4 - Vacuua unit. stage II

o ZE3 carburetor only
o Checking for leaks and
checking operation
- page 22-53
o Checking vacuum
- page 22-54

5 - Adjusting screw
o Only on 2E3 carburetor for
idle speed adjustment
- page 22-45
o Shear screw on 2E4 carbur-
etor (adjustment is not to
be changed)

8 7 6 5
22-31

122-16791

6 - CO adjusting screw
o Adjusting idle speed
- page 22-45
o Renew 0-ring if damaged
1 2 3 4 7 - Part-load duct heating
o Qkecking - page 22-57

8 - Accelerator puap
o Checking and adjusting
injection capacity
- page 22-56 ·

9 - Mushrooa valve

10 - Idle cut-off valve. 6 Hm

o Must click when ignition
is switched on
o Use 3064 to remove and
install

8 7 6 5

22-32

122- 16791
 SerYicing eo•ponents of ~dling speed
.I
7 4 s 6 stabilisation system

---""-Y-!J-14
~.
(2E4 carburetor)

Bote:

. 1?:--15
o Dismantling and assembling car-
buretor - page 22-28

o Electrical check on idling speed

I stabilisation page 01-1

~pb16 1 - Cover
o Removing: Screw M 4 bolt into
tapped hole and pull cover out

2 - 0-ring
o Renew if damaged

3 - Filter
o Installation position: must fit
on cover -1-

4 - Breather valve
·o Checking - checking throttle
valve positioner, page 22-61

~--21

~~----22
<JJ'' ______ • .,._

22-33

22-1571

7 4 s 6 5 - ~hrottle valve positioner

o Checking --. page 22-61

6 - Vaeu- valve
o Checking' ..;_._ checking the
throttle valve positioner,
page 22-61

7 - Throttle YalYe switch

o Idling switch
o Checking - checking th~
throttle valve positioner,
page 22-61

8 - Current supply relay

o For control unit and throttle
'----.........~--17 valve positioner
o Checking - page 01-3
:..-----18 9 - Connector, 4-pin
o To current •upply relay
o On automatic gearbox also to
selector lever switch

10 - Green wire
o To TCI-H switch unit, term-
inal 7

22-34
 11 - Black/white wire
7 4 5 6 o To ignition coil ter-
minal 15

12 - Breather valve filter

o Location: on control unit
bracket
o When dirty, idling speed
too low, renew

13 - Clip
14 Branch pipe

15 - Vacuua pipe
o To distributor
o On syncro vehicles, the
vacuum pipe must be routed
'---....:.....,..,l.---17 over the fuel reservoir on
the carburetor
~~---18
16 - Vacuua pipe
o To temperature regulator
on air cleaner housing

17 -·Bracket

22-35

I 22-1sn

7 4 5 6 18 - Choke valve
o With flap valve

---""Y4J- 19 - Fast idle c::aa

o With cold start detent
.

r:---15{J

I
14
20 - Theraosvitch, 15 N•
o Below 17" C throughflow
o Above 25" C ~ no throughflow

21 - Shear screw

~rb16
o Basic stage I throttle valve
adjustment - page 22-60

22 - Pressure switch - power ass-

isted steering, 15 Ha
"------.!...=!-----17 o Check with engine running
o Steering in straightahead
position: no throughflow
:.-----18 o Steering on lock: through-
flow

23 - Idling speed stabilisation

control unit
o To remove, take out left-
hand taillight

;'<.._--21
~-----22
H ..,- "----~ ""'"'"

22-36

22-1571
 7 4 5 6
24 - Connector
0 Only disconnect or connect
ii
with ignition switched off j
J

---~
o To detach, press spring up
t
25 - Red/blue wire l:
'lj
. ll 14 o To A/C compressor

r:--15 I
26 - Earth wires
o To cylinder head
lit
~:
1!'

27 - Adjustment screw
'
' ~?16
0 Adjusting distance between
throttle valve switch and
throttle valve lever -
jl
.checking throttle valve
switch, page 22-63
17

i
·--21 :lJ

___~----22
_,.... ,,_

22-37

22-1571

Carburetor adjustaent data

Code letters DG 10.82 ~ 10.85 ·DG 11.85 ~ 02.87 DG 03.87 ~

(RWD engine)
SP 10.86 ~ 02.87 SP 03.87 ~

Carburetor
Type 2E3 2E3 2E4
Part No.
1
Manual gearbox 025 129 015 025 129 015 H/K } 025 129 015 E
Automatic gearbox 025 129 015 A 025 129 015 J/L 1 ) 025 129 015 F

Test specs. and settings Stage I Stage n Stage ·I Stage II Stage I Stage II
Injection capacity
Man. g/box cm'/stroke 1.35 +/- 0.2 1.35 +/- 0. 2 1.35 +/- 0.2
Auto. g/box cm'/stroke 1.00 +/- 0.2 1.00 +/- 0. 2 1.00 +/- 0.2
Choke valve gap mm 3.30 +/..: 0.2 2.50 +/- 0.2 2.50 +/- 0.2
Cold idle speed rpm 2000 +1- 200 2000 +/- 200 3600 +/- 200
Idle
Engine speed 3 ) rpm 900 +I- 50 900 +I- 50 850 950 4 )
CO content3) % by vol. 1.5 +I- 0.5 1.5 +I- 0.5 1.5 +/- 0. 5

1) Carburetors 025 129 015 K and 025 129 015 L in conjunction with cyclone-type air cleaner
2) Pay attention to checking and adjustment conditions --- page 22-45
3) Current values - "Exhaust gas and idling speed test" binder
4) Idling speed regulated automatically, not adjustable

22-38
 Code letters DG 02,85 • 10.85 DG 11.85 ... 02.87 DG 03.87 ...
(syncro engine)
SP 10.86. 02.87 SP 03.87 ...

Carburetor
Type 2E3 2E3 2E4
Part No.
Manual gearbox 025 129 015 D 025 129 015 M 025 129 015 G
Automatic gearbox

Test specs. and settings Stage I Stage II Stage I Stage II Stage I Stage II
Injection capacity
Man. g/box cm'/stroke 1.-35 +/- 0.2 1.35 +/- 0.2 1.35 +/- 0.2
Auto. g/box cm'/stroke
Choke valve gap mm 3.30 +/- 0.2 2.5_0 +1- 0.2 3.30 +/- 0.2
Cold idle speed rpm 2000 +1- 200 2000 +/- 200 3600 +I- 200
Idle adjust•ent 1 )
Engine speed 2 ) rpm 900 +I- 50 900 +/- 50 850 950 3 )
CO content2) % by vol. 1.5 +I- 0.5 1.5 +/- o. 5 1.5 +I- 0.5

1) Pay attention to checking and adjustment conditions--. page 22-45

2) Current values --. "Exhaust gas and idling speed test" llinder.
3) Idling speed regulated automatically, not adjustable

22-39

Jets and settings

Code letters DG 10.82 • 10.85 DG 11.85 .. 02.87 DG 03.87 ...

(RWD engine)
SP 10.86 .. 02.87 SP 03.87.

Carburetor
Type 2E3 2E3 2E4
Part No.
Manual gearbox 025 129 015 025 129 015 H/1 1 ) 025 129 015 E
Automatic gearbox 025 129 015 A 025 129 015 J/L 1 ) 025 129 015 F

Jets and settings Stage I Stage II Stage I Stage n Stage I Stage II

Venturi mm dia. 22 26 22 26 22 26
Main jet X 102,5 X 110 x 102.5 A x 110 L X 102.5 A X 110 L
optionally X 102,5 + -x 110
Air correction jet 50 45 so + 45 + 50 D 45 F
with emulsion tube
Pilot fuel/air jet 45/110 45/125A 45/+125
optionally 45/+125
Full-load enrich- mm dia. 1.1 o.s 0.5
ment
Pump injection tube
Manual gearbox mm dia. 0.45 0,45 0.45
Automatic g/box mm dia. 0.30 0.30 0.30
Marking on choke 256 293 303
cover

1) Carburetors 025 129 015 K 'and 025 129 015 L in conjunction with cyclone-type air cleaner

22-40
Code letters DG 02.85 II' 10.85 DG 11.85 II' 02.87 DG 03.87 II'
(sync~o engine)
SP 10.86 II' 02.87 SP 03.87 II'

Carburetor
Type 2E3 2E3 2E4
Part No.
Manual gearbox 025 129 015 D 025 129 015 M 025 129 01S G
Automatic gearbox

Jets and settings Stase I Stase II Stage I Stage II Stase I Stage II

Venturi mm dia. 22 26 22 26 22 26
Main jet X 100 X 112 • 5 X 102.S A X 110 L x 102.5 A x 110 L
optionally 102.5 + -x 110
Air correction jet so 45 "
so + 4S + SO D 45 F
with'emulsion tube
Pilot fuel/air jet 4S/110 4S/125 A 45/+12S
optionally 45/+125
Full-load enrich- mm dia. 0.9 o.s 0.5
ment
Pump injection tube
Manual gearbox mm dia. 0.45 0.45 0.45
Automatic g/box mm dia.
Marking on choke 286 293 303
cover

22-41

Fig. 1 Jets'at top in top part of carburetor

- Pilot fuel/air jet

2 - Air correction jet with emulsion tube,

stage I (c~nnot be exchanged)

3 - Air correction jet with emulsion tube,

stage II •( cannot be exchanged)

4 - Full throttle enrichment tube

Fig. 2 Jets at bottom in top part of carburetor

1 -Main jet, stage I

2 - Main jet, stage II

3 - Vertical tube for full throttle enrichment

4 - Vertical t~be for changeover, stage II

22-42
Fig. 3 Installing injection tube

The fuel must be sprayed towards the recess as

indicated by the arrow.

Fig. 4 Adjusting choke cover

22-43

Fig. 5 Fuel reservoir

A fuel reservoir is fitted on the carburetor of

the syncro to avoid the formation of gas bubbles.

Connections:

A - From fuel pump

B - To carburetor
C - Return line

Attention:
The vacuu• hose for the distributor must be laid
over the fuel reservoir, as otherwise the vacuum
hose could become full of fuel.

22-44
 Adjusting idle speed

Checking and adjustment conditions

o Minimum engine oil temperature 60° C.

o Crankcase breather hose pulled off and sealed

on air cleaner end.

o Radiator fan must not be. in operation.

o Electrical loads switched off.

o Choke valve fully open,

o No leaks in exhaust system~

o Ignition timing adjustment OK; checking --.

page 28-14.

22-45

Checkins ••• adjust:i.ng idle speed and CO content

o Hose/hoses at vacuum unit of distributor must

be at.tached.

-Connect up ignition tester V.A.G 1367.

- Connect CO tester V.A.G 1363A to tailpipe.

Attention:
Only c.onnect up testers with ignition switched off.

V.A.G l36?/9 l2a. 1021!

- Check idle speed and CO content.
With 2E3 carburetor, screw -C- must not make con-
tact with fast idle cam. Turn fast idle cam where
necessary.
Specifications;!)
Engine speed 900 +/-.50 rpm
CO content 1.5 +/- 0.5% by vol.

1) Current values --- "Exhaust gas and idling speed

test" binder

22-46
 2
- If necessary, correct idling speed ) and CO content
by alternately turning adjusting screws.

A Idle adjusting screw2)

B - CO adjusting screw

- When correction has been made, fit new anti-tamper

cap to CO adjusting screw.

1) Current values - , "Exhaust gas and idling speed

test" binder
2) 2E3 carburetor only.
Notes on 2E4 carburetor - page 22-48

Note:
The crankcase breather hose must be re-connected when
the CO adjustment has been made. If the CO level rises
afterwards, this does not mean that the adjustment is
incorrect, but is 'due to enrichment from oil dilution
in the crankcase resulting from frequent stop/start
operation.
A long fast drive will reduce the amount of fuel in the
oil and the CO content will return to the normal level.
At short notice, this can also be done by means of an
oil change.

22-47

2E4 carburetor only:

Directly after the engine has st•rted, the idling

speed is automatically regulated to the following
values as a function of the temperature of the
thermoswitch at the carburetor:
Below + 17° C approx. 1100 rpm
Above + 25° C 900 +/- SO rpm
' '

If the prescribed idling speed is not attained or

exceeded, the following faults could be present:

Speed below 800 rpm Filter for breather valve

of throttle valve posit-
ioner clogged - checking
throttle valve positioner,
page 22-61.

Speed above 2000 rpm Open circuit to the idling

, speed stabilisation control
unit or insufficient vacuum
at vacuum valve of throttle
valve positioner.

22-48
Checking and adjusting cold idle speed

o Minimum engine oil temperature 60° C.

o Ignition timing adjustment OK.

o Idle speed adjustment OK.

Connect up ignition tester V.A.G 1367.

2E3 carburetor

Accelerate until engine speed is approx.

2500 rpm. Press down fast idle cam as far
as stop -arrow- and release throttle.

Adjusting screw -2- is at second highest stage

of fast idle cam -1-.
Specification: 2000 ~/- 200 rpm

- If necessary, adjust cold idle speed to the

specified value by means of the screw -2-,

22-49

t.t
I
~I'
2E4 carburetor

- Ac~elerate until ebgine speed is approx.

4000 rpm. Press down fast idle cam -arrow-
such that on releasing throttle adjusting
screw -2- is at highest stage -1- as shown '. i
ji
in Fig. 22-1082.
Specified value: ~600 +/- 200 rpm
~f
il
i'l

1rl
1

necessary, adjust cold idle speed to the

specified value with adjusting screw -2-.

22-50
Checking and adjusting pull-down unit

Checking operation

Remove intake air cowl.

Run engine at idle speed.

- Close choke valve by hand. If it is easy to

close the choke valve down to a gap of approx.
3 mm and if a fair amount of resistance is
then felt, the pull-down unit is OK.
If it is possible to fully close the choke with
no resistance. cthis means that either the dia-
phragm is torn or that there is a leak in the
vacuum system.

Checking pull-down unit for leaks

-JDisconnect vacuum hose -1- of pull-down unit -2-

from carburetor and connect up both vacuum tester
V.A.G 1368 and vacuum pump V.A.G 1390.

Switch vacuum tester to throughflow.

- Generate approx. 300 mbar vacuum with vacuum pump.

Set vacuum tester such that vacuum is retained on

the pull-down unit end.

22-51

- Set vacuum on tester to 200 mbar. The ~et vacuum

must not drop off within 2 minutes. Otherwise
the pull-down unit is to be replaced.

Checking and adjusting choke valve gap

- Remove choke cover.

- Operate throttle valve and turn fast idle cam -1-

of cold start device such that adjusting screw -2-
is at highest stage of fast idle cam.

Press control rod for choke valve at the adju.sting

screw -1- in direction of pull-down unit -arrow-
as far as it will go.

In this position, check gap with twist drill -2-

and adjust if necessary,at adjusting screw -1-.

Code letters Carburetor Specification (mm)

DG
• 10.85 2E3 3.3 +I- 0.2
DG 11.85 • . SP 10.86. 2E3 2.5 +I- 0.2

DG 03.87 • . SP 03.87. 2E4 3.3 +I- 0.2

22-52
 Checking operation of throttle valve, stage II

Checking vacuum unit for leaks

- Detach vacuum hose -1- of vacuum unit stage II -2-

from carburetor and connect up both vacuum tester
V.A.G 1368 and vacuum pump V.A.G 1390.

- Switch vacuum tester to throughflow.

- Generate approx. 300 bar vacuum with vacuum pump.

- Set vacuum tester such that vacuum is retained on

the vacuum unit end:

Set vacuum on tester to 200 mbar. The set vacuum

must not drop off within 2 minutes or the vacuum
unit is to be renewed.

Checking operation of vacuum unit

o Leak test OK.

Place throttle controls in full throttle position

at 200 mbar vacuum. The throttle valve of carbur-
etor stage I I must 'be lifted by the vacuum unit
linkage -arrow-.

22-53

Checkin& •acuu for yacuua unit, stage II

llote:
The vacuum is meastired at full throttle whilst
driving or on a roller dynamometer.

- Use T-piece to connect up the vacuum tester

V.A.G 1368 between vacuum unit stage I I and
vacuum connection at bottom part of carbur-
etor.

- Connect up ignition tester V.A.~ 1367.

- Place test appliances on passenger's seat and

set vacuum tester such that vacuum is retained.
V.A/31367
Jfote:
When laying vacuum hose, make sure that it is not
kinked or trapped.

V.A13l367/9 l2s. 1021l 22-54

- Measure vacuum at full throttle.

o On roller dynamometer:
Select load (speed) such that max. 5000 rpm are
attained in 2nd gear or in 1st driving range.

o On the road:
Drive at a constant 3000 rpm in 1st or 2nd gear
or in 1st driving range. Then accelerate with
full throttle to ~ax. 5000 rpm.

-Read vacuum off te,ter at 4000 ••• 5000 rpm.

Specified values:
Large vacuum unit (approx. dia. 65 mm)
min. 30 mbar
Small vacuum unit (approx. dia. 50 mm)
min. 50 mbar

If the specifications are not obtained, check the

vacuum hoses and connections for leaks/blockages
and renew carburetor if necessary.

22-55

Checking and adjustina accelerator pu•p injection

rate

o Carburetor removed.

Turn fast idle cam -1- and hold such that it does
not make contact with adjusting screw for the cold
idle speed -2-.

Hold funnel and measuring glass VW 119/10 beneat~

carburetor.

- Rapidly open throttle valve lever five times as far

as it will go (approx. 1 second/stroke). Allow an
interval of approx. 3 secon~s between each stroke.

- Read off figure for injected quantity, divide it by

five and compare it to the specified value.
Specified value:
Manual gearbox 1.35 0.2 cm'/stroke
Automatic gearbox 1.0 0.2 cm'/stroke

22-56
- Adjust amount injected by loosening the clamping
screw -1- and turning the fast idle cam -2-.

A Larger ~mount

B - Smaller amount

- Secure clamping screw with paint after adjusting.

Checking part-load duct heating

o Contact surface of heating element must make con-

tact with c•rburetor (earth connection). Clean the
surfaces if necessary.

- Switch on ignition and pull plug -1- off idle cut~

off valve.

- Separate connector for heating element -2-.

- Connect test lamp to plugs -1- and -3-.

Test lamp lights: Heating element OK
Test lamp does not light: Heating element defective,
renew

22-57

Baade Atlj-.taeat of th.r~ttle ..-ah·e. stage I I

aot:e:. .{)

The limiting ~crew -2- ~s set at the factory and

must pot be ~oved. If the screw has been turned,
adjustment should be carried out as follows.

- Remove carburetor.

- Open throttle valve for stage I and clamp it in

position -arrow-.

- Pretension locking lever -1- for throttle valve

stage II with rubber ring.

- Unscrew limiting screw -2- until there is a gap

between the limiting screw and the stop -3-.

- Screw in limiting screw -2- until it contacts the

stop -3-.

22-58
Note:
In order to find the exact stop point of the
limiting screw, place a thin sheet of paper
between the limiting screw and the stop. The
stop point can be determined by constantly
moving the paper and simultaneously screwing
in the limiting screw.

- When this point is reached, turn the screw

a further 1/4 turn.

- Secure limiting screw with paint.

- Check play at locking lever -arrows- with

throttle valves closed.
Specified value: 0.4 +/- 0.15 mm on
either side

If necessary, adjust play to the specified

value by bending the sides.

- Install carburetor, adjust idle speed and

CO content --- page 22-45.

22-59

Basic adjustaent of throttle valve, stage I

(2E4 carbureto~~aly)

Note:
The limiting screw -1- (shear screw) is set at the
factory and must not be moved. If screw has been
turned, adj ustm,ent should be carried out as fallows.

- Remove throttle valve positioner.

- Turn out limiting screw -1- with pliers until there

is a gap between limiting screw and stop at throttle
valve lever.

Screw in limiting screw -1- until it contacts stop.

Note:
In order to find the exact stop point of the limiting
screw, place a thin sheet of paper between limiting
screw and stop. The stop point can be determined by
constantly moving the paper and simultaneously screwing
in the limiting screw.

22-60
- When this point is reached, turn the screw a
further 1/4 turn.

- Secure limiting screw with paint.

Checking throttle valve positioner j

(2E4 carburetor only)

- Pull connector, breather hose and vacuum hose

off throttle valve positioner.

Connect up vacuum tester and vacuum pump to the

vacuum connection on the vacuum valve.

-Connect test cables from V.A.G 1594 to contacts

1 and Q on the throttle valve positioner and one
cable to earth (-).

- At the same time, generate at least 400 mbar with

vacuum pump and touch the positive terminal at the
alternator with the second cable until the plunger
of the positioner is fully retracted.
Plunger length a 55 +/- 0.5 mm
$

22-61

The plunger must remain pulled in for at least

one minute or the throttle valve positioner .is
to be renewed.

- With th~ pl~nger fully in, check the gap -b-

between throttle valve lever and throttle valve
switch and adjust if necessary with the adjust-
ment screw -8-.
Gap b ~ 0.8 +/- 0.4 mm

- Change test cables at throttle valve positioner

from contacts 1 and 2 to 6 and 7 and touch ter-
minal (+) at alternator with free cable until
plunger is fully extended.
Plunger length c = 72 +/- 0.5 mm

The plunger must be fully extended in max. 1 sec.

If this is not the case:

o Breather valve filter -arrow- dirty; clean or

renew.

o Throttle valve positioner defective; renew.

22-62
- Use hand multimeter V.A.G 1526 to measure resistance
at the following contacts:

Potentiometer:
3 and 4 m max. 1.5 ohms
3 and 5 =max. 1.5 ohms

- If not, renew throttle valve positioner.

Throttle valve switch:

Operating lever -8- pushed off switch= max. 1.~ ohms
Pressed against switch = infinity ohms

- If not, renew throttle valve positioner.

22-63
 Repairing TCI-B ignition SJStem

Note:
o Note safety precautions -
page 28-7

o Adjustment data - page 28-8

o Spark plugs --+ page 28-9

o Distributor data --+ page 28-10

o Components marked with *

are fitted
with M4 ignition cable connections.
The two versions are not mutually
interchangeable.

Part I

1 - Ignit:1on coil*
o Green sticker
Primary resistance:
0.52 .•. 0.76 ohms
(between term. 1 and 15)
Secondary resistance:
2.4 ..• 3.5 k ohms
(between term. 15 and 4)

-!----5

10 9

28-1

o Grey sticker
Primary resistance:
0.6 ••• 0.8 ohms
(between term. 1 and 15)
Secondary resistance:
6.~ ••• 8.5 k ohms
(between term. 15 and 4)

2 - DIS idle stabilising unit

• o Engine code letters DF only
o Before adjusting tdle speed
and ignition timing point,
pull connectors off and join
them together
o Checking - page 28-28
3 - TCI-8 transistorized ignition
unit
o Checking ~ page 28-24

4 - Suppression plug*
o 0.6 .•. 1.4 k ohms

5 - Ignition leads*
o Check for continuity

10 9 6

[:..I
28-2
 6 - Spark plug connector*
o 4 ••• · 6 k ohms

7 - Spark plug, 20 Nm
o Type and electrode gap
- page 28-9

8 - Carbon brush with spring

o Check for wear, damage and
ease of movement

9 - Distributor cap*
o Check for cracks and signs
of tracking
o Check contact wear
o Clean be.fo;e installing
10 ,- Connector

10 9 6

'
L7 128-341 I
28-3

-------1 Part I I

------2 1 - Rotor arm

o Identification: Rl
o 0.6 •.• 1.4 k ohms
~~~---3
2 - Dust cap
------4
3 - Circlip
L--------5
4 - Cover
...i!U-L-----3 o Removing and installing
, page 28-13
7--- 5 - Pin

17---...,J!Jl::V:..~--.. 6 Spring washer(s)

16-----" 7 - Washer(s)
o No. of washers:
Hall sender free of play
15--- and easy to turn
14------+ 8 - Hall sender
o Apply thin coat of grease
to bearing surfaces
o Checking - page 28-27
~----.......;10

I 11
f.;iJ:<I------12

~13 28-4

I 28-3421
 9 - Vacuua unit
1 0

-
Checking for leaks
page 28-18
2
3
--
0 Checking advance
page 28-19
o Chetking retard
page 28-21
6 4 10 - Sealing ring
o Renew
18 5
11 - Spring
19 3 12 - Distributor drive shaft
7
17
-
o Removing and installing
page 28-11

13 - Thrust washers
0 Install with screwdriver
16 and align

15 14 Distributor
0 Installing - - page 28-12

14 0 Checking - page 28-16

o Checking and adjusting

10
-
ignition timing point
page 28-14

15 - Base plate

11
12

.v--13 !28-3421
28-5

1 16 - Washer

2 17 - Magnet

18 Connection piece
3
19 - Retainer
6--- 4
18--~

19---
7---
17----;l!ll:w-.. . .~-
16----
15----
14-------+

---------10
1--------11
~------12

~13 28-6
l28-342l
 Safety precautions for TCI-B ignition systea

In order to prevent personal injury and/or damage

to the TCI-H ignition system, the following is to
be observed when working on vehicles which feature
a TCI-H system:

o Ignition must be switched off before disconnecting

or connecting ignition system leads - including
high-tension leads - and test appliance leads.

o If the engine is to be turned at starter speed

without starting, for example when checking the
compression, pull high-tension lead (terminal 4)
out of distributor and earth it.

o Vehicles on which a defect on the ignition system

exists or. is suspected may only be towed with the
plug on the TCI-H unit pulled out.

o Do not connect a capacitor to terminal 1 (-).

o Do not replace 1 k ohm rotor arm (marking: Rl)
with a different version even to eliminate radio
interference.

o When suppressing interference, only resistors with

1 ~ ohm and spark plug connectors from 1 to 5 k ohms
may be used on the high-tension leads.

28-7

Adjustaent data

Engine code lettera DF 10.82 ~ DG 10.82 ~ 10.85 DG 11.85 ~ ,SP 10.86 ~

Distributor Part No. 025 905 205 Bl) 02.'1 905 20s c ) 025 905 205 Q
1
025 905 205 G 025 905 205 J

Ignitipn tiaing Test spec. 3 7" after TDC 3 70 before TDC 3 70 before :rnc
point2) 3)
Setting 5 +!- 1• after TDC 5 +I- 10 before TDC 5 +I- 10 before TDC

Engine apeed 3 )
Mark

rpm
-Fig. 1

750 +/- so
- Fig. 1
900 +/- 50 4 )
- Fig. 1

900 +/- 50 4 )

Vacuua hoses 3 ) Attached Detached 4 ) Detached 4 )

Idle stabilis- Plugs pulled off

ation switch and joined
unit together

Governed speed rpm 4650 ••. 5250 ••• 5550 5250 .•• 5550

Firing order - 4 - 3 - 2 1 - 4 - 3 - 2 1 - 4 - 3 - 2

1) With M4 ignition lead connections

2) Pay attention to checking and adjustment conditions - page 28~14
3) Current values .:_,. "Exhaust gas and idling speed test" binder
4) After speed drop, increase speed to specified value by opening throttle

28-8
Spark plugs

Engine code letters DF 10.82 .. ,DG 10.82 .. ,DG 11.85 .. ,SP 10.86 ..

Spark plugsl) Coil sticker green grey

VW/Audi 101 000 005 AB, 101 000 006 AC,

101 000 001 AC, 101 000 002 AB,
101 000 007 AB 101 000 000 AB

Manufacturers' w7 DTC, 14-7 DTU, w 7 nco, 14-7 DUO,

designations N 7 BYC N 7 YCX

Electrode gap 0.7 0.9 mm 0.7 0.8 mm

Tightening torque 20 Nm 20 Nm

1) Current values - "Exhaust gas and idling speed test" binder

Fig. 1 Ignition tiaing aark

28-9

Distributor data

Engine code letters DF 10.82 .. DG 10.82 .. 10.85 DG 11.85.. SP 10.86 ..

Distributor Part: No. 025 905 205 B 025 905 205 c 025 905 205 Q
025 905 205 G 025 905 205 J

Centrifut~al
advancel)
Start rp~ 1500 ••• 1700 1500 ••• 1700 1050 1160

rpm 2400 2400 2400

degrees 6 .•• 10 10 ... 14 13 . .. 17

End rpm 3800 4200 4200

degrees 20 ••. 24 24 .•. 28 24 ... 28

Vacuua advance
Start mbar 160 240 150 220 150 220
mmHg 120 180 113 165 113 165
End mbar 370 380 310 330 310 330
mmHg 278 285 229 237 233 248
degrees 14 18 12 16 12 16

Vacuua retard
Start mbar 120 240
mmHg 90 180

End mbar 300 360

mmHg 225 270
degrees 8 12

1) Speed engine speed

28-10
Removing and installing distributor drive shaft

Removing

- Remove fuer pump.

- Remove distributor drive shaft with normal

extractor 14.5 18.5 mm dia. (e.g. with
KUKKO 21/2).

Installing

- Set crankshaft to TDC on No. 1 cylinder.

- Insert drive shaft so that the offset slot

in the head of the distributor drive shaft
is pointing towards the tapped hole or the
screw -arrow-. The small segment faces the
coolant pump.

Install spacer spring.

28-11

Installing distributor

- Set crankshaft to TDC o~ No. 1 cylinder.

Turn rotor arm until it is pointing towards

mark for No. 1 cylinder on the distributor
housing.

Insert distributor.

- Clean distributor cap and check for cracks,

signs of tracking and tightness.

- Adjust ignition timing --. page 28-14.

28-12
 Re•oving and installing rotor plate

- Insert hooks -1- and -2- of puller as shown

and remove rotor plate.

Note:
o When pulling off the rotor plate, make sure
that locking pin does not fall in~o the dis-
tributor.

o Following installation, check the freedom of

movement of the rotor plate by turning dist-
ributor shaft. The rotor plate is to ~ re-
newed if it is bent.

I
fr
t
r
f
f
l

28-13

Checking and adjusting ignition ti•ing

o Minimum engine oil temperature 60° C.

-Connect up ignition tester V.A.G 1367.

Engine code letters DF

- Pull plugs off idle stabilising unit

and join them together -arrow-.

- Check idling speed and adjust if nec-

essary.
Setting: 750 +/- 50 rpm

- Check and, if necessary, adjust the

ignition timing.

With TDC sender:

The ignition timing point is indicated
directly on the tester.
Test specification: 3 •.• 7° after TDC
Setting: 5° after TDC

28-14
 With0stroboscopic lamp:
Notch on belt pulley must be in line with
joint on crankcase.

Engine code letters DG, SP

Detach hose from vacuum unit.

- Accelerate until speed is 900 +/- SO rpm.

C.\leck and, if necessary, adjust the ignition

timing.

With TDC sender:

The ignition timing point is indicated directly
on the tester.
Test specification: 3 •.. 7• before TDC
Setting: 5° before TDC

With stroboscopic lamp:

Notch on belt pulley must be in line with
joint on crankcase.

- Decelerate and attac~ hose for vacuum unit.

Speed: 900 +/- 50 rpm
Ignition timing point: 17 ••. 21° before TDC

28-15

Checking distributor

o Minimum engine oil temperature 60° C.

l

A Checking centrifugal .~d't'ance with TDC sender

(Specified values --. page 28-10)

- Connect up ignition tester V.A.G 1367.

- Pull vacuum hose(s) off vacuum unit of the ~

distributor.

Pull plugs off idle stabilising unit and join

them together (ir present).

- Start engine.

- Set engine speed to approx. 900 rpm.

·- Note down advance angle indicated c basic value.

Slowly increase engine speed.

Start of advance is indicated by • greater number
of degrees.

- Increase engine speed to next test speed.

28-16
 - Read off advance angle on tester.

- Calculate centrifugal advance angle:

Advance angle read off

- Basic value noted down
= Centrifugal advance angle

- Repeat test at other test speeds.

B Chei:king centrifugal advance with

stroboscopic la•p
(Specified. values - page 28-10)

-Connect up ignition tester V.A.G 1367.

- Pull vacuum hose(s) off vacuum unit of

distributor.

- Pull plugs off idle stabilising unit

and join together (if present).

Start engine.

- Set engine speed to approx. 900 rpm.

V.ADl367/9 l2s-1021l

28-17

Direct flashes onto notch on belt pulley and

note down advance angle • basic value.

- Slowly increase engine speed. The start of

advance is indicated by movement of the
notch.

Increase engine speed to next test speed,

"bring notch back" and read off the advance
angle.

- Calculate centrifugal advance angle:

Advance angle read off

- Basic value noted down
Centrifugal advance angle

- Repeat test at other test speeds.

C - Checking vacuu• unit for leaks·

- Connect vacuum tester and vacuum pump to

vacuum unit "advance" or "retard".

~ Switch tester to throughflow.

- Use vacuum pump to generate vacuum of

approx. 500 mbar.

28-18
 Set tester such that vacuum is retained on the
vacuum unit end.

- Set vacuum on tester to 450 mbar. The vacuum

may drop off by a maximum of 10%. in 1 minute.
Otherwise the vacuum unit or hose \s leaking.

D - Checking vacuum advance angle

(Specified values --. page 28-10)

- Connect up ignition tester V.A.G 1367.

- Pull vacuum hose off vacuum unit "retard" and

seal it off (if applicable).

-'Pull plugs off idle stabilising unit and join

together (if present). '

V.A.G1367/9 128-10211

Connect vacuum tester and vacuum pump to vacuum

unit "advance".

VAG1368 - Switch tester to throughflow.

- Start engine.

28-19

Set engine speed to approx. 900 rpm.

- Testing with:

TDC sender Stroboscopic lamp

Note down advance Check and adjust

angle indicated ignition timing
= basic value point if approp-
riate

- Use vacuum pump to generate vacuum until the

ignition timing point starts to move.

- Read off vacuum value and compare it to the ·

test specification for start of advance.

- Further increase vacuum as far as the test

specification for end ~f advance.

- If necessary, reduce engine speed to a level

of approx. 900 rpm.

Checking with TDC sender:

- Read off advance angle and calculate vacuum

advance:

Advance angle read off

Basic value noted down
Vacuum advance angle

28-20
- Further increase vacuum. The ignition timing
point must not move any further.

Checking with stroboscopic laap:

- "Bring notch back" to ignition timing point

mark.

Advance angle indicated

• Vacuum advance angle

- Further increase vacuum. The ignition timing

point must not move any further.

E Checking Yacuua retard angle

Engine cod~ letters DF
(Specified values --. page 28-10)

-·connect up ignition tester V.A.G 1367.

Pull vacuum hose off vacuum unit "retard" and

seal it off.

- Pull plugs off idle stabilising unit and join

together.

- Start engine.

28-21

- Pull off vacuum hose at vacuum unit "advance",

- Check ignition timing point, Set S 0 after TDC

if necessary.

- Pull off vacuum hose at vacuum unit "retard".

Checking with TDC sender:

~ Add S 0 to the advance angle indicated. Compare

this Yalue to the specified value for the end
of advance.

Checking with stroboscopic laap:

- "Bring notch back" and compare advance angle

indi~ated to specified valOe for end of advance.

28-22
 Checking TCI-H ignition systea

Checking with TCI tester V.A.G 1451

- Perform testing in accordance with operating

instructions for test appliance.

Checking with digital multimeter V.A.G 1315 A/

hand aultiaeter V.A.G 1526 and auxiliary cables
fro• V.A.G 1594

Mote:
o In view of the fact that the design internal
impedance of the measuring instruments and
the ambient temperature have a major effect
on the measured values, use is to be made for
test purposes of the digital multimeter V.A.G
1315 A or the hand multimeter V.A.G 1526.

o The specified values stated apply to an amb-

ient temperature range of between 0 and 40° C.

Attention:
The voltage range -V- is. to be selected on the
multiaeter before connecting up the test cables
to prevent destruc1;:ion of the electronic comp-
onents.

28-23

Checking TCI-H switch unit

o Ignition coil OK.

Pull plugs off DIS unit and join together

-arrow-.

- Connect up multimeter between contacts

4 and 2 on plug.

- Switch on ignition.
Specified value: approx. battery
voltage

If this is not the case, the open cir-

cuit is to be located and eliminated
using the CFD.

- Switch off ignition.

1--7
28-24
 - Reconnect plugs to TCI-H switch unit.

-Pull connectors off Hall sender (distributor).

·connect up multimeter between terminal 1 (-)

and terminal 15 (+) of ignition coil.

- Switch on ignition.
Specified value:
At least 2 volts; must drop to 0 after
1 • • . 2 seconds.

- If ·this is not the case, renew TCI -H switch

unit and check ignition coil to see whether
sealing compound has oozed out. Likewise
renew if necessary.

Briefly connect centre wire of connector at

distributor to earth.

The voltage value indicated must briefly

increase to at least 2 volts.

- If this is not the case, locate and elimi-

nate open circuit ~n centre wire/renew the
switch unit •

..l
28-25

- Switch off ignition.

Connect up multimeter to outer contacts of

~lug of. Hall sender (distributor).

- Switch on ignition.
Specified ~alue: at least 5 volts

l'ote:
If the defect is present despite the specified
values being obtained, the TCI-H switch unit
should be renewed, or the open circuit between
the plug of the Hall sender and switch unit is
to be located and eliminated.

28-26
 Checking Ball sender

o TCI-H switch unit OK.

o Ignition coil OK.

o Wire between TCI-H switch unit and dist-

ributor OK.

o Connectors and connection parts on dist-

ributor, Hall sender and tci-H switch
unit OK.

o Plugs pulled off DIS unit and joined

together.

Pull high-tension lead terminal 4 out of

distributor and earth it. Use auxiliary
cable if necessary.

Detach rubber grommet from connector on

switch unit.

-Use auxiliary cables from V.A.G 1594 to

connect up multimeter between contacts
6 and 3 on attached plug for the TCI-H
switch unit~

28-27

- Switch on ignition.

Turn engine slowly by hand in direction of

rotation and watch reading on the measuring
instrument.
Specified value:
Voltage must alternate between 0 and at
least 2 V.

- If this is not the case, renew Hall sender.

Checking DIS switch unit

(Engine code letters DF)

Rote:
In the event of starting difficulties or mis~
firing, pull plugs off DIS switch u-nit, join
them together and start engine.
If this remedies the defect, check that ~he
contact pins and sleeves of both plugs ate in
the correct position; thew must not be damaged
or pushed back. Otherwise renew the DIS switch
unit.

-Connect up ignition tester V.A.G 1367.

V.AD 136719 l2s- 1021! 28-28

 - Fully apply hand ~~ake.

Attention:
For safety reasons, there must not be anyone in
front of the vehicle whilst carrying out test
procedure.

Start engine and briefly increase engine speed

(burst of throttle).

- Actuate foot brake.

- Allow engine to idle; read off and note down

ignition timing point.

-Engage 4th g~ar and slowly allow.the clutch to

bite.

- Ignition timing point must be advanced as the

engine speed drops below 840 rpm.

- If this is not the case, renew the DIS switch

unit.

Repairing breaker-triggered ignition

system

Note:
---------------------1 o Adjustment data --. page 28-34

p Spark plugs page 28-35

o Distributor data --. page 28-36

o Components marked with * are fitted

with M4 ignition cable connections.
3 The two versions are not mutually
interchangeable.

Part I

1 - Ignition coil*
o Primary resistance:
1.7 ••• 2.1 ohms
(between term. 1 and 15)
o Secondary resistance:
7 .. . 12 k ohms
(between term. 1 and 4)

2 - Suppression plug*
o 0.6 ... 1.4 k ohms

7 6 5 4 28-30

128- 906l
 3 - Ignition leads*
o Check for continuity

4 - Spark plus, 20 ••

1 -
o Type and electrode gap
page 28-35

5 - Spark plug connector*

0 4 ...6 k ohms

2 6 - Carbon brush with spring

o Check for wear, damage and
ease of movement

7 - Distributor cap*
o Check for cracks and signs
of tracking
o Check contact wear
o Clean before installing

7 28-31
6 5 4
128.9061

Part II

1 - Rotor ara
o Not marked
o 4 ••• 6 k ohms

2 - Dust cap
3 - Contact breaker point
o Coat cam surface, plastic
cam follower on contact
side and bearing pin with
multi-purpose grease
o Adjust dwell angle
Specified value:
47 +/- 3° (53 +/- 3%)

4 - Vacuua unit
o Checking for leaks
- page 28-42
o Checking spark control
- page 28-43
5 - Sealing ring
6,..---------5 o Renew

6 - Spring
1-----------~--6

28-32

128.9071
 7 - Distributor d~iYe shaft

1
0

-
Removing and installing
page 28-37

8 - Thrust washers
0 Install with screwdriver
2 and align

9 - Distributor
3 0 Installing - page 28-38
o Adjusting ignition timing
point - page 28-39
4
--
f
0 Checking centrifugal advance
10----~~~~~~~~ page 28-40

10 - Ignition capacitor

9------

r---------5

28-33

128. 907l

Adjustaent data

Engine code letters BY 10.82 .. 07.89

Distributor Part No, 025 905 205 E

025 905 205 Hl)

Ignition tiaina Test 3 7" before TDC

point2) 3)
Setting 5 +/- 1" before TDC

Mark - Fig, 1
Engi.ne speed 3 rpm 850 +/- so
Vacuua hose Detached

Dwell ansle Sett·ing 47 +/- 3° (53 +/- 3%)

Wear limit 42 sa• (47 ••• 64%)

Governed speed rpm 4650 ••• 5550
Firins order 1 2

1) With M4 ignition lead connections

2) Pay attention to checking and adjustment conditions - page 28-39
3) Current values ...:..- "Exhaust gas and idling speed test" binder

28-34
Spark plugs

Engine code letters EY"l0.8~. 07.89

Spark plngal)

Manufacturers' W 7 C, 14-7 C, N 288,

designations w 7 cc, 14-7 cu
Electrode gap 0.6 0.8 mm
Tightening torque 20 Nm

Current value& - "Exhaust gas and idling speed test" binder

Fig.· 1 Ignition tiaing aark

28-35

Distributor data

Engine code letters RY 10.82. 07.89

Distributor Part No. 025 905 205 E

025 905 205 H

Centrifu,al "
adTancel
Start rpm 1400 ... 1600
rpm 2400
degrees 13 ... 18 J

End rpm 3400

degrees 26 ... 30
Vacuua adTance
Start mbar 180 220
mmHg 135 165
End mbar 290 310
mmHg 218 233
degrees 12 16
1) Speed Engine speed

28-36
Reaoving and installing di~tributor drive shaft

Reaoving

- Remove fuel pump.

- Remove distributor drive shaft with a normal

extractor 14.5 18.5 mm dia. (e.g. with
KUHO 21/2).

Installing

- Set crankshaft to TDC on No. 1 cylinder.

Insert drive shaft such that offset slot in

head of ·distributor drive shaft is pointing
towards tapped hole or screw -arrow-.
The small segment faces the coolant pump.

- Install spacer spring.

28-37 .

Installing distributor

- Set crankshaft to TDC on No. 1 cylinder.

- Turn rotor arm until it is facing mark for

No. 1 cylinder on distributor housing.

- Insert distributor.

- Clean distributor cap, check for cracks,

signs of tracking and tightness.

- Adjust ignition timing.

28-38
 Adjusting ignition timing

o Minimum engine oil temperature 60° C.

Connect up ignition tester V.A.G 1367.

- Check and, if necessary, adjust dwell angle.

Setting: 47 +/- 3° (53 +/- 3%)
Wear limit: 42 ••• 58° (47 •.• 64%)

- Check and, if necessary, adjust idling speed.

Specified value: 850 +/- 50 rpm

- Pull vacuum hose off distributor.

- Check and, if necessary, adjust the ignition

timing point.

With TDC sender:

The ignition timing point is indicated dir-

ectly on the tester.
Test specification: 3 ... 7° before TDC
Setting: s• before TDC
With stroboscopic lamp:

Notch on belt pulley must be in line with

joint on crankcase.

28-39

Checking distributor

o minimum engine oil temperature 60° C.

A - Checking centrifugal advance with TDC sender

(Specified values · - page 28-36)

-Connect up ignition tester V.A.G 1367.

- Start engine and run it at idling speed.

Specified value: 850 +/- 50 rpm '

Pull vacuum hose off vacuum unit.

- Check and, if necessary, adjust the ignition

timing.

- Note down advance angle indicated basic

value.

Slowly increase engine speed.

Start of advance is indicated by greater
number of degrees.

- Increase engine speed to next test speed.

28-40
 - Read advance angle off tester.

Calculate centrifugal advance angle:

Advance angle read off

- Basic value noted down
= Centrifugal advance angle

- Repeat test at other test speeds.

B - Checking centrifugal advance with'

stroboscopic la•p
(Specified value --. page 28-36)

- Connect up ignition tester V.A.G 1367.

- Start engine and run it at idle speed,

Specified value: 850 +/- 50 rpm

- Pull vacuum hose off vacuum unit.

Check and, if necessary, adjust igni-

tion timing.

V.A.9l367/9 l2s-1021l

28-41

Slowly increase engine speed;

The start of advance is indicated by move-
ment of the notch.

- Increase engine speed to next test speed;

"bring notch back" and read off the advance
angle.

- Repeat test at other test speeds.

C - Checking vacuaa unit for leaks

- Connect up vacuum tester and vacuum pump to
vacuum unit "advance".

- Switch tester to throughflow.

- Use vacuum pump to generate approx. 500 mbar

vacuum.

Set tester such that vacuum is retained on

vacuum unit end.

- Set vacuum on tester to 450 mbar. The vacuum

must not drop off by more than 10% in l min.
Otherwise there is a leak in the vacuum unit
or hose.

28-42
 D - Checking •acuua advance angle
(Specified value --. page 28-36)

-Connect up ignition tester V.A.G 1367.

Pull vacuum hose off vacuum unit of the

distributor and seal it off.

V.AJJ 136719 l28- 10211

- Connect up vacuum tester and vacuum pUmp

to vacuum.unit "advance".

- Switch tester to throughflow.

- Start engine and run it at idling speed.

Specified value: 850 +/- SO rpm

28-43

- Checking with:

TDC sender Stroboscopic laap

Note down advance Check and adjust

angle indicated ignition timing
a basic value point if approp-
riate

- Use vacuum pump to generate vacuum until the

ignition timing point starts to move.

- Read off vacuum value and compare to the test

specification for the start of advance.

- Further increase vacuum as far as test specif-

ication for the ~nd of advance.

- If necessary, decrease engine speed to below

1400 rpm.

Checking with Tnc· sender:

Read off advance angle and calculate vacuum

advance:

Advance angle read off

- Basic value noted down
Vacuum advance angle

- Further increase vacuum. The ignition timing

point must not m0 ve any further.

28-44
 Checking with stroboscopic la•p:

- "Bring notch back" to the ignition timing

point mark.

Advance angle indicated

= Vacuum advance angle

Further increase vacuum. Ignition timing

point mark must not move any further.

28-45