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Contents
1. 7 Disconnect the filler pipe and ventilation hoses from the fuel pump Disconnect the fuel line from the tank 8 Remove the securing strap nuts under the tank 9 Lower the tank To fit Check that the rubber seals are undamaged and that they are correctly fitted round the opening for the fuel gauge sender unit 2 Check that the straps are properly mounted and cover the filler and vent hose openings with masking tape 3 Lift the tank into position and suspend it in the two straps 4 Centre the tank and tighten the nuts Re move the masking tape from the filler pipe and vent hose 5 Connect the fuel line and the hose to the fil ler pipe Make sure that the rubber grommet is in place 6 Connect the vent hoses between the upper filler pipe section and top of the tank Con nect the cables to the fuel gauge sender unit and replace the access panel Replace the floor panel and rear floor cover in the lug gage compartment 7 Lower the rear of the car 8 Connect the battery earth lead Fuel pipes Fuel pipe runs Fuel pipes should not come into contact with any object that could result in wear through chafing The risk of wear from chafing is particularly great from contact with plastic components subjected to engine vibrations e g other fuel pipes the dipstick pipe throttle cable etc It is therefore of special importance when work ing in the engine compartment that all fuel pipes are run clear of such2. carburettor and fit the vapour trap and clamp 3 Fit the flange to the carburettor 4 Connect the inlet hose to the carburettor 3 a 5 Fit the throttle and choke cables 6 Connect the electrical lead to the float chamber ventilation shut off valve 7 Fit the earth lead to the top of the carburet tor 8 Connect the hoses forthe EGR valve and dis tributor 9 Fill the damper cylinderwith oil 10 Run the engine until it reaches normal operating temperature and then adjust the CO setting idling speed and fast idling speed Changing the adjusting screw in the vacuum piston Stromberg Removal vacuum piston with needle removed 1 Using a drift press out the adjusting screw until it protrudes a few centimetres an inch or so beyond the bottom of the piston 2 Press in the adjusting screw again MWS WT X a5 Taw Ef Te e e u a a a a ROSHax w i il aor 3 Rock the retaining washer to loosen it and then remove it by means of a bent piece of wire The adjusting screw can now be re moved By VY f ty ZA E Refining 1 Using a drift press the adjusting screw with 0 ring into the piston NOTE Grease the 0 ring with Vaseline or the equiva lent to prevent the ring from being damaged on fitting by any scoring on the cylinder bore 2 Press a new retaining washer into the damper cylinder using a drift Beek OIWIL To check and to
3. loaded solenoid which is then deprived of its electric current The air fuel mixture can now only pass through the aperture in the throttle butterfly which is insufficient to keep the engine running which therefore stops Twin carburettor engines incorporate a solenoid valve which regulates communication between the section of the float chamber above the fuel level and the constant depression CD chamber When the ignition is switched off a time relay closes a circuit which causes the sol enoid valve to open the connection to the float chamber giving rise to a depression above the fuel level This eliminates the pressure differ ence needed for fuel to be drawn through the needle valve and the engine therefore stops Current to the solenoid flows for a limited time only after six seconds therefore with the en gine idle the relay will be de energized Idling shut off valve twin carburettors Stromberg carburettors as from 1984 models Preheated air for cold start device choke As from 1984 models the induction air for the cold start device is preheated The preheated air enters the air intake hose to the carburettor and flows through a hose to the cold start device When the air is preheated condensation is re duced with a consequent reduction in the risk of moisture freezing in the system Outlet for EGR valve In conjunction with the introduction of the EGR system the carburettor has been equipped wit
4. start mechanism If the mechanism has been dismantled fit the choke disc spindle and cam lever as illus trated The calibrated holes should face away from the cable linkage 8 Check the setting of the temperature com pensator and that it operates freely see section temperature compensator and mount it together with the rubber gaskets To refit 1 Fit the inlet manifold gasket 2 Fit the carburettor into the inlet manifold 3 Connect the fuel line throttle cable and choke cable and the vacuum hose to the distributor 4 Fitthe dipstick tube mounting bolts 5 Connect the inlet hose to the carburettor 6 Fill the damper cylinder with oil the oil level should be within 10mm 0 394 in of the top of the damper cylinder 7 Setthe idling speed and CO content Twin carburettors Stromberg To remove 1 a Upto and incl 1982 models Unclip the four wire clips holding the air box cover loosen the aircleaner hose clip and remove the cover together with the in take hose b As from 1983 models Remove the air box cover retaining screws and the cover on the dipstick tube Lift up the toggle fastener forthe dipstick tube Slacken the hose clip at the air cleaner and remove the cover complete with intake hose 2 Disconnect the throttle and choke cables from the carburettors 3 Remove the clips from the choke linkage and remove the linkage from the operating rod 4 Remove the air box retaining screws and re mov
5. that the resultant depression in the exhaust system is not too high as this may affect the readings of the CO content To prevent excessive suction use an extraction hose with an open coupling oN OO Disconnect the vacuum hose from the EGR valve and plug the hose Disconnect the vacuum hose from the vac uum control unit on the distributor and plug the hose Connect the CO meter Adjust the engine speed to 2 000 r min Ensure that the choke control is pushed in Read the CO value immediately after the radiator fan cuts in CO setting value at 2 000 r min 1 7 0 3 Correct Wrong ST Toadjustthe COsetting Adjust the CO emission by means of the adjust ing screw on the float chamber cover The screw is sealed with a plastic plug Prise out the plug with a screwdriver and fit a new plug after making the adjustment e Turn the screw clockwise in to reduce the CO content e Turn the screw anti clockwise out to in crease the CO content Use an 8 mm socket Caution Do not use uninsulated tools as there is a risk of short circuiting unprotected electri cal connections on the alternator and star ter motor After adjusting the CO value 1 Adjust the idling speed to 850 50 r min 2 Adjust the fast idling speed at normal temp erature to 1350 50 r min Fault tracing when CO reading toohigh 1 Check the calibration of the CO meter 2 With the engine at idling speed disconnect the crankca
6. valve fitted in the underside of the inlet manifold opens when the ignition is switched on Idling control valve On cars with AC the carburettor is equipped with an idling control valve instead of plug 29 This valve opens when the AC compressor cuts in thereby enriching the mixture and preventing a decrease in the engine speed Float system Stromberg Fuel enters the float chamber through the float valve The float which is double is mounted on the float chamber by an arm and spindle which fits into two retaining clips As the fuel level rises the float rises with it and when the correct level is reached the float valve is closed by a tongue on the float arm Fuel is also drawn Into the jet where the level will be the same as in the float chamber engine at standstill Float chamber ventilation twin carburettors 1 Throttle stop and fast idle lever 2 Throttle relay lever and idle adjust screw 3 Ventilation valve 4 Ventilation outlet throttle shut 5 Ventilation outlet throttle open The carburettors are fitted with a special float chamber vent valve When the throttle valve is closed airis expelled directly through a venthole in the carburettor When the throttle valve is opened ventilation of the float chamber will be by means of the air cleaner connection Pierburg The float system controls the fuel flow by means of the float which operates the float valve via the float arm thereby keeping the fuel
7. venting and overfill protection When fuel is added to the tank air is evacuated partially through breather pipe 3 An air cushion is formed at the top of the tank when the level of fuel reaches the lower opening of the breather pipe 3 owing to the action of a restriction 5 positioned in the breather hose for the upper section of the tank 4 The restriction hinders rapid changes in volume when the car is being re fuelled but does not affect gradual changes in volume occasioned by temperature changes or movement of the car The tank is vented externally through the vent hose 6 which runs from the filler pipe up the rear corner pillar and along the roof above the headlining down through the left front corner pillar and opening into the engine compartment In cars produced as from the latter half of the 1985 model year the vent hose is connected to a spigot on the outer end of the filler pipe Under normal conditions the filler cap makes a tight seal with the filler pipe However the cap incorporates a vacuum valve which will prevent the fuel tank from collapsing as a result of the pressure difference that could arise if the venti lation system should become blocked Fuel lines The fuel system includes both plastic and rubber fuel lines Plastic pipes are used for runs through the body and rubber hoses for connections to the fuel tank fuel pump and carburettor The fuel supply and fuel return lines which run toge
8. where it passes through the body Secure the line with tape in two places along the sill beam 5 Fit the insulation felt to the bulkhead panel Replace the carpet and kick plate
9. 1 Carburettor body Float chamber cover Carburettor top cover Choke disc Cover Oil filler plug Throttle spindle Throttle butterfly Na OaRWND ml 13 14 16 26 27 29 30 Throttle lever Choke lever Choke cable guide Deceleration valve CO adjusting screw Plug connection for idling speea adjustment valve for cars equipped with AC Spigot for vacuum line to distributor Carburettor design The carburettor consists of four main parts held together by screws Carburettor body Float chamber cover Carburettor top cover Choke mechanism 1 Carburettor body 2 Float chamber cover 3 Carburettor top cover 4 Choke disc 5 Cover 6 Damper piston and oil cap assembly 7 Piston diaphragm 8 Damper piston 9 Vacuum piston 10 Vacuum piston spring 11 Throttle spindle 12 Throttle butterfly 13 Throttle lever 14 Choke lever 15 Fast idling adjusting screw 16 Choke cable guide Modulator valve lean mixture valve Float Float valve Jet Jet holder Needle Bi metal washers Springs Idling by pass passage Deceleration valve CO adjusting screw Damper oil Plug connection for idling speed adjustment valve for cars equipped with AC Spigot for vacuum line to distributor Auxiliary devices Shut off valve for idling mixture The induction system incorporates a shut off valve for the idling mixture to prevent the engine running on after the Ignition has been switched off The valve a solenoid
10. 850 50 r min Plerburg Float level Oil level in damper cylinder Needle type YC Basic setting Needle shoulder flush with bottom of piston 2 5 mm below the bridge Fast idling 1350 50 r min Position of float valve Cam 4 Idling 850 50 nmin Special tools 8393035 Adjusting toot for metering needle 8392789 Drift for installation of fuel jet Stromberg Stromberg 83 93 365 Key for fuel gauge sensor unit Technical description General 200 1 Full load operation Pierburg 200 15 Single carburettor Stromberg 200 1 Engine overrun 200 15 Twin carburettors 200 3 Idling shut off valve 200 17 Single carburettor Pierburg 200 3 Air cleaner 200 20 Float system 200 6 Preheating 200 20 Cold start device 200 8 Fuel pump 200 21 Fast idling 200 11 Fuel tank 200 22 Idling Stromberg 200 11 Fuel tank venting and Acceleration Stromberg 200 12 overfill protection 200 22 Normal driving Stromberg 200 12 Fuel supply and Idling Pierburg 200 13 fuel return line 200 22 Acceleration Pierburg 200 14 Roll over valve 200 24 Normal driving Pierburg 200 14 General The engine is equipped with one or two Strom berg horizontal carburettors As from 1987 models the engine is equipped with a Pierburg carburettor Single carburettor Stromberg The carburettor made of light alloy metal com prises three main sections the vacuum chamber the carbur
11. 9 The vacuum of the jet 20 briefly increases thus enriching the fuel mixture Normal driving Pierburg When the throttle is opened the vacuum acts on a chamber in the carburettor cover 3 through the compensating passages in the bottom of the vacuum piston and thus also on the diaphragm 7 on the vacuum piston 9 Due to the differ ence between the vacuum in the chamber and the atmospheric pressure on the underside of the diaphragm the piston is raised by an amount proportional to the air flowing past the throttle and the cross sectional area of the intake is in creased The air velocity and the vacuum atthe jet 20 thus remain practically constant and provide reliable atomization of the fuel atall en gine speeds Acceleration 3 Carburettor cover 7 Diaphragm 8 Damper piston 9 Vacuum piston 10 Vacuum piston sprinj 20 Jet 28 Damper oil Full load operation Pierburg The more air drawn through the carburettor the higher position of the vacuum piston 9 and the needle 22 The piston reaches its highest position at full load and maximum engine speed and the proportional increase of the annular gap at the jet 20 matches the fuel supply to the amount of air being drawn in The shape of the needle ensures that the fuel air ration is step lessly adjusted to the correct value under all operating conditions Full load operation 9 Vacuum piston 20 Jet 22 Needle Engine overrun Sweden specifica
12. Adjustthe position of the needle which is correct when the needle shoulder is flush with the bottom of the piston d Tighten the setscrew This position Is the basic setting for subsequent COadjustment Needle shoulder flush with bottom of piston 3 Install the piston complete with diaphragm and spring in the carburettor body Make sure that the outer tab on the diaphragm en gages the matching slot in the carburettor body Place the vacuum chamber cover care fully in position aligning the marks The groove and locating rim should be a good fit if not fit a new part Tighten the screws 4 Fit the floatvalve and washer and assemble the float and spindle The flat side of the float faces away from the carburettor body 5 Check the float level as follows a To check the float level the carburettor must be removed from the engine and in verted with the float chamber and gasket off b For the level to be correct the highest point of the float should be 16 17 mm 0 63 0 67 in above the flange of the carburettor body gasket removed when the float valve is closed Ifthe level is not correct adjust by bending the end tab at the float valve 16 1 mm Note 063 067 Do not bend the arm between the float and the spindle 6 Fit a new gasket and the float chamber First insert all screws and give them a few turns then push down the float chamber until it butts firmly and tighten the screws 7 Fit the cold
13. Units The basic units as well as the derived units used throughout the Service Manual are in accordance with the SI system As a supplement to these a number of other units are specified within brackets The following symbols for the various units have been used in this issue Sl unit mm kg N Nm bar Conversion factors 1in 25 4mm 1 Ibf 4 45 N 1lofft 1 36Nm psi 0 07 bar igt 0 95l Supplementary unit unit in lb lof lbfft psi qt US F 1 mm 0 039 in 1N 0 23 lbf 1Nm 0 74lbfft 1bar 14 5 psi 11 1 05 qt Codes for different markets The specified codes refer to the market variants of the cars AT Austria AU Australia BE Belgium CA Canada CH Switzerland DE Germany DK Denmark ES Spain EU Europe FE Far East Fl Finland FR France GB Great Britain GR Greece IS Iceland JP Japan IT Italy ME Middle East NL Holland NO Norway SE Sweden US U S A Technical data CO values and engine speeds applicable to engines at nor mal running temperature As from 1981 models with Sweden specifica tions and 1983 models with Switzerland specifi cations the CO checks should be carried out at an engine speed of 2000 r min with the hoses to the vacuum control unit the crankcase ventila tion and the EGR system where applicable dis connected On all other cars the check should be carried out at 850 r min Note 1983 models onwards The secondary CO ad justing
14. a O E eb 5 Q p 90 oO fd Ra E O _ amp ab oO O 5 fob ra o gt O fo oc N a E amp O ke cC 5 a S fa a S gt a D 2 2 a fa rs 8 Unbolt the carburettor from the flange on the inlet manifold Todismantle 1 Remove the damper piston 1 and the cover 2 2 Remove the carburettor cover 3 and the spring 4 3 Remove the vacuum piston 8 and dia phragm 7 4 Release the setscrew and remove the needle 9 from the piston 5 Remove the diaphragm 7 from the piston 8 by removing the screws the retaining ring 5 and the plastic washer 6 Carburettor 1 Damper piston 6 Plastic washer 2 Cover 7 Diaphragm 3 Carburettor cover 8 Piston 4 Spring 9 Needle 5 Metal retaining ring A Passage under vacuum piston B Floatchamber vent passage Remove the float chamber cover 10 N Remove the jet 15 and the spring 16 Remove the plastic bracket 17 for the float and then remove the float 11 9 Remove the float valve 12 and the washer 10 Remove the choke 13 11 Remove the modulator valve 18 10 Float chamber cover 15 Jet 11 Float 16 Jetspring 12 Float valve 17 Plastic bracket 13 Choke mechanism 18 Modulator valve 14 Carburettor body C Signal outlet for distributor D Signaloutletfor EGR E Fuel inlet spigot F Modulator valve spigot To clean Wash the carburettor
15. alve is stiff or sticks it can be adjusted provided that it is not scratched or coated with deposits Should this prove to be the case fit a new valve Adjustment Note The temperature compensator is adjusted at the factory and should therefore not be tampered with unless absolutely necessary Back off the bi metallic strip retaining screw slightly and centre the valve by pressing it to wards its seating Retighten the screw Setting At 20 68 the valve should have opened 0 1 0 3 mm 0 004 0 012 in To check the setting the temperature compensator should be remo ved from the carburettor and kept at a tempera ture of 20 C 68 until it has acquired this tem perature Setting is by means of the bi metallic strip adjusting nut Changing Change the temperature compensator as a complete unit To remove it undo the two slotted screws Note Both the outer and inner rubber gaskets must be exchanged ip Temperature compensator 1 Air passage 2 Valve 3 Bi metallic strip 4 Adjusting nut 5 Bi metallic strip retaining screw 6 Seal 7 Jet bridge Choke modulator Stromberg To check 1 Connect exhaust extraction equipment and aCO meter 2 Start the engine and run it up to normal operating temperature 3 Pull the choke control out to about one third of its travel 4 Use a finger or a piece of fabric tape to seal off the filter orifice in the choke modulator Note The filter orifice
16. ced Check the needle for wear bent or worn needles should be replaced Check that the contact and sealing surfaces are not damaged Clean the hole in the choke valve disc by means of com pressed air Clean the temperature compensator and check that the valve moves freely Refer to the separate sections on the needle adjusting screw jet temperature compensator and float chamber ventilation Assembly Tools Adjusting tool 83 93 035 Vernier calliper 1 Fit the diaphragm on the vacuum piston so that the inner locating tab engages the cor responding slot in the piston A Note If after having been allowed to dry for a while the diaphragm is still so distended that it will not fit into the piston renew it A distended dia phragm will usually revert to its original form after a while Place the plastic washer 4 and retaining ring 3 carefully in position lining up the screw holes with those in the piston and diaphragm without turning the ring and match ing the notches in the ring with the tab on the diaphragm A Inner tab and matching slot in vacuum piston B Outer tab to match slot in carburettor body 2 Fit the needle as follows a Insert the spring housing of the needle into the vacuum piston Screw in the setscrew until the spring loaded pin drops into the groove in the side of the spring housing b Screw the spring housing onto the adjus ter by turning the adjuster with Alien key tool 83 93035 c
17. components in paraffin kerosine Note Clean the diaphragm in paraffin kerosine only Do not use highly volatile cleaning agents such astrichlorethylene Check that the diaphragm is in good condition If ithas split fita new one Check the needle for wear and replace it if it is bent or worn Check that all contact and sealing surfaces are undamaged Check that the choke disc and corresponding sealing surface on the carburettor body are not scratched Clean the holes in the choke disc with compressed air Toassemble 1 Fit the diaphragm on the vacuum piston so that the inner locating tab A engages the corresponding slot in the piston Note If after drying for a while the diaphragm is still so distended that it will not fit into the slot renew it A distended diaphragm will usually revert to its normal shape after being allowed to dry for a while Place the plastic washer and metal retaining ring in position so thatthe screw holes are in line with those in the piston and diaphragm without twisting the ring and with the notch matching the tab on the diaphragm Fit and tighten the screws A Innertaband matching slot in vacuum piston B Outer tab to match slot in carburettor body 2 Fitthe needle as follows a Insert the spring housing of the needle into the vacuum piston with the flat sur face facing the setscrew b Adjust the needle so that the shoulder is flush with the bottom of the piston c T
18. cuum chamber cover 1 and spring 2 2 Remove the piston 6 with the diaphragm 5 3 Remove the needle as follows a Slacken the setscrew b Turn the adjusting screw counter clockwise using tool 83 93 035 until the needle is free Backoff the setscrew until it is clear of the needle shoulder then re move the needle Carburettor 1 Vacuum chamber cover 2 Spring 3 Metal retaining ring 4 Plastic washer 5 Diaphragm 6 Vacuum piston 7 Metering needle 4 Remove the screws retaining ring 3 plas tic washer 4 and diaphragm 5 w il LS t amp Carburettor 1 Vacuum chamber cover 2 Spring 3 Metal retaining ring 4 Plastic washer 5 Diaphragm 6 Vacuum piston 7 Metering needle 5 Remove the float chamber 8 6 Carefully disengage the float spindle from the retaining clips and remove the float 9 7 Remove the float valve 10 and washer 8 Remove the cold start mechanism 11 9 Remove the temperature compensator 13 and the rubber gaskets 14 8 Float chamber 9 Float 10 Float valve 11 Cold start assembly 12 Carburettor body 13 Temperature compensator 14 Rubber gaskets Cleaning Wash the carburettor parts in paraffin Caution The diaphragm should only be cleaned with paraffin Avoid using volatile cleaning agents such as trichloroethylene Check that the diaphragm is in good condition If the diaphragm is cracked it should be repla
19. d a fraction more the passage should close again 3 Release the locknut and adjust the valve by rotating the setting screw Use the proce dure outlined in steps 2a and 2b 4 The idling speed CO setting and synchroni zation twin carburettors only must be checked following the above adjustments and reset if necessary Plerburg Switch on the ignition and pull off the plug on the electrical connector to the valve which should cause a Clicking sound to be heard Idling shut off To check single carburettor engines 1 Connect a tachometer and let the engine run at idling speed 2 Temporarily disconnect the lead from the shut off valve and check that the idling speed drops by at least 200 r min Note The engine will run on after the ignition has been turned off ifthe idling speed is too high To check twin carburettor engines Disconnect the standard and blow into the con nections for the float chamber vent valves a With the ignition turned on or about 6 seconds after the igni tion has been switched off the float chambervent valve should allow the entry of air from the at mosphere b The connection between the float chamber and the passage to the vacuum chamber should open within approx 6 seconds of the ignition being turned off Engine runs on The likely causes of the engine running on are as follows e Idling speed settoo high Ignition timing too far advanced Mixture in carburettor
20. djusting screw Adjusting screw float chamber ventilation Spindle Spacer single carburettors only CO adjusting screw Deceleration valve 1985 models onwards Twin carburettors The carburettors used on twin carburettor en gines are similar in principle to those on single carburettor engines Located in front of the two carburettors is an air box which serves both carburettors and is con nected to the air cleaner by means of a hose The inlet manifold passages from the rear carburet tor go to number 1 and 2 cylinders and from the front carburettor to cylinders number 3 and 4 A connecting passage links the two manifolds and this serves to correct any minor variations in the fuel air mixture from the two carburettors Pierburg 175 CDUS carburettor The 175 CDUS carburettor is a horizontal con stant depression CD carburettor with a mixing chamber diameter of45 mm 1 3 4 In a constant depression CD carburettor the vacuum is the mixing chamber does not vary i e the pressure of the air stream is practically con stant regardless of the engine speed or load The piston and thus the jet are controlled by a vacuum which varies with the throttle opening the engine speed and the engine load The in teraction of these factors and the atomization of the fuel due to the nearly constant vacuum re sulting from a constant air speed at the jet corn prise the basic principle of a constant depres sion CD carburettor T
21. e the box the throttle cable bracket the choke lever and the gaskets 5 a Undo the clips and disconnect the fuel pipe b Remove the suction hoses from the car burettors 6 Remove the carburettor retaining nuts and lift out both carburettors simultaneously Dismantling Tools Needle adjusting tool 83 93 035 1 Remove the vacuum chamber cover 2 and spring 3 2 Remove the vacuum piston 6 and dia phragm 5 Carburettor 1 Damper and oil cap assembly Vacuum chamber cover Spring Retaining ring Diaphragm Piston Metering needle NOOR WN 3 Remove the metering needle as follows a Back off the setscrew b Turn the adjusting screw inside the damper counter clockwise using adjust ing tool 8393035 until the needle is free Back off the setscrew until it is clear of the needle shoulder then remove the needle 4 Remove the screws aluminium retaining ring 4 and diaphragm 5 Exploded view of twin carburettors A 1 Damper and oil cap assembly Vacuum chamber cover Spring Retaining ring Diaphragm Piston Metering needle NO AWN 5 Remove the float chamber 9 6 Carefully separate the float spindle from the retaining clips and remove the float 8 7 Remove the float valve and washer 8 Remove the cold start mechanism 10 9 Remove the temperature compensator 11 Save both rubber gaskets 12 Exploded view of twin carburettors B 8 Float 9 Float chamber 10 Co
22. equipment Sheath the pipes with PVC sleeves if contact is unavoidable Checking fuel pipes Follow the pipes and check to see if there is any evidence of wear through chafing Special care should be taken when checking pipes that touch or are run near plastic compo nents Re route the pipes and fit PVC sleeves if chafing is detected If the wear is greater than half of the thickness of the pipe wall then the fuel pipe should be replaced Checking pipe connections Check fuel pipe connections for leaks Replacing fuel lines inside the car The fuel line from the tank to the engine com partment runs through the passenger compart meintalong the left hand sill beam To remove E Remove the kick plate and turn back the car pet from the sill beam 2 Remove the tape holding the fuel line 3 Remove the insulation felt from the bulk head 4 Disconnect the fuel line in the engine com partment Disconnect the connection atthe fuel pump 5 Undo the clip and disconnect the fuel line from the fuel tank To fit 1 Clean the fuel line by blowing through with compressed air Close the ends with mask ing tape 2 Push the fuel line through the hole in the bulkhead and the spring link bracket and connectthe line in the engine compartment 3 Insert the rubber grommets in the hole in the bulkhead panel and in the front hole in the spring link bracket 4 Push the fuel line into position and connect it at the rear
23. ettor body casting and the float chamber The vacuum chamber which is the top part of the carburettor has a diaphragm at the bottom to which a piston is attached and communicates with the inlet port of the carburettor through two drillings in the piston The fuel jet is press fitted in the carburettor body which isthe middle section of the carburet tor The cross sectional area of fuel flow inside the jet orifice is varied by a moving tapered Twin carburettors needle attached to a piston whose position is varied by variations in the depression inside the carburettor body The piston also regulates the cross sectional area of the flow of induction air Thus the engine always receives the correct amount of fuel and air under all load conditions The bottom section of the carburettor the float chamber houses a float which opens and closes the float valve by means of a tab on the float arm THU MTT WN fe a yy om tof o vm Carburettor Stromberg 1 Damper and oil cap assembly Vacuum chamber cover Spring Retaining ring for diaphragm Diaghragm Retaining clip Adjusting screw Metering needle Vacuum piston Setscrew with spring loaded plunger Jet Carburettor body Float valve 14 15 16 17 Float and arm Float chamber Throttle cam lever Deceleration valve not Sweden spec Temperature compensator Cold start device with cam lever Arm float chamber ventilation Idling a
24. fill oil in the damper cylinder and fit the damper piston Fine adjustment of the setting is effected in con junction with the subsequent CO check To check the needle Pierburg Check the needle for signs of wear or damage and also the needle setting Release the setscrew to adjust the height of or to replace the needle Make sure that the flat in the needle shoulder is towards the setscrew The needle designation is stamped on the needle and can be seen after the needle has been withdrawn from the socket needle shoul der To synchronize twin carburettors 1 Run the engine to normal operating temper ature and then let it idle The idling speed adjusting screw serves both carburettors and is located on the front carburettor Loca tion of idling speed adjusting screw 1984 Europe spec models onwards Placement of adjusting screw Europe specifica tion as from year model 1984 Synchronize the carburettors by means of the adjusting screw on the linkage between the two carburettors Compare the air flow through the carburettors by means of a syn chro tester The adjusting screw should be locked by means of the locknut after setting CO setting Stromberg Before adjusting the CO setting E Change the engine oil OONDAAWD 10 11 12 13 14 15 16 Check the condition of the spark plugs Check the HT leads Check the valve clearance Check the position of the camshaft timing Check the i
25. g the fit of the thermostat A check should be made of the fit of the thermo stat in all 1982 model cars with single or twin carburettors and 1983 model cars with chassis nos up to and including AD 1013638 AD 20 05225 and AD 60 01036 If the thermostat body can be rotated easily by hand adjust it so that the distance between the plastic sleeve and the thermostat body is 9 1mm 0 35 0 04 in Lock the thread with Loctite IS496 Saab part nr 83 43 808 Changing the bimetallic valve 232 3 Even if no adjustment is made to the thermostat apply Loctite to the thread Note After the valve and thermostat have been ad justed check the carburet tor setting To fit Fit the thermostat first Check that the valve closes the cold air intake at 20 C 68 F If the valve is open slacken the plastic nut for the cable sheath and turn it through 1809 in the di rection it will go to select a new position for fit ting This changes the direction in which the cable tension acts exerting a force on the valve in the direction of the cold air intake Note When fitting a new preheater valve body assem bly make sure that the thermostat is securely fit ted Checking the preheating sys tem 1986 models onwards 1 Detach the preheater valve body from the air cleaner so that the butterfly can be ob served 2 Detach the air intake hose from the car burettor to expose the bimetallic valve 3 Start the engine and al
26. gnition timing Check the idling speed Check the float chamber ventilation Checktheoil level inthecarburettordashpot damper Check the air preheater air cleaner Check the delay valve Check the radiator fan Check the fuel shut off valve Check the fast idling speed engine at nor mal running temperature Check the operation of the choke modulator by blanking off the filter aperture Check that the secondary CO adjusting screw is screwed fully home Note To minimize the possible effect on the readings caused by various engine and exhaust emission control components the CO setting on cars with Sweden specifications and Switzerland as from 1983 models should be carried out at an engine speed of 2000 r min On Europe spec cars the setting should be made at idling speed CO setting at 2 000 r min 1 Runthe engine to normal temperature con nect a tachometer and set the speed to 2000r min 2 Disconnect the crankcase ventilation as fol lows A Disconnect the hose from the valve cover B Plug the end of the small bore hose C Connect the evacuation hose to the valve cover Evacuate the crankcase gases from the out let in the valve cover by connecting the other end of the hose to the evacuation hose of the building s extraction system at a point downstream of the CO meter probe to en sure that the readings will not be affected Note When connecting exhaust extraction equipment in conjunction
27. h two vacuum outlets The outlet marked E is con nected to the pressure upstream of the throttle butterfly This outlet is for control of the EGR valve The other outlet is in communication with the pressure downstream ofthe throttle butterfly and is connected to the vacuum control unit on the distributor Stromberg 1 Outlet for EGR valve 2 Vacuum control unit distributor Pierburg 1 Outlet for EGR valve 2 Vacuum control unit distributor Air cleaner The air cleaner is positioned at the front of the left wheel housing and is connected to the car burettor by means of a hose Its purpose is twofold to clean the air inducted into the engine and to reduce the noise caused by the induction system The air cleaner element which is made of a special grade of paper must not be washed or wetted but should be replaced at the specified service interval Air preheating A thermostatic valve situated in the air cleaner intake regulates the temperature of the induc tion air There are two air intakes in the valve housing one for cold air and one for heated air The heated air is drawn in through an insulated hose from a hot spot on the exhaust manifold On 1985 and earlier carburettor engines the valve is activated by a thermostat in front of the carburettor The thermostat senses the tempera ture ofthe pre mixed induction air and maintains it at 23 37 C 73 98 F by means of a cable In operation the valve
28. he combination of a vari able jet system and an air controlled vacuum piston provides stepless adjustment of the fuel air mixture supplied to the engine from idling to full load Twin carburettors 4s from 1987 models the engine is equipped with a Pierburg carburettor Because of the central location of the jet system the carburettor can be installed horizontally or inclined at the angle of up to 26 The fuel supply to the jet is regulated by the double float and is kept at a constant level so that centrifugal braking and acceleration forces will not affect the fuel air mixture The CDUS carburettor is equipped with a choke disc controlled by a manual choke control a de celeration valve overrun braking valve which reduces exhaust emissions during overrun brak ing and gear changing and a device which allows the idling mixture to bypass the throttle At idling speed the mixture bypasses the almost closed throttle via the idling shut off valve and flows direct to the inlet manifold This provides a higher effective cacuum for delivery of the mix ture and thus guarantees smooth idling Another feature of this carburettor is the temper ature compensation function of the main jet The jet holder contains bi metal washers which move the jet axially when the temperature changes This in turn changes the flow area of the jet The fuel flow is thus adjusted to suit the prevailing operating temperature
29. he diaphram to close the air bleed port Cold start device Stromberg Operating principle of the cold start device Stromberg Z am 1 f i a W FA b m N d kin n N A cA D A At constant speed idee 1 Diaphragm 2 Diaphragm spring 3 Airjet 4 Disc 5 Fuel inlet passage from float chamber 6 a Fuel air passage rich mixture to mixing chamber 6 b Fuel air passage lean mixture to mixing chamber On starting during acceleration and at full throttle Fuel Air at atmospheric pressure Strong depression Weak depression Fuel air mixture 7 Air inlet from atmosphere as from 1984 models 8 Passage to inlet manifold 9 Air bleed passage 10 Air bleed passage inlet from atmosphere 11 Fast idiingcam Pierburg rhe choke disc which is controlled by the choke control permits reliable starting and warm up of the engine regardless of the ambient tempera ture When a car is started from cold a rich fuel air mixture is required at first When the choke control is withdrawn the throttle 12 is partially opened fast idling and the choke disc 4 is turned to a position in which the fuel apertures are opened During starting fuel is metered from the float chamber A via the fuel apertures in the choke disc 4 Immediately after the engine has started the modulator valve lean mixture val
30. ighten the setscrew Fit the float valve and washer and the float and spindle Make sure that the adjusting tab on the float is inserted under the locking needle of the float valve Fit the plastic brac ket 4 Check adjust the float level Press down on the plastic bracket to position the float correctly Tilt the carburettor ap prox 109 until the float arm just touches the ball on the needle valve Note The ball must not be pressed home Measure the float height to the gasket face Adjust the height as necessary to the cor rect value of 8 1mm by bending the tab at the needle valve 5 Fit the jet spring and the jet 6 Fit the float chamber cover 7 Carry out basic setting of the fuel jet Adjust the height by means of the adjusting screw on the float chamber cover The jet should be 2 5 mm 0 098 in below the face of the jet bridge at 20 C 68 F Note Take care not to press down on the spring loaded jet with the calliper as this will affect the read ins 8 Fit the piston with the diaphragm and spring into the carburettor body Make sure that the tab on the diaphragm fits into the corresponding slot in the carburettor body Fit the carburettor cover in position as indi cated by the marks and tighten it 9 Fit the cover and the damper piston 10 Fit the modulator valve 11 Fit the choke To refit 1 Fit the carburettor to the rubber of the inlet manifold 2 Connect the fuel hose to the
31. is spring assisted Normal driving Stromberg When the throttle is opened the pressure in the vacuum chamber which is in communication with the top of the diaphragm falls causing the piston to rise to a new position stabilizing the depression in the vacuum chamber As the needle rises with the piston the flow of fuel is adjusted to the flow of air Carburettor with throttle open Stromberg 1 Damper piston and oil cap assembly 2 Diaphragm 3 Compensating aperture 4 Damper piston 5 Float chambervent 6 Valve 7 Float 8 Vacuum piston 9 Starting fuel aperture 10 Throttle butterfly 11 Vacuum aperture 12 Jet orifice 13 Needle 14 Float chamber 15 Constant depression chamber CD chamber 16 Aperture for additional air temperature compen sation Idling Pierburg This carburettor is not equipped with a separate idling system Instead the idling mixture de pends on the position of the throttle butterfly 12 the vacuum piston 9 and the taper needle 22 in the jet which controls the fuel flow Turning the adjusting screw 27 which is in con tact with the jet holder 21 alters the position of the jet 20 thus also changing the annular gap between the jet and the needle When the adjusting screw is turned clockwise the annular gap is reduced thus providing a leaner idling mixture Turning the screw anti clockwise has the opposite effect When the engine is running the resulting vac
32. ld start mechanism 11 Temperature compensator 12 Rubber seals 13 Idling speed adjusting screw Idling adjustment screw Europe specification as from year model 1984 Cleaning and assembly The procedure for cleaning and assembly of the carburettors is the same as for the single car burettor see page 231 3 To refit 1 Fit the two gaskets with the insulation be tween them to each of the inlet manifold flanges as shown 2 Mount the two carburettors simultaneously and secure by means of the nuts and washers Ensure thatthe springwhich keeps the rear carburettor arm and adjusting screw in contact with the arm of the front carburet tor is fitted 3 a Connectthefuel line andfitthe clips b Connect the vacuum hose 4 Fit the gaskets bracket air box and flange washers to the carburettors 5 Fit the choke links to the connecting rods andfitthe clips 6 Connect the throttle and choke cables Single carburettor Pierburg To remove Disconnect the positive lead from the bat tery 1 Disconnect the hoses to the EGR valve and Ag Sx distributor lt lt BS en Ll ai es en z 6 Be NV WP hae 2 Disconnect the earth lead from the top of the carburettor 3 Disconnect the electrical lead from the float chamber ventilation shuft off valve 4 Disconnect the accelerator and choke cables 5 Disconnect the inlet hose from the carburet tor flange 6 Remove the flange and the gaskets re
33. level in the float chamber constant under all conditions The fuel supplied by the fuel pump flows through the supply tube and the open float valve in the float chamber As the fuel level rises the float also rises pressing the float valve needle against its seat When the preset fuel level has been reached the float valve closes and will not reopen until the fuel level in the float chamber hasagain fallen When the engine is running the float chamber is vented via the valve in the chamber to the air fil ter internal venting With the engine at a standstill venting is via the valve in the float chamber to the engine compart ment external venting The valve is located in the air inlet flange When the engine is running this valve is closed and the internal vent passage open When the ig nition is switched off and the engine has stop ped the electrical supply to the valve is cut off causing the passage for internal venting to close and the passage for external venting to open Float chamber ventilation 1 Ventilation through air cleaner 2 Direct atmospheric ventilation Float chamber vent valve Cold start device choke The carburettor is equipped with a cold start de vice to assist starting and running the engine from cold As the engine warms up the choke control is pushed in to maintain the correct fuel air mixture as the fast idling speed decreases Stromberg When the choke control is pulled
34. low air at a minimum temperature of SO C 86 to be drawn through the bimetallic valve Observe the butterfly and check that it closes the port for preheated air Next allow air at a tempera ture below 20 68 to be drawn in through the bimetallic valve and this time make sure that the butterfly closes the cold air port To change the bimetallic valve 1 Detach the vacuum lines from the underside of the air intake hose at the carburettor 2 Snip off the retaining clip for the bimetallic valve and remove the valve from the hose Note When fitting a new valve always use a new clip Fuel system Removal 233 1 Cleaning the fuel filter 233 2 Refitting 233 1 To remove Disconnect the fuel hoses from the pump Re move the fixing bolts and washers and then re move the pump and gasket The pump cannot be dismantled and consequently cannot be over hauled in the event of damage to the diaphragm or valves the entire unit must then be replaced Up to and including engine no D052892 The filter can be removed forcleaning or replace ment with the pump in situ Remove the cover retaining screw and lift off the cover Torefit Always fit a new gasket If the fuel pump has been removed with the valve cover in situ refitas follows 1 Fit together the pump body and adaptor 2 Apply sealant to the cylinder head flange and then fit a new gasket 3 Guide the push rod into the groove in the camshaft T
35. must be tightly sealed If the choke modulator is working properly the CO value will increase markedly To check the modulator valve and hose Pierburg Suck at the valve and check that it opens and closes Check that the hose is intact and that it is still flexible and soft The valve can also be checked as follows when the CO content is checked Run the eingine at fast idling speed Disconnect the hose from the valve and plug it whereupon the CO valve should increase Recon nect the hose whereupon the CO valve should fall Ifthere is no change in the CO content fit a new valve or remove the valve and blow clean the pas sages with compressed air Float chamber vent valve Checking and setting Stromberg The valve should be set so that atmospheric air is drawn in through the connection to the air cleaner 1 Connect a hose to the mouth of the atmos pheric air pipe 2 Blow down the hose Ifthe fuel pipe is nottfit ted and connected to the pump the fuel inlet connection must be sealed off a With the throttle fully closed it should not be possible to blow through the connec tion as the float chamber is an enclosed space Throttle valve fully closed 1 Airfrom air cleaner 2 Atmospheric air b If the throttle is opened 2 3 mm 0 08 0 112 in at the throttle stop a passage will be opened for internal air flow mak ing it possible to blow through the con nection c lf the throttle is opene
36. ng 5 Free the cable atthe bulkhead grommet and withdraw it Refit in the reverse order Vapour trap Vappor trap 1986 Because of the increasing proportion of volatile substances in the fuel there is now a greater likelihood of vapour locks occurring in the fuel system resulting in erratic performance of the engine immediately after starting and at high ambient temperatures To overcome this problem a vapour trap has been fitted in the line between the fuel pump and carburettor Any bubbles in the fuel rise to the top of the vapour trap and then flow through a re turn line back to the fuel tank Twin carburettors Vapour trap 1987 models onwards A modified vapour trap on which the fuel outlet is on the opposite side is fitted to cars as from 1987 models Induction system Checking the preheater butterfly 1985 232 1 Checking the preheating system 1986 232 3 Checking the preheater but terfly 1985 A rough check of the valve operation can be made by noting its movement when the cold air intake is removed A more accurate check can be made by removing the valve body with the cable and the thermostat and immersing it in hot or cold water and check ing the position of the valve from the figures below 23 C 73 F preheated air only 37 C 99 F cold air only Note When performing this check the cable should adopt approximately the same position as it has in the car Checkin
37. ng the throttle valves 3 Idling setting 4 Vent valve float chamber rear carburettor 3 Idling setting If any adjustment is made it wilt affect the setting of adjusting screw 4 which should also be checked 4 Vent valve float chamber rear carburettor Adjust if adjusting screw 1 2 or 3 has been altered Choke cable Removal of choke cable earlier models 1 Detach the choke cable and the sheath from thecarburettor s Note the run ofthe cable Free the cable from the clips in the engine compartment Note The end of the cable is covered by a rubber pro tective piece to prevent injury to hands when working with the controls Europe specification cars as from 1984 models 1 Synchronizing the throttle valves 2 Idling setting 3 Vent valve float chamber rear carburettor 2 Loosen and lift up the gear lever cover and then disconnect the cable and sheath from the gear lever housing 3 Withdraw the cable from the bulkhead grom met and then remove it Refit in the reverse order Removal of choke cable later models 1 Disconnect the cable and sheath at the car burettor or carburettors Note the cable run Free the cable from its clips in the en gine compartment 2 Unscrew the choke control handle Choke control as from 1982 models 3 Slacken the screws in the cover of the gear lever housing and raise it so that the cable and sheath can be disconnected from the housing 4 Disconnect the wiri
38. out a disc 4 is rotated and fuel flows from the float chamber through one two three or four ofthe holes in the disc The fuel flow through the disc is determined by the number of the holes that are not blanked off Additional airtothe disc is drawn in through air jet 3 to form an emulsion with the fuel The additional fuel air mixture then flows into the mixing chamber through passage 6a Refer to Fig A To enable the engine to run smoothly under all driving conditions the quantity of choke fuel is optimized to meet the requirement during accel eration or at full throttle Fig A This quantity of fuel is much greater than that needed when the car is travelling at a constant speed A leaner mixture is obtained as follows Fig B At constant speed constantthrottle opening a depression is present in the inlet manifold Via connecting passage 8 the depression acts on the diaphragm 1 once the force of the spring 2 has been overcome allowing air to be drawn through passage 9 into the fuel inlet passage 5 The fuel air mixture flows through the disc 4 where additional air is drawn in through air jet 3 This lean mixture 6b then flows into the mixing chamber providing additional fuel air On renewed acceleration opening of the throt tle the mixture is automatically enriched load sensing choke since there is a reduction in the depression in the inlet manifold which allows the spring loading on t
39. p up the oil in the damper cylinder Check the oil level which should be 10 mm 0 04 in below the top of the cylinder Top up as necessary using automatic transmission oil To check the damper piston Check for damage and wear Check the axial play of the damper piston which should be between 0 5 mm and 1 5 mm 0 02 0 06 in In case of any defect replace the entire damper piston and oil cap assembly Check that the vent hole in the oil cap is open 4 ere LAAD Sia lt Pierburg carburettor f Sa 2 SSS i reo i 5 5 Changing the jet Stromberg Tools Drift 83 92 789 The jet is press fitted in the carburettor body and should not be moved from the specified position However the jet can be changed using tool 83 92 789 as follows 1 Remove the carburettor and then take off the vacuum chamber cover and remove the vac uum piston and float chamber cover 2 Tap out the jet using tool 83 92 789 3 Using the tool tap in the new jet from the float chamber side using drift 8392789 until the distance of the jet below the level of the bridge in the carburettor body is as fol lows Single carburettors 2 5 0 1 mm 0 0984 0 00339 in Twin carburettors 2 3 0 1 mm 0 0906 0 00339 in If you happen to tap the jet in too far it can be tapped back from above using the same tool Caution Avoid resting any type of measuring tool against the upper inner surface of the je
40. r to maintain a constant fuel air mixture regardless of engine temperature The temperature com pensator consists of an atmospheric valve con trolled by a bi metallic strip The valve starts to open when the temperature of the air at the temperature compensator reaches 68 F 20 C approx Additional air is introduced through a vent which discharges behind the airvalve shaft Carburettor with throttle closed Stromberg 1 Damper piston and oil cap assembly 2 Diaphragm 3 Compensating aperture 4 Damper piston 5 Float chamber vent 6 Floatvalve 7 Float 8 Vacuum piston 9 Starting fuel aperture 10 Throttle butterfly 11 Vacuum aperture 12 Needle 13 Jet orifice 14 Float chamber 15 Constant depression chamber CD chamber 16 Aperture for additional air temperature compen sation Acceleration Stromberg A damper piston is provided in the centre of the air valve in order to provide a richer mixture when the throttle is opened rapidly acceleration The damper consists of a piston which runs in oil at tached to a rod When the throttle is opened quickly the depression in the vacuum chamber increases rapidly When the air valve rises the piston damper is forced against its seat prevent ing the oil from flowing past which retards the movement of the air valve This causes a tempor ary increase in the depression above the jet orifice and the air fuel mixture is enriched The downward movement of the air valve
41. screw on Stromberg carburettors must be screwed fully home before any adjustment of the CO value is made Engine Model Specification C0 EngineCO value Idlingspeed year speed idlingspeed r min 50 Single carbure 1981 Sweden 1 5 2 0 2000 4 5 max 850 ttor CM CA 1983 Europe 0 5 2 5 850 850 1983 Switzerland 1 5 2 0 2000 0 4 1 6 850 1984 Switzerland 1 4 2 0 2000 0 4 1 6 850 1984 Europe 0 2 1 0 850 850 1985 Sweden 1 4 2 0 2000 0 4 1 6 850 Twin carbure 1981 Sweden 0 75 1 25 2000 4 5 max ttors TM TA 1982 Europe 0 5 2 5 850 1983 Switzerland 0 75 1 25 2000 3 5 max 1983 84 Europe 0 2 1 0 850 Temperature compensator Opening at room temperature 20 C 68 F mm in 0 1 0 3 0 004 0 012 Fuel pump Fuel pressure at starter motor speed bar psi 0 17 0 25 2 5 3 6 Quantity of fuel remaining when fuel warning light comes on approx 7 1 85 USgal Carburettor Carburettor type Single carburettor CM CA 1984 175 CD CM CA 1985 175CDSEVX CM CA 1987 175CDUS Twin carburettors TM TA 1984 150 CD Fuel needle designation CM CA B1DS TM TA B5EQ Stromberg Oil level in damper cylinder CM CA 2 520 imm TM TA 2 340 1mm Float valve A mmm 7501S D Needle shoulder flush with bottom of piston Fast idling speed cam CM 1981 82 1100 50r mm A6 CM 1983 1350 50r min AS CA CM 1984 1350 50r mm AS TM TA 1981 84 1100 50r mm A5 Idling speed
42. se ventilation hose Ifa lower CO reading is now obtained this will be be cause of fuel in the engine oil Change the oil and read off the CO content again 3 Adjust the basic setting by removing the vac uum piston orpistons and makingsurethat the needle shoulder is level with the bottom of the vacuum piston Before refitting the components clean the piston and carburettor Read offthe CO con tent again 4 Check the setting of the air preheater valve see section 232 5 Check that items 2 to 6 inclusive under Be fore adjusting the CO setting have been car ried out correctly if not run through the pro cedure again Note Do not take CO readings when the engine temp erature is above normal as this will result in faulty readings Adjusting screws twin car burettors 1 Vent valve float chamber front carburettor The setting is fixed and adjustment is not normally necessary In the event of any ad justment being made this will affect the set tings of adjusting screws 2 3 and 4 These must therefore be readjusted in the given order 2 Synchronizing the throttle valves This is carried out in conjunction with check ing the idling speed and CO setting Any ad justment will affect the settings of adjusting screws 3 and 4 which must also sub sequently be readjusted in the given order e Adjusting screws 1983 models and earlier 1 Vent valve float chamber front carburettor 2 Synchronizi
43. sembly 231 11 Refitting 231 12 Single carburettor Pierburg Removal 231 13 Dismantling 231 15 Cleaning 231 16 Assembly 231 16 Refitting 231 19 Changing the adjusting screw in the vacuum piston Stromberg 231 20 Checking and replenishing damper oil 231 22 Changing the jet 231 23 Basic setting of metering needle 231 24 Temperature compensator Stromberg 231 25 Choke modulator Stromberg 231 27 Single carburettor Stromberg Removal 1 Disconnect the inlet hose from the carburet tor 2 Disconnect the fuel line throttle and choke control cables and vacuum hose to the dis tributor 3 Remove the screw for the dipstick tube 4 Back off the four retaining nuts and lift off the carburettor Checking the modulator valve and hose Pierburg Float chamber vent valve Idlingshut off Engine run on Checking and adjusting Choke twin carburettors Choke control Pierburg Fast idling Pierburg Choke Pierburg Basic setting of needle Stromberg Checking the needle Pierburg Synchronization of twin carburettors COsetting Stromberg COsetting Pierburg Fault diagnosis high CO value Adjustingscrews twin carburettors Choke Vapourtrap 231 27 231 28 231 30 231 31 231 31 231 32 231 33 231 33 231 34 231 35 231 35 231 36 231 40 231 43 231 44 231 45 231 47 Dismantling Tools Adjusting tool 8393035 1 Remove the va
44. t as necessary Fast idling Pierburg Note Disconnect the vacuum line to the distributor and run the engine to normal operating tempera ture Pull out the choke until the mark on the choke lever is in line with the fast idling screw Adjust the engine speed to 1350 50 r min by means of the fast idling screw Choke Pierburg Make sura the choke does not bind Check the valve disc and the corresponding seal ing surface on the carburettor body Remove any minor scratches using fine emery cloth and lapping paste Basic setting of metering needle Strom berg Tools Needle adjusting tool 83 93 035 As regards twin carburettors the basic setting must be adjusted on both The jet is fixed in the carburettor and the height of the needle must therefore be adjusted to effect the basic setting Proceed as follows 1 Remove the damper and oil cap assembly 2 Remove the vacuum chamber cover and the return spring 3 Withdraw the piston and diaphragm to gether 4 Using tool 83 93 035 bring the should of the needle in line with the lower edge of the vac uum piston Needle should flush with bottom ofpiston 5 Fitthe piston and diaphragm complete in the carburettor making sure that the outer tab on the diaphragm engages the matching slot in the carburettor body 6 Fit the spring and vacuum chamber cover making sure that the marks coincide and then fit and tighten the screws 7 Check and if necessary
45. t when tapping it into position Even the siightest deformation in the surface can affect the jet orifice Plerburg To remove 1 Remove the carburettor from the car and then remove the damper piston and car burettor cover 2 Empty all fuel from the carburettor 3 Remove the float chamber cover 4 Remove the jet and the return spring Tom 1 Fit the return spring and the new jet 2 Refit the float chamber cover complete with gasket 3 Adjust the height of the jet see below 4 Fitthe carburettor cover and damper piston 5 Refit the carburettor Basic fuel jet setting Pierburg When measuring remember that the jet is spring loaded Adjust the height by means of the adjusting screw in the float chamber cover The jet should be set 2 5 mm 0 098 in below the face of the bridge in the carburettor body Temperature compensator Stromberg The temperature compensator serves to main tain a constant fuel air mixture regardless of the ambient carburettor temperature The tempera ture compensator valve is governed by a bi metallic strip whieh on heating opens an air passage past the vacuum piston The valve opens at around 20 C 68 F In the event of the idling speed dropping rapidly after prolonged idling particularly in warm weather check the operation of the temperature compensator by removing the plastic cover and pressing in the valve whereupon the tickover should become less smooth If the v
46. the CO meter and tachometer CO setting Before adjusting the CO setting E Change the engine oil Check the spark plugs Check the HT leads Check the valve clearances Check the ignition timing Check the float chamber ventilation Check the oil level in the damper cylinder Oo ON ODO A F W DN Check the air preheater air cleaner Check the position of the camshaft timing 10 Check the delay valve for vacuum control unit on distributor 11 Check the radiator fan 12 Check the fuel shut off valve Ifthe car has been taken into the workshop after having been outdoors at ambient temperatures below 10 C 14 F and the fuel is thus cold pro ceed as follows e Pinch closed the fuel return line at the car burettor until adjustment of the CO emission has been completed e Run the engine with the bonnet hood closed until the radiator fan has cut in Tocheck 1 Run the engine to normal temperature and connect a tachometer 2 Disconnect the crankcase ventilation as fol lows a Disconnect the nipple from the valve cover b Plug the small bore hose c Connect an evacuation hose to the valve cover Evacuate the crankcase gases by connect ing a hose from the opening in the valve cover to the evacuation hose of the build ing s extraction system at a point downstream ofthe CO meter sensor Note When connecting exhaust extraction equipment for running the engine in the workshop make sure
47. ther between the fuel tank and fuel pump are routed along the rear seat member and LH side member Body lead throughs are sited to the left in the bulkhead panel and to the right in the floor pan pressing for the rear axle The lines enter the en gine compartment through the LH wheel arch bracket Return fuel Surplus fuel is returned to the fuel tank via the fuel return line which is connected to a restric tion type branch connector between the fuel pump and the carburettor As from 1986 models the fuel return line is connected to the fuel return outlet on the vapour trap Fuel tank ventilation and breather system 1 Fuel tank 2 Filler pipe 3 Breather pipe 4 Breather hose 5 Restriction 6 Vent hose 7 Filler cap 8 Vacuum valve 9 Expansion space 10 Fuel return line Roll over valve 1984 model cars onwards are equipped with a roll over valve The valve is connected to the vent hose for the fuel tank and prevents petrol escap ing in the event of the car being involved in a col lision The valve is located on the right hand side in the luggage compartment mounted on the rein forcement panels inside the rear wing 1 Fuel tank 2 Roll over valve Single carburettor Stromberg Carburettor Removal 231 1 _____ Dismantling 231 2 Cleaning 231 3 Assembly 231 4 Refitting 231 7 Twin carburettors Stromberg ____Removal 231 8 i i 231 9 Cleaning and as
48. therefore alternates between the non preheated and preheated position As from 1986 models the valve butterfly in car burettor engines is controlled not only by a ther mostat but also by a bimetallic strip in the air in duction hose upstream of the carburettor The bimetallic strip senses the temperature ofthe in duction air and uses the depression in the inlet manifold to operate the valve butterfly When the engine is under full load and the depression in the inlet manifold is weaker the butterfly is con trolled by the thermostat This system ensures that the induction air to the engine is always at the correct temperature of 25 5 77 15 Fuel pump The fuel pump is a diaphragm pump driven by a push rod from an eccentric on the camshaft Apart from the filter which can be removed for cleaning up to engine No D 052892 the pump cannot be dismantled for overhaul or repair 1 Valve housing Cold air intake Preheated air intake Valve butterfly Thermostat body Bimetallic strip Inlet manifold Carburettor Crankcase ventilation OMONODO AWN 1 Fuel pump body 2 Adaptor 3 Push rod 4 Seal 5 Filter 6 Cover Fuel tank The fuel tank made of injection moulded plas tic houses the fuel gauge sender unit the pump inlet line and a connection for the fuel return line The tank is equipped with a breather system and overfill protection which allows for expansion of the fuel inside the tank Fuel tank
49. tion A mechanical dashpot delays the closure of the throttle when the accelerator is released Sweden specification 1984 and earlier models Europe specification 1984 and earlier models The carburettor is equipped with a diaphragm valve which is affected by the manifold depres sion during overrun thereby opening the throttle by pass and permitting the correct air fuel mix ture to reach the engine Deceleration valve normal driving 1 Adjusting screw 2 Rubber ring 3 Cover 4 Nut 5 Spring 6 Passage to diaphragm upper side Deceleration valve engine overrun 7 Diaphragm 8 Valve 9 Throttle 10 Aijr fuel mixture inlet passage 11 Air fuel mixture outlet passage 1985 models onwards A poppet valve is incorporated in the throttle but terfly On engine overrun the valve opens a port in the butterfly allowing the correct mixture of fuel and air to be admitted to the engine Idling shut off valve Carburettor engines are equipped with an idling shut off valve to eliminate the engine running on after the ignition has been switched off Deceleration valve normal driving Deceleration valve engine overrun 1 Poppet valve 2 Spring seat 3 Spring 4 Spring seat Single carburettor engines obtain their air fuel mixture at idling speed through a small aperture in the throttle butterfly and through a throttle by pass passage When the ignition isturned off the by pass passage is blocked by a spring
50. too weak idling These three factors tend to produce a wider opening of the throttle butterfly Carbon deposits in combustion chamber caused by prolonged use of choke and engine failing to reach normal running temperature Grade of fuel too low higher octane rating needed Float chamberventilation incorrectly adjusted twin carburettors only Checking and adjustment Choke Control Twin carburettors Check that both choke controls strike their stops at the same time If necessary adjust the control spindle linkages Fast idling Stromberg Check the fast id ing speed with the engine warm asfollows Vacuum line to distributor plugged a Place an 8 mm 0 315in dia spacer drill bit between the notch in the cam lever and the stop on the choke housing a 7 ay ij F T a T r b Check that the fast idling speed is cor rect Adjust the stop screw on the throttle lever if required Code on r min fast idling cam CM81 82 1100 50 A6 CM83 1350 50 A8 CA CM B4 1350 50 ASA TMJAS8 1 84 1100 50 AS Note Ifthe code on the cam differs from that shown for a given engine variant follow the setting applic able to the cam code Choke control Pierburg Make sure the lever deflects fully when the choke is pulled out Push in the choke Make sure the lever is at the lower limit of its travel and that the fast idling screw is not touching the lever Adjus
51. tor 1 75 0 25 Twin carburettors 1 010 25 For adjustment remove the dashpot damper pistons and then turn needle adjusting screwsby means of tool 8393035 Support the vacuum piston by means of the sleeve of the tool to prevent the rubber diaphragm from being damaged Rotate clockwise to Increase CO value needle raised Rotate counter clockwise to reduce CO value needle lowered 8 Remove the plugs and connect the crank case ventilation the EGR hose and the vac uum hose to the distributor 9 Set the idling speed to 850 50 r min and check the CO value Maximum CO reading at idling speed Sweden 4 5 Europe 3 5 CO setting at 850 r min Idling speed 1 Run the engine until it reaches its normal running temperature so thatthe CO reading can be made justafter the fan has cut in The reading must be made with the headlights switched off Connect the CO meter and tachometer 2 Check the idling speed adjust as necessary and then read off the CO value Refer to the Technical data section for the correct CO reading at 850 r min Toadjust Remove the damper piston orpis tons and then use tool 83 93 035 to turn the needle adjusting screw Use the sleeve of the tool to support the vacuum piston to prevent damage to the diaphragm Turn the screw clockwise to increase the reading needle raised Turn the screw counter clockwise to red uce the reading needle lowered 3 Disconnect
52. uum causes fuel to be drawn into the mixing chamber where it is mexed with the air flowing past the top of the jet The carburettor is equipped with a by pass de vice for the idling mixture Most ofthe idling mix ture flows from the mixing chamber past the throttle which is setto a minimum opening and into the inlet manifold The rest of the idling mix ture flows through the throttle gap into the en gine The bi metal washers 23 located below the jet contract when the temperature of the fuel and the surrounding metal is low As the temperature increases the bi metal washers expand axially in the jet holder causing the annular gap between the jet and the taper needle to decrease This results in a leaner mix ture at higher temperatures and a richer mixture at lower temperatures This temperature compensation helps to ensure that the optimum fuel air ratio will be main tained regardless of the viscosity of the fuel Idling 9 Vacuum piston 12 Throttle butterfly 19 Float valve 20 Jet 21 Jet holder 22 Needle 23 Bi metalwashers 27 Adjustingscrew Acceleration Pierburg When the accelerator is suddenly depressed a richer fuel air mixture is required briefly This temperary enrichment of the mixture is achieved by means of vacuum piston spring 10 and damper piston 8 in the damper oil 28 When the throttle is suddenly opened the damper piston prevents an immediate upward movement of the vacuum piston
53. ve 17 opens in the inlet manifold Thus the air required for a leaner mixture flows through a passage B from the clean air side of the air cleaner 4 Choke disc 12 Throttle butterfly 17 Modulator lean mixture valve Cold starting A Fuel supply from float chamber Warm starting B Air supply Fast idling When the choke control is pulled out a cam which acts on the throttle is rotated The further the choke control is withdrawn the faster will be the fast idling speed Idling Stromberg The carburettor does not have a separate idling system At idling speed there is a depression in the vacuum chamber In this position the thickest section of the tapered metering needle is in the jet orifice and only a small quantity of fuel sufficient for idling is inducted into the cylinders The air fuel mixture should be set while the engine is idling by adjusting the re lationship between the metering needle and the jet aperture This is effected by altering the orifice adjusting screw which raises or lowers the tapered metering needle and it is this setting which then covers the entire range of engine speeds The idling speed is changed by adjust ing the setting of the throttle stop screw idle ad just screw On twin carburettor engines the throttles can be synchronized by adjusting the clamping bolt on the coupling assembly between the two throttle spindles The carburettor is equipped with a temperature compensato
54. wist the push rod to ensure that is has engaged in the groove 4 Use asmall screwdriver to hold the push rod in position and guide the end of the pump link rod into the collar of the push rod Press the pump against the flange and hold it there while fitting and tightening the three fixing bolts Cleaning the filter Remove the screw in the centre of the pump cover liftoffthe cover and remove the filter and seal Clean the filter and cover Reassemble As from engine no D052893 the filter is an in tegral part of the fuel pump and therefore cannot be dismantled for cleaning Fuel tank and fuel lines Removaloftank 234 1 Replacing fuel lines inside car 234 4 Refitting of tank 234 2 Fuel gauge sender unit 234 5 PUG WINGS a sadake et ob had a lk 234 3 Replacing the roll over valve 234 6 Fuel tank Toremove 1 Disconnect the earth lead from the battery 2 Jack up the rear of the car 3 Drain the fuel tank To prevent the emission of hydrocarbons into the workshop drain the tank by means of a closed system Connect an electric fuel pump designed for injection engines to the inlet line of the fuel tank and pump the fuel through a hose into a container The work should be done with the car jacked up 4 Remove the rear floor panel in the luggage compartment 5 Remove the fuel gauge sender unit plate 6 Disconnect all electrical connections from the tank
55. with running the engine inside the workshop avoid excessive depressurization of the exhaust system as this may affect readings e g ofthe COcontent To prevent excessive extraction pressure use an extraction hose with an open coupling Secondary CO adjusting screw single carb Carburettors equipped with a secondary CO ad justing screw for use at idling speed are fitted to O o CORRECT CORRECT single carburettor cars as from engine no 18191 Conventional adjustment of the CO con tent should be carried out as before at 2 000 r min Note In its normal setting the secondary adjusting screw should be screwed right home to the end of its travel If during subsequent checking ofthe CO value at idling speed the value exceeds the specified maximum 4 5 the CO content can be reduced using the secondary adjusting screw 3 Disconnect the vacuum line from the dis tributor and blank off the end of the hose 4 Plug the end of the vacuum hose to the EGR valve where applicable 5 Connect the CO meter and tachometer 6 Switch on the daylight driving lights 7 Read the CO value immediately after the radiator fan cuts in If the reading is within the specified limits reset the idlingspeed to 850 r min Idling adjustment screw Europe specification as from year model 1984 CO setting at 2 000 r min Hoses to vacuum control unit crankcase ventilation and EGR valve disconnected Single carburet
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