Service Manual Section 2, A1-A8. 1991
Contents
1. may damage the nozzle and result in a faulty spray pattern 360 58 Adjustment Adjust the nozzles so that the jet of washer fluid stri kes the headlamp glass 0 5 mm from the upper edge of the glass Turn the washer nozzles to the side with the auxiliary tool so that the spray pattern is symmetrical on the right and left sides Note 480 In order to test the washer system the head lamp main beam must be switched on and off for eve ry operation The system sprays twice in sequence with an interval of 5 seconds 4401460 The washer system only functions when the headlamp main beam is switched on The system sprays washer fluid with a 5 second interval A5 Clutch 41095 x gt amp heck adjust Measure the distance A between the fork and the bracket without touching the clutch pedal With extended release fork Measure the distance B between the fork and the bracket with the clutch pedal pressed to the floor Adjust the fork s stroke X with the adjustment nut so that distance A B 3041 mm Without extended release fork Measure the distance A between the fork and the engine gearbox contact area without pressing the clutch pedal Measure the distance B between the release fork and the engine gearbox contact area with the clutch pedal pressed to the floor Note Use a pedal hook here Adjust stroke X for the release fork with the help of the adjustment nut so that di2. A1 Automatic gearbox selector lever inspect 43239 137 449 Check the start inhibitor switch reverse lamp switch Check that the engine can only be started when the gear selector lever is in P or N and that the reversing lights are on when the lever is in R Important Gearbox oil should be at the right level and operating temperature Move the lever to D and maintain pressure on the bra ke pedal Turn the ignition key to the starting position and keep it there Slowly move the lever to N until the engine starts Release the brake pedal and check if the car creeps forward Repeat the test this time with the lever already in R at the start of the test The car should not creep in either test 240 AW 70 71 Check the gearshift control It should only be possible to start the engine in P and N The reversing light should come on in R Play in the shift from D to N should be greater than or equal to the play in the shift from 2 to 1 700 940 AW70 71 72 ZF 4 HP 22 Check the gearshift control It should only be possible to start the engine in P and N Note On cars with an electronic start inhibitor the gear selector lever should be able to be moved from P only when the engine is on and the brake pedal is pressed The reversing light should come on in R The gear selector lever should be vertical in P Play in the movement from D to N should be notice able and less than
3. end Correct distance 39 5 mm dimension X Tolerance 0 5 mm If the correct distance cannot be achieved adjust with the sheath or move the wire stopper Clamp the wire stopper into its end position Release the throttle control Note Check that the wire stopper does not strike the pulley 1700025 1700026 8146587 Check the setting of the kickdown wire Turn the pulley to the full throttle stopper In this position it should be possible to pull the wire out a further 1 mm A Kickdown wire adjustment Undo the two lock nuts 1 Turn the pulley to the full throttle stopper and tension the wire by pulling on the sheath s adjustment socket Note Do not pull on the sheath itself Adjust the upper lock nut to obtain a play of 1 mm B between the attachment and the nut Tighten the lower nut 5 Nm Lock the nuts in place with a coat of paint BW55 AW55 70 71 ZF 4 HP 22 Check that the wire is tensioned in the idling setting without pulling against the pulley and that it is loca ted securely in the pulley groove running smoothly in the sheath Check Pull the wire out about 10 mm and release it suddenly A metallic clicking noise should be heard from the throttle cam when it reaches the standby setting Wire too firmly tensioned No clicking sound Slack wire No kickdown function Adjustment Adjust with the wire tensioner A7 Crankcase ventilation clean Note Winter o
4. from the air filter housing and bend it forward somewhat Remove the oil filler cap Clean the crankcase ventilation replace the fla me trap Remove the flame trap by rotating it about 15 mm to the left bayonet catch Clean the flame barrier casing 2 after the flame trap has been removed Blow clean the hoses 1 amp 3 Clean the multi nipple 4 inlets and outlets does not apply to MA 1995 Note The nipple on the small hose 3 has a calibra ted hole with a diameter of 2 5 mm Use a drill for cleaning Important Do not disconnect the hoses from the flame trap s outer casing The positioning of the hoses can affect the function of the throttle control Fit a new flame trap Fit a new flame trap with its outer casing in the inlet hose Refit all the other parts e Clean check the hose e Clean the nipple e Clean check the hoses e Clean the nipple e Clean check the hoses e Clean the nipple A8 Engine check for signs of leakage from above Check that there is no visible oil leakage and that the fuel lines coolant lines vacuum hoses and crank case ventilation hoses are correctly fitted and are completely tight with no leakage whatsoever 138 182
5. heels If not adjust the bra ke mechanism See service manual for brakes ops D1 and D5 Drum brakes Press the brake pedal firmly at least 20 times to ensu re maximum setting for the automatic adjustment me chanism Adjusting the parking brake Disc brakes Turn the adjustment nut 1 in until the lever 2 lies against the stops on both wheels Drum brakes Screw in the adjustment nut 1 until the lug 3 can ro tate freely A3 Exterior lighting Check Check that all exterior lighting functions properly Check that the glass lenses are undamaged and seal properly A4 Windscreen and headlamp wash wipe Check adjust S360 57 that the various speeds function including the intermit tent wipe facility setting and stop position tailgate wiper headlamp wiper function and stop position Adjust if necessary Wipers check Check the windscreen washers Adjust the washer nozzles as in the illustrations Check the tailgate window washer too Check the headlamp washers If necessary adjust the nozzles with a 0 6 mm thick piece of piano wire Do not use a needle Note 400 see below The illustration shows an auxiliary tool which can ea sily be made in the workshop for adjustment of the he adlamp washers on the 400 Auxiliary tools Insert the tool in the washer nozzle under section Note Never use the nozzle opening for adjustment This
6. or equal to play in movement from 3 to 2 ZF play in movement from 2 to 1 AW AW 30 43 AW 50 42 Check the gearshift control It should only be possible to start the engine in P and N A2 Parking brake check adjust Drive the car into the workshop bay with the parking brake slightly engaged pull up handbrake lever until resistance is felt plus one additional notch Drive max 400 metres max speed 40 km h with the lever in this position Check brake performance Full brake effect should be attained at 2 8 notches for the 200 700 940 960 850 max 7 notches for the 400 Check that the catch functions and that the warning lamp in the central instrument goes on and off as ne cessary Adjustment of parking brake 2401260 700 9401960 Adjust inside the car 850 Adjustment should always be performed first at the wheels as follows Adjust the brake linings by rotating the link in the bra ke drum with a screwdriver Rotate the link until the wheels lock then release 5 notches If full braking effect is not attained at 2 8 notches adjustment should be made at the lever inside the car 400 Returning the parking brake If fitted remove the heat shield on the exhaust pipe Undo adjustment nut 1 until the wires are slack Use an extended socket 1159202 9 or 9986916 6 on the B 20 F Disc brakes Check that the lever 2 on the brake caliper rests aga inst the stoppers on both w
7. peration and short driving distances can result in the formation of ice in the flame trap This may in extreme cases result in destroyed crankcase gaskets It is therefore important to clean the flame trap thoroughly B 16 F B18 K KP EP FP U B 20 F U e Clean check the hose e Clean the connection B 18 FT FTM e Clean check the hose e Clean the connection 5200 220 Check the condition of the hoses and check for block age e Clean the nipple in the inlet manifold e Replace the flame trap does not apply to turbo mo dels The flame trap should be positioned in the T piece e Check the condition of the hoses and check for block age e Clean the nipple in the inlet manifold e Replace the flame trap does not apply to turbo mo dels The flame trap should be positioned in the T piece e Clean check the hoses e Clean the calibrated nipple e Clean the oil filler cap if necessary change the strai ner in the cap B 6244 6254 6304 e Rotate the flame trap casing about 15 mm to the left bayonet catch e Pull out the flame trap and remove the oil filler cap e Blow clean the hoses down towards the crankcase ventilation e Insert a new flame trap in the inlet hose and rotate the flame trap outer casing back to its original position B 5202 5204 5234 5252 5254 Remove the cover above the throttle pulley Undo the hose clamp holding the inlet hose to the air filter housing Remove the hose
8. stance B A is 22 mm 1 mm A6 Kickdown wire check adjust ESEE e a 1700007A 1700007A ZF 4HP14Q Check the kickdown wire s setting Check that the throttle functions properly Delete the play in the throttle control cam by rotating it clockwise a few mm see illustration A only ap plies to the B 20 Check the distance dimension X between the wire sheath end and the wire stopper Min distance 0 1 mm lf necessary adjust with the sheath so that the cor rect distance is obtained Turn the throttle control until a slight resistance is felt kickdown setting Recheck the distance between the wire sheath end and the wire stopper dimension Y Correct distance 39 mm dimension X If necessary adjust with the sheath until the correct play is obtained Kickdown wire adjustment Remove the wire stopper from the wire Warning Be careful not to damage the wire Attach a new wire stopper loosely to the wire Turn the throttle control in its middle position Delete the play in the throttle control cam by turning it clockwise a few mm see figure A applies only to the B 20 Attach the wire stopper press it in lightly 1 mm B 18 or 4 mm B 20 from the outer end of the sheath dimension X Turn the throttle control until a slight resistance is felt kickdown setting Keep the throttle control in this po sition Measure the distance dimension Y from the wire stopper to the sheath
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