Service Manual Repairs $533555"
Contents
1. g A FOS Na NG NG law A o 3lb 31 87 WY 3 5 TN El L ANA NG NG ch CIS SYSTEM blue white f Sy D un sues laf K gt red OXYGEN SENSOR SYSTEM 1334552. B16 Micro switch UP Engine NOT running throttle CLOSED Slacken micro switch retaining screws Move micro switch UP until test light illuminates 130881 B17 Set micro switch position Move micro switch DOWN 2 2 5 mm 0 08 0 10 Test light MUST NOT illuminate Tighten screws Remove test lamp install panel etc 130882 24 Group 25 Intake exhaust emission systems Basic setting B21F Turbo 1981 1984 B21F Turbo Intercooler 1984 Basic setting of Constant Idle Speed System B21F Turbo 1981 Engine Identification Number EIN 498898 manual transmission automatic not available B21F Turbo 1982 Engine Identification Number EIN 1982 1983 1984 except intercooled 1984 intercooled manual transmission 498966 499800 499868 499926 automatic transmission 498967 499801 499869 499927 CI Disconnect throttle control rod At throttle lever C2 Check cable assembly Make sure cable and pulley run smoothly and do not bind in any position 130889 C3 Check throttle Make sure throttle shaft and throttle plate do not bind in any position 130890 25 Group 25 Intake exhaust emission systems Basic setting B21F Turbo 1981 1984 B21F Turbo Intercooler 1984 133310 C4 Remove panel in front of right front door Electronic Control Unit for Constant Idle Speed Systems is located below Electronic Control Unit for
3. Color point Orange B21F Turbo Volvo P N 1317499 0 1306937 2 127687 1 9 Engine identification numbers Bosch No 0 280 220005 0 280 130023 0 280 140 500 498966 and 498967 Color point Orange B28F Volvo P N 1274452 0 1306024 9 1276871 9 Engine identification number Bosch No 0 280 220008 0280 130028 0 280 140 500 498667 auto trans only Color point Gray 1983 1984 models B21F Turbo Volvo P N 1317499 1306937 2 1316957 7 Engine identification numbers Bosch No 0 280 220 005 0280 130 023 0 280 140 501 499800 and 499801 1983 Color point Orange 499868 and 499869 1984 B21F Turbo Intercooler Volvo P N 1317499 1306937 2 1317957 7 Engine identification numbers Bosch No 0 280 220 005 O 280 130 023 0 280 140 501 499926 and 499927 Color point Orange Group 25 Intake exhaust emission systems Specifications Resistance temperature specification Coolant temperature sensor ohms Volvo P N 1306024 9 Bosch O 280 130 028 WGWG PIN Er 1306024 9 Boschi NG 4 u un 0 280 130 028 BE GN A 1981 DL BR rs PRE I REDE 1981 and 1982 Suggested test values 10 C IPF 32000 53000 ohms F20 CCE P 2 8500 11500 ohms 80 C 176 770 1320 ohms ohms Volvo P N 1306937 2 Bosch O 280 130 Qi 10000 8000 6000 aon Volvo PIN ua pas aag 1306937 2 rit Basch NG nenne 0 280 130 023 B21F B21FT all 1982 2000 1000 a00 Suggested test values 600
4. Ballast resistor Ki ara to control test point General Ev Coolant temperture sensor l con tinuously sends a signal to the ECU so it can set an idle speed that corres ponds to the coolant temperature G is designated control test point It is a connection that for convenience is used on the production line Throttle switch C has a double func tion At idle it grounds a wire con nected to the ECU for ignition system When the air conditioning is operat white green or red 15 ing a micro switch at the AC switch energizes terminal 7 of the ECU This will increase idle speed from approx 750 rpm to 900 rpm and improve AC operation and cooling due to faster uhite red or gra running coolant pump and fan Idle speed Above idle speed Ground circuit through throttle switch C is interrupted Ground circuit through throttle switch C is closed ECU The Electronic Control Unit A ECU controls air con H controls air control valve H to set high air flow to trol valve H to set correct idle speed avoid engine stalls Blue yellou 12 Group 25 Intake exhaust emission systems Wiring diagrams A ev en CIS SYSTEM blue white SENSOR SYSTEM ee to terminal 7 of ign system ECU WG NA Ned blue red 133449 Group 25 Intake exhaust emission systems Wiring diagrams Fuse No 13 Instruments Turn signals Seat belt warning switch A white
5. NG LALA NS DNA H 2 EN ee a H AN EN SAN TIME NID og CIS system blue white red OXYGEN SENSOR SYSTEM Group 25 Intake exhaust emission systems Wiring diagrams D H white red or gray I i e7 Idle speed Paa AN Ground circuit through throttle svvitch C is interrupted The Electronic Control Unit A ECU controls air con trol valve H to set correct idle speed J F f es SES ME Ts blue yellow 12 p white red or gray CIS System B28F Fuse No 13 Instruments Turn signals Seat belt warning CIS System Legend A ECU Electronic Control Unit B Seat belt reminder unit C Throttle switch D Ignition switch E Fuel pump relay F Fuse box G Control test point H Air control valve Coolant temperature sensor J Ignition coil K Ballast resistor General Coolant temperature sensor I con tinuously sends a signal to the ECU so it can set an idle speed that corres ponds to the coolant temperature G is designated control test point It is a connection that for convenience is used on the production line Above idle speed Ground circuit through throttle switch C is closed ECU H controls air control valve H to set high air flow to avoid engine stalls f 3 133454 Group 25 Intake exhaust emission systems Wiring diagrams
6. Test light should illuminate at idle speed If not readjust adjuster screw for throttle butterfly valve position Open throttle slightly Engine running on idle Open throttle slightly by hand at throttle control lever 133379 D6 Test above idle speed Test lamp should go OUT If not recheck and try a new vacuum switch 133380 Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 Basic setting of Constant Idle Speed System B28F 1981 Engine Identification Number EIN 498638 manual transmission 498639 automatic transmission B28F 1982 Engine Identification Number EIN 498667 automatic transmission only El Disconnect throttle control rod At cable pulley E2 Check cable assembly Make sure cable and pulley run smoothly and do not bind in any position 13090 E3 Check throttle Make sure throttle shaft and throttle plate do not bind in any position 130902 33 Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E4 idle speed adjustment screw Make sure it is screwed to bottom NOTE This screw is used to adjust idle speed on engines without CIS System 130903 E5 Remove panel in front of right front door Electronic Control Unit for Constant Idle Speed System is located below Electronic Control Unit for Lamda sond system 133310 B28F 1981 133393 34 E6 B28F 19
7. Unit faulty Air control valve faulty Coolant temperature sensor faulty a u _ 090 UL YY Group 25 Intake exhaust emission systems Fault tracing Fault tracing CIS system 1 IMPORTANT Check wires and connectors These fault tracing procedures assume that the engine This is a very important part of the fault tracing procedures itself is in good operating condition and that ignition Bad contacts cause many problems timing is correctly adjusted Test only with engine at Operations illustrations a m below will underscore this im normal operating temperature Engine OFF when dis portance and at the same time show various connectors connecting connectors Electronic control unit connectors 2 Check connectors at Electronic Control Unit Remove panel in front of right front door to gain access to the unit Blue connector at top and black connector at bottom Firewall connectors CEN Connectors on firevvall There are tvvo connectors on firevvall This illustration shovvs B28F but is typical for all models Group 25 Intake exhaust emission systems Fault tracing Connector on firewall This illustration is typical for all engines all cars Shows B21F LH jetronic with cruise control Firewall connector disconnected Firewall connector B28F The other firewall connector Typical location also applicable to B28F 133352 Group 25 Intake exhaust emissio
8. 21F LH Jetronic Electronic Control Unit for CIS Constant Idle Speed system The Electronic Control Unit automatically increases engine rpm when the air conditioning is operating The Electronic Control Unit has two extra terminals 7 and 10 For basic idle mode terminal 10 is grounded When air conditioning is switched on a micro switch in the air conditioning control energizes terminal 7 This will change the operating mode of the Electronic Con trol Unit and set a higher idle rpm This provides im proved air conditioning operation and also improved cooling due to faster running coolant pump and fan 133266 B28F Throttle Switch New throttle switch same as on 4 cyl Infinite resistance in idle position Electronic Control Unit New control unit with test terminal for basic idle mode Reversed input from the throttle switch as compared with previous unit Modification introduced on 1983 models B21FT New smaller air control valve Group 25 Intake exhaust emission systems Specifications Specifications Idle speeds Basic setting Normal running Electronic Control Electronic Control Unit de activated Unit activated 1981 models rpm lower upper limit rpm lower upper limit BATE iis Ts ea rien sansa leerer 850 800 850 900 850 950 BAGNPG E susanne 700 700 750 750 700 800 B2IF Turbo 2 Hase rn 850 850 900 900 850 950 30 BAGA ducat EAT EP TF fa 850 850 900 900 850 950 1982 models
9. 81 De activate Electronic Control Unit Disconnect white red wire at terminal 12 of blue connec tor plug at Electronic Control Unit NOTE Same wire ends at ignition coil but cannot be discon nected there Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E7 B28F 1982 De activate Electronic Control Unit Ground terminal 10 connector in place Best way is to insert a copper wire along terminal wire 133384 ES Connect test lamp Connect across battery positive terminal and orange wire terminal on micro switch 1981 test light should illuminate while adjusting electric circuit through micro switch is closed 1982 test light shuld NOT illuminate while adjusting electric circuit through micro switch is interrupted Connect tachometer 130904 Adjusting idle s ed m ju g e spe E9 Start engine Should be at normal operating temperature Adjust idle speed 850 rpm 850 900 rpm permitted Adjust at throttle position adjustment screwn DO NOT adjust idle speed screw It should be screwed to the bottom 130905 35 Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E10 B28F 1982 B28F 1981 Activate Electronic Control Unit B28F 1981 Reconnect white red wire in blue connector plug at Electronic control unit B28F 1982 Disconnect test point from ground E11 Idle speed change After activating Electr
10. 910 NOTE B28F is equipped with two micro switches actuated by throttle control The second micro switch closes a Lambda sond circuit at full throttle to provide richer air fuel mixture at maximum acceleration NOTE Vehicles modified for high altitude have this micro switch disconnected 130911 E17 Adjusting full throttle enrichment switch Loosen retaining screws for micro switch Turn micro switch sideways Test light should come on go out 2 5 mm 3 32 before pulley touches full throttle stop Tighten retaining screws Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E18 Checking full throttle enrichment switch operation Disconnect green wire at micro switch Connect test light between micro switch terminal and battery posi tive terminal Turn pulley slowly to full throttle stop Test light should illuminate 4 to 1 mm 2 to Y2 before pulley touches stop Adjust as necessary see E17 130913 39 Group 25 Intake exhaust emission systems Wiring diagrams Fuse No 13 Instruments CIS System Turn signals Seat belt warning B21 F Cl CIS System Legend m A ECU Electronic Control Unit B Seat belt reminder unit C Throttle switch D Ignition switch to Electronic Control E Fuel pump relay Unit for Cor Controlled Tanitica F Fuse box TR G Control test point H Air control valve Coolant temperature sensor J Ignition coil K
11. B21F Turbo Intercooler 1984 ki THROTTLE POSITION 5 ADJUSTMENT SCREW 130893 Adjusting idle speed C10 Adjust throttle position Use throttle position adjustment screw to adjust idle speed to 850 rpm 850 900 rpm permitted NOTE Test light MUST NOT illuminate If necessary readjust micro switch position DOWN B21F TuRBo 1981 Hall 133392 C11 Activate Electronic Control Unit B21F Turbo 1981 Reconnect white red wire in terminal 12 of blue connec tor at Electronic Control Unit B21F5 Turbo 1982 B21F Turbo Intercooler 1984 Disconnect test point from ground 130885 C12 idle speed change After activating Electronic Control Unit idle speed should change to 191 itear 900 50 rpm u gt yore ons 900 20 rpm Stop engine install panel etc C13 Reconnect throttle control rod at lever Cable pulley should be completely retracted Disconnect throttle cable automatic transmission also kickdown cable Adjust control rod length as necessary Basic setting B21F Turbo 1981 1984 821F Turbo Intercooler 1984 130895 C14 Attach and adjust throttle cable CABLE LENGTH BEING PULLED OUT 130869 FEELER GAUGE 130896 C15 Automatic transmission adjust kickdown cable Check cable length at closed and open throttle Open throttle measurement should be checked with throttle pedal in car depressed NOT b
12. F Cl 1982 B21F MPG 1981 B2IF CI 1982 133391 B10 Activate Electronic Control Unit B21F MPG 1981 Reconnect vvhite red vvire in terminal 12 of blue connec tor plug at Electronic Control Unit B21 CI 1982 Disconnect ground wire at terminal 10 of blue connector plug at Electronic Control Unit 130876 B11 Idle speed change After activating Electronic Control Unit idle speed should change to 750 rpm 700 800 rpm permitted for 1981 730 770 for 1982 Stop engine 130877 B12 Reconnect throttle control rod at lever Cable pulley should be completely retracted If adjustments of engine controls must be made follow operations B11 B13 below 22 130878 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21F CI 1982 Adjusting cents e B13 Adjust control rod length Disconnect throttle cable and automatic transmission kickdown cable Adjust control rod length as necessary 133387 B14 Attach and adjust throttle cable 130880 B15 Automatic transmission kickdown cable Check cable length at closed and open throttle engine off Open throttle measurement should be checked with throttle pedal in car depressed NOT by actuating linkage by hand Cable should be pulled out 50 mm 1 968 23 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21F CI 1982 Adjusting micro switch
13. Lambda sond system 133381 C5 B21F Turbo 1981 De activate Electronic Control Unit Disconnect white red wire at terminal 12 of blue connector plug at Electronic Control Unit NOTE Same wire ends at ignition coil but cannot be disconnected there 133384 CE B21FT 1982 B21FT Intercooler 1984 De activate Electronic Control Unit Ground terminal 10 connector in place Best way is to insert a copper wire along terminal wire 26 Group 25 Intake exhaust emission systems Basic setting B21F Turbo 1981 1984 B21F Turbo Intercooler 1984 C7 Connect test lamp Connect across battery positive terminal and orange wire terminal on micro switch NOTE Test light MUST NOT illuminate while adjusting idle speed electric circuit through micro switch is open See op C7 C8 If test light illuminates adjust micro switch position Slacken micro switch retaining screws Move micro switch DOWN until test light goes OUT Tighten screws This is a temporary adjustment Final adjustment will follow later on C9 Connect tachometer Good instrument to accurately measure engine speed Start engine Should be at normal operating temperature Idle speed should be 850 rpm 850 900 rpm permitted If not see op C9 C15 ee 27 Group 25 Intake exhaust emission systems Basic setting B21F Turbo 1981 1984
14. SWESTIR Les 55 7000 11600 ohms m HEG ERF U 2100 2900 ohms Rt 80 C 176F 270 390 ohms O 200 100 133373 Group 25 Intake exhaust emission systems Fault tracing Faults in CIS system It is advisable to eliminate other systems as fault source The reference list below may be helpful in finding prior to fault tracing the CIS system possible reasons for an incorrect idle speed Simple reference list of symptoms and possible reasons Symptom Possible reasons Idle varies up and down CO adjustment incorrect more than 50 rpm for 1981 models Ignition timing incorrect more than 20 rpm for 1982 models Throttle butterfly valve incorrectly adjusted Electronic Control Unit faulty Air control valve faulty Air leakage Idle speed too high Low basic idle speed Air control valve sticks Throttle switch incorrectly adjusted Temperature sensor faulty or not connected Throttle butterfly valve incorrectly adjusted No idle speed control Bad contact in connector Throttle switch incorrectly adjusted Electronic Control Unit faulty Air control valve faulty Engine stalls when braking to stop CO adjustment incorrect Ignition timing incorrect Throttle butterfly valve incorrectly adjusted Faulty contact in connector Electronic Control Unit faulty Low basic idle speed No high idle speed when cold Air control valve sticks Electronic Control
15. Service Manual Repairs and maintenance VOLVO Contents Operation Page Un O esc Sabha ree arte 1 System description 4 4 4 0 e0 2 SOCIS NS tota Al sides Nah pinalo ag ii faciadezes 4 Fault tracing CIS system 20 22 a dimen mena sawan mama 6 Basic setting of Constant Idle Speed system ESP TOET sess sat casera Ta REITEN A1 A15 14 B21F MPG 1981 B21F CI 1982 4 1 i phi B1 B17 19 HAF Tuo DB a oc ne ann anne nen nm C1 C18 25 B21F LH Jutrorig 1982 iiassscarsxoaiszeescoib is rimida D1 D6 31 es B28P 8004 E CE KATI ITA kai ah Pas Pes dns E1 E18 33 Wiring Diagrams ABE picab Shao 265 ce PANANT ALT IDANG AD TANI 102 NAAN 40 BAECH AANDE Re ia RID Uk ei durs 42 B21FETUTDO dae yale eyes NAN ae ec an er TE 44 BIBE iaia Ka dy pas Kg ira dama a AN a a pls a 46 Indicates changes in text and or specifications in this manual TP 30363 2 6000 10 84 Printed in U S A 1984 VOLVO OF AMERICA CORPORATION We reserve the right to make alterations Contents Operation Basic setting of Constant Idle Speed system DONA SOTA era as ESE Se ee A1 A15 B21F MPG 1981 B21F CI 1982 B1 B17 SBF TUTOO ADE iN tact eases ED PANG C1 C18 B2IF LH Jetronie 1962 aaa pana een es D1 D6 ZD TORT BR nette ag age arsine AS E1 E18 Wiring Diagrams BE typical FARI NAAT en sig Db ABG i snk onside HERA MANNA ANGKAN AGANE PINA TA Indi
16. __ BEIFEL Sr tue neu 700 700 750 750 730 770 B21F LH Jetronic 700 700 750 750 730 770 821F Turbo inc intercooled 850 850 900 900 880 920 oo AB hese AS or WHE ROP EEN 850 850 900 900 880 920 On B21F Cl and B21F LH Jetronic with idle speed 750 rpm idle speed increases to 900 rpm when AC is switched on Component identification numbers Electronic Coolant Air Control temperature control Unit sensor valve 1981 models B21F California Volvo P N 1276897 4 1306024 9 1276871 9 Engine identification numbers Bosch No 0 280 220003 0 280 130028 0 280 140 500 498892 and 498893 Color point Green B21F MPG Volvo P N 1306544 6 1306024 0 1276871 9 Engine identification numbers Bosch No 0 280 220002 0280 130028 0 280 140 500 498896 and 498897 Color point VVhite B21F Turbo Volvo P N 1276897 4 1306024 9 1276871 9 Engine identification number Bosch No 0280 220003 0280 130028 0 280 140500 498898 manual trans only Color point Green B28F California Volvo P N 1274293 8 1306024 9 1276871 9 Engine identification numbers Bosch No 0280 220001 0 280 130028 0 280 140 500 498638 and 498639 Color point Yellow 1982 models B21F Cl Volvo P N 1317499 0 1306937 2 1276871 9 Engine identification numbers Bosch No 0280220005 0280 130023 0 280 140 500 498960 and 498961 Color point Orange B21F LH Jetronic Volvo P N 1317499 0 1306937 2 1276871 9 Engine identification numbers Bosch No 0280 220005 0280 130023 0280 140500 498962 and 498963
17. al depressed Regulated flow idle Maintains steady idle speed EEE New air control valve Group 25 Intake exhaust emission systems CIS system description 130549 Electronic Control Unit Receives information from three sources Coolant temperature sensor gives input to provide higher idle rpm at low temperatures Terminal 1 on ignition coil provides information on engine speed A micro switch at the throttle provides input when the throttle control is at idle position The Electronic Control Unit is located below the Control Unit for the Lambda sond system in front of right front door Air Control Valve Bypasses air around the throttle valve A small electric motor rotates clockwise or counter clockwise depending on signal from the Electronic Control Unit The valve responds very quickly to obtain a precise air flow Left Air Control Valve for B21F 1981 Left Air Control Valve for B28F Air Control Valve for B21F Turbo is located in front under intake manifold Throttle switch The throttle actuates a micro switch which controls a circuit in the Electronic Control Unit when the throttle goes to idle position This occurs during idle and deceleration For B28F 1981 itis closed at idle for all others 1981 and 1982 interrupted at idle Group 25 Intake exhaust emission systems CIS system description Additional features introduced on 1982 models B21F CI B
18. ansmission Al Disconnect throttle control rod At lever Check cable assembly Make sure cable and pulley run smoothly and do not bind in any position 130858 A2 Remove panel in front of right front door Electronic Control Unit for Constant Idle Speed System is located below Electronic Control Unit for Lambda sond system 133310 A3 De activate Electronic Control Unit Disconnect white red wire from terminal 12 of blue connector plug at Electronic Control Unit Reinstall connector plug NOTE Same wire ends at ignition coil but cannot be disconnected there 133381 14 Group 25 Intake exhaust emission systems Basic setting B21F 1981 130861 A4 Connect tachometer Good instrument to accurately measure engine RPM Connect test lamp Connect across battery plus terminal and terminal on micro switch with yellow wire connected Start engine Should be at normal operating temperature 130862 A5 Test light OUT Test light MUST NOT illuminate at idle speed If test light illuminates adjust micro switch position Slacken micro switch retaining screws Move micro switch DOWN until test lig t goes out Tighten retaining screws This is a temporary adjustment Final adjustment will follow later on 130882 A6 Idle speed Idle speed should be 850 rpm 850 900 rpm permitted If outside these limits idle speed should be adjus
19. cates changes in text and or specifications in this manual TP 30363 2 6000 10 84 Printed in U S A 1984 VOLVO OF AMERICA CORPORATION We reserve the right to make alterations Page Q A N Group 25 Intake exhaust emission systems CIS system description Constant Idle Speed System CIS System The system is comprised of the following main The Electronic Control Unit processes information on components engine temperature engine speed and throttle position Electronic Control Unit It controls engine at idle or near idle by regulating the Air Control Valve Air Control Valve Throttle switch Coolant temperature sensor Distributor via ignition coil ELECTRONIC CONTROL UNIT THROTTLE SWITCH VhrwrortLE FT KE GROUND ia TERMINAL 1 ON OPENI nin IGNITION COIL SENSOR 130545 Air flow modes New features introduced on 1982 models As introduced in 1981 the system had three basic air Regulated flow with A C on B21F CI and B21F LH flow modes When the air conditioning is switched on a second Low flow deceleration regulated flow with increased idle speed is engaged Reduced air flow occurs when the throttle switch circuit is closed during deceleration Test point for basic idle aatting High flow driving New throttle switch B28F Increased air flow at normal driving speeds with New feature on 1983 models accelerator ped
20. e red wire at terminal 12 of blue connec tor plug at Electronic Control Unit NOTE Same wire ends at ignition coil but cannot be discon nected there B5 B21F CI 1982 De activate Electronic Control Unit Ground terminal 10 connector in place Best way is to insert a copper wire along terminal wire Connect tachometer Good instrument to accurately measure engine RPM Connect test lamp Connect across battery plus terminal and terminal on micro switch with yellow wire connected Start engine Should be at normal operating temperature 130873 20 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21F CI 1982 B7 Test light OUT Test light MUST NOT illuminate at idle speed If test light illuminates adjust micro switch position Slacken micro switch retaining screws Move micro switch DOWN until test light goes out Tighten retaining screws This is a temporary adjustment Final adjustment will follow later on B8 Idle speed Idle speed should be 700 rpm 700 750 rpm permitted If outside these limits idle speed should be adjusted See operations BI B11 Inside limits proceed to op B12 idle speed me B9 Idle speed NOT 700 rpm 700 750 rpm permitted NOTE Test light MUST NOT illuminate If necessary readjust micro switch position 21 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21
21. green or red white red or gray Idle speed Ground circuit through throttle switch C is interrupted The Electronic Control Unit A ECU controls air con trol valve H to set correct idle speed R CIS System To terminal 7 of Electronic Control Unit for ignition system and terminal 3 of LH Jetronic Control Unit ZE p rme to control test point CIS System B21F LH Jetronic Legend A ECU Electronic Control Unit B Seat belt reminder unit C Throttle switch D Ignition switch E Fuel pump relay F Fuse box G Control test point H Air control valve Coolant temperature sensor J Ignition coil K Ballast resistor General Coolant temperature sensor I con tinuously sends a signal to the ECU so it can set an idle speed that corres ponds to the coolant temperature G is designated control test point It is a connection that for convenience is used on the production line Throttle switch C has a double func tion At idle it grounds a wire con nected to the ECU for ignition system When the air conditioning is operat ing a micro switch at the AC switch energizes terminal 7 of the ECU This will increase idle speed from approx 750 rpm to 900 rpm and improve AC Operation and cooling due to faster running coolant pump and fan Above idle speed Ground circuit through throttle switch C is closed ECU H controls air control valve H to set high air flow to avoid e
22. inated B28F zero resistance test lamp illuminated Incorrect readings adjust according to instructions in this manual Check coolant temperature sensor Use ohmmeter to test coolant tempera ture sensor resistance Connnect across terminals 9 and 11 See graphs in Specifications section showing relations resistance tempera ture Group 25 Intake exhaust emission systems Fault tracing 8 Check signal from ignition system Connect tachometer across terminal 12 and ground Start engine Tachometer should show engine speed Incorrect or no reading Check connectors on firewall see first operation of these fault tracing procedures Check air control valve Prepare and connect jumper wire across terminals 4 and 1 Connect another jumper wire across terminals 5 and 2 Start engine Engine should obtain a high idle speed of 1600 2400 rpm indicating that the air control valve is in order 133366 10 Engine does NOT obtain that high idle speed indicates that the air control valve is defective No fault is found Try a new Electronic Control Unit Check operation Reconnect connectors Make sure all connections are in order Check for proper operation 133367 13 Group 25 Intake exhaust emission systems Basic setting B21F 1981 Basic setting of Constant Idle Speed System B21F 1981 Engine Identification Number EIN 498892 manual transmission 498893 automatic tr
23. minal contacts just TOUCH Otherwise terminal contacts may be permanently damaged Prepare for test Remove panel in front of right front door Disconnect both connectors at the Electronic Control Unit Switch ignition ON 133362 Black connector Check current supply Ignition ON Terminal 1 is positive energized from ignition switch Terminal 2 is negative ground Connect voltmeter alt test lamp across terminals 1and 2 in connector Voltmeter should read battery voltage test lamp illuminate fully No reading first check alternate ground then check fuse No 13 11 Group 25 Intake exhaust emission systems Fault tracing Check throttle switch micro switch Ohmmeter ignition can be OFF Connect ohmmeter test leads across terminal 8 blue connector and ground Test lamp ignition ON Connect leads to terminal 8 blue connector and terminal 1 black connector 133369 6 Throttle pedal NOT depressed idle position 1981 models B21F all infinite resistance test lamp NOT illuminated B28F zero resistance test lamp illuminated 1982 models B21F all infinite resistance test lamp NOT illuminated B28F infinite resistance test lamp NOT illuminated Throttle pedal depressed above idle position 1981 models B21F all zero resistance test lamp illuminated B28F infinite resistance test lamp NOT illuminated 1982 models B21F all zero resistance test lamp illum
24. n systems Fault tracing Air control valve connectors 4 h Air control valve B21F 1982 i Connector disconnected j Air control valve B21F LH Jetronic 1982 k Connector disconnected Group 25 Intake exhaust emission systems Fault tracing Air control valve B28F Connector disconnected If engine idle speed is considerably lower than specified Check air hoses for obstructions The air control valve can be stuck or obstructed by deposits from the Positive Crankcase Ventilation PCV system Check oil replacement intervals and engine oil quality Clean PCV system Photos show B21F Turbo Note two clamps and strip between them 133368 133428 Testing CIS system Group 25 Intake exhaust emission systems Fault tracing For the tests it is advised to use a high quality voltmeter metering range 0 to approx 15 20 volts For the resistance tests an ohmmeter with a range of 100 to 10 000 ohms is needed Most common faults are bad connections in the multipin connectors on firewall at the Electronic Control Unit and at the Coolant Temperature Sensor System voltage and currents are low In some tests below it is suggested an alternate testing method using a test lamp It uses more current than a voltmeter or ohmmeter and might in some cases reveal a bad connection better WARNING In any test DO NOT press in the test point between the ter
25. ngine stalls Group 25 Intake exhaust emission systems Wiring diagrams N NN NG CIS system blue white red OXYGEN SENSOR SYSTEM 133451 Group 25 Intake exhaust emission systems Wiring diagrams to control test point VO uhite red or gray Idle speed Ground circuit through throttle switch C is interrupted The Electronic Control Unit A ECU controls air con trol valve H to set correct idle speed CIS System B21F Turbo B21F Turbo Intercooler Fuse No 13 Instruments Turn signals Seat belt warning CIS System Legend A ECU Electronic Control Unit B Seat belt reminder unit C Throttle switch D Ignition switch E Fuel pump relay F Fuse box G Control test point H Air control valve Coolant temperature sensor J Ignition coil K Ballast resistor General Coolant temperature sensor I con tinuously sends a signal to the ECU so it can set an idle speed that corres ponds to the coolant temperature G is designated control test point It is a connection that for convenience is used on the production line Above idle speed Ground circuit through throttle switch C is closed ECU H controls air control valve H to set high air flow to avoid engine stalls 133452 Group 25 Intake exhaust emission systems Wiring diagrams ES NG a 8 a NEE EE EE SN IX NG N
26. onic Control Unit idle speed should change to 900 rpm 1981 permitted 850 950 rpm 1982 permitted 880 920 rpm Stop engine install panel etc 130885 Adjusting rg Na ee aan E12 Reconnect throttle control rod at cable pulley Disconnect throttle cable and automatic transmission kickdown cable Cable pulley should be completely retracted Adjust control rod length as necessary Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E13 Attach and adjust throttle cable 130908 E14 Automatic transmission adjust kickdown cable Check cable length at closed and open throttle engine off Open throttle measurement should be checked with throttle pedal in car depressed NOT by actuating linkage by hand Cable movement should be 50 mm 1 968 Closed throttle L 1mm Open throttle L 51mm Adjusting micro switch 130908 FEELER GAUGE THROTTLE POSITION ADJUSTMENT SCREW E15 Install feeler gauge Use feeler gauge 0 3 mm 0 12 Insert between throttle position adjustment screw and stop Illustration shows 1981 switch arrangement 1982 model switch looks slightly different 37 Group 25 Intake exhaust emission systems Basic setting B28F 1981 1982 E16 Adjust 1981 turn adjustment screw until test light goes out 1982 turn adjustment screw until test light illuminates 130
27. ted See operations A7 A9 If inside continue to A10 15 Group 25 Intake exhaust emission systems Basic setting B21F 1981 Adiusti idl EE o_o oe djusting idle spe FC Idle speed NOT 850 rpm 850 900 rpm permitted Use throttle position adjustment screw to adjust idle speed to 850 rpm 850 900 rpm permitted NOTE Test light MUST NOT illuminate If necessary readjust micro switch position Activate Electronic Control Unit Reconnect white red wire in terminal 12 of blue connector plug at Electronic Control Unit A9 Idle speed change After activating Electronic Control Unit idle speed should change to 900 rpm 850 950 rpm permitted Stop engine Group 25 Intake exhaust emission systems Basic setting B21F 1981 A10 Reconnect throttle control rod at lever Cable pulley should be completely retracted If adjustments of engine controls must be made follow operations A11 A13 below 130866 8 14 an ee Adjusting controls A11 Adjust control rod length Disconnect throttle cable and automatic transmission kickdown cable Adjust control rod length as necessary 130867 A12 Attach and adjust throttle cable Group 25 Intake exhaust emission systems Basic setting B21F 1981 CABLE LENGTH BEING PULLED OUT ADJUST ON NUT A13 Automatic transmission kickdown cable Check cable length at closed and open throttle engine off Open
28. throttle measurement should be checked with throttle pedal in car depressed NOT by actuating linkage by hand Cable should be pulled out 50 mm 1 968 Adjusting micro switch A14 er Move micro switch UP Sy Engine NOT running throttle CLOSED Slacken micro switch retaining screws Move micro switch UP until test light illuminates 130870 13087 A15 Set micro switch position Move micro switch DOWN 2 5 5 mm 0 08 0 10 Test light MUST NOT illuminate Tighten screws Remove test lamp install panel etc 18 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21F Ci 1982 Basic setting of Constant Idle Speed System B21F MPG 1981 Engine Identification Number EIN 498896 manual transmission 498897 automatic transmission B21F CI 1982 Engine Identification Number EIN 498960 manual transmission 498961 automatic transmission Disconnect throttle control rod At lever B2 Check cable assembly Make sure cable and pulley run smoothly and do not bind in any position 133386 B3 Remove panel in front of right front door Electronic Control Unit for Constant Idle Speed System is located below Electronic Control Unit for Lambda sond system 133310 19 Group 25 Intake exhaust emission systems Basic setting B21F MPG 1981 B21F CI 1982 B4 B21F MPG 1981 De activate Electronic Control Unit Disconnect whit
29. y actuating linkage by hand Cable should be pulled out 50 mm 2 Adjusting throttle switch C16 Insert feeler gauge Insert 0 3 mm 0 01 in feeler gauge between throttle ad justment screw and throttle control lever 29 Group 25 Intake exhaust emission systems Basic setting B21F Turbo 1981 1984 B21F Turbo Intercooler 1984 C17 Switch UP Move switch UP until test light illuminates 130897 C18 Setting micro switch Move micro switch DOWN until test light just goes out Remove feeler gauge instruments etc Install panel 130898 30 Group 25 Intake exhaust emission systems Basic setting B21F LH Jetronic 1982 Basic setting of Constant Idle Speed System B21F LH Jetronic 1982 Engine Identification Number EIN 498962 manual transmission 498963 automatic transmission DI Seat throttle butterfly valve Loosen stop nut on adjuster screw Unscrew adjuster screw a couple of turns Make sure throttle butterfly valve is properly seated in housing Set adjuster screw Screw in adjuster screw until it just touches lever then additional 1 4 turn Lock with lock nut D2 Disconnect connector at firewall 133376 er IT T gt Group 25 Intake exhaust emission systems Basic setting B21F LH Jetronic 1982 D4 Test on idle speed Connect test lamp across battery plus and orange wire terminal in connector Start engine
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