Haynes Porsche 914 Owners Workshop Manual [239] 0856962392, 9780856962394

Citation preview

PORSCHE it

4- cylinder

1969 thru 1976 d 102.5 cu in (1679 cc) 110 cu in (1795 cc) □ 120 cu in (1971 cc)

Automotive Repair IVianuai

Digitized by tine Internet Arcliive in 2012

http://archive.org/details/porsclie9144cylin00jhha

Porsche 914 Automotive Repair IVIanual by J H Haynes Member of the Guild of Motoring Writers

and Peter Ward Models covered:

Porsche 914 1.7 Litre Porsche 914 1.8 Litre Porsche 914 2 Litre Does not cover 6-cy Under version of the Porsche 914 (914/6)

ISBN 0 85696 239 2 (g) Haynes Publishing Group 1989 All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. Printed in England (10R3-239)

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Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgements Special thanks are due to the Porsche organisation for their assistance in supplying general information and certain illustrations, and to Mr Ian Dunham in particular for technical information. The Section dealing with radio interference suppression in Chapter 9 was originated by Mr I. P. Davey, and was first published in Motor magazine. Many of the photographs used in the bodywork repair Section of

Chapter 10, were supplied by Car Mechanics magazine. Castrol Limited provided information on lubrication. Lastly, thanks are extended to all of those people at Sparkford who helped in the production of this manual. Particularly, Brian Horsfall who carried out the mechanical work, Les Brazier who took the photographs, and Ted Frenchum

who planned the layout of each

page.

Introduction to the Porsche 914

It uses the well tried VW air-cooled flat-four engine originally used on the Type 4 models but it is mounted ahead of a five-speed transmission unit. Whilst this gives some problems from the accessibility

liter (1795 cc) version for 1974. A Bosch manifold pressure controlled (MPC) fuel Injection system was used for all 1.7 liter models but the 1.8 liter version used a new airflow controlled (AFC) fuel injection system for USA markets and twin downdraft carburetors for other markets. The 9148 2.0 liter (1971 cc) model Introduced in 1973 has always used the MPC injection system. The integral body/frame carries single wishbone front suspension

polnt-of-view, it provides for exceptional road-holding and manoeuvrability due to the excellent weight distribution. (Some

with torsion bars and shock absorber struts at the front, and semitrailing arms and spring/shock absorber struts at the rear. Steering is by

models, not covered by this manual, were designated 914-6 as they are fitted with a 6-cy Under Porsche engine). The car is a comfortable, roomy and well equipp)ed two-seater providing good, if not outstanding, performance. The original version used a 1.7 liter (1679 cc) engine, which was replaced by a similar 1.8

means of a rack-and-pinion steering gear thru tie-rods and balljolnts to the front hub steering knuckles. Dual circuit disc brakes are used on all four wheels, with the F>arking brake op>erating thru a cable and linkage to the rear brake pads.

The Porsche 914, more correctly called the VW-Porsche 914 although the manufacturers ceased to use the VW prefix for USA models after 1972, is a mid-engined sports car with some unusual characteristics.

About

this manual

The aim of this book is to help you get the best value from your car. It can do so in two ways. First it can help you decide what work must be done, even should you choose to get it done by a garage, and secondly the routine maintenance and the diagnosis and course of action when random faults occur. But it is hofjed that you will also use the second and fuller purpose by tackling the work yourself. On the simpler jobs, it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, much money can be saved by avoiding the costs a garage must charge to cover their labor and overheads. The book has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step by step sequence so that even a novice can cop)e with complicated work. Such a pjerson is the very one to buy a car needing repair yet be unable to afford garage costs. The jobs are described assuming only normal tools are possible. Many special workshop tools produced by the makers merely speed the work, and in thesp cases guidance is given as to how to do the job without them, the oft quoted example being the use of a large hose clip to compress the piston rings for insertion in the cylinder. But on a very few occasions the special tool is essential to prevent damage to components; then their use is described. Though It might be possible to borrow the tool, such work may have to be entrusted to the official agent. To avoid labour costs a garage will often give a cheaper repair by

fitting a reconditioned assembly. The home mechanic can be helped by this book to diagnose the fault and make a repair using only a minor spare part. The manufacturer's official workshop manuals are written for their trained staff, and so assume special knowledge; detail is left out. This book is written for the owner, and so goes into detail. The book is divided into ten Chapters. Each Chapter is divided into numbered sections which are headed in bold typje between horizontal lines. Each section consists of serially numbered paragraphs. There are two tyfjes of illustration: (1) Figures which are numbered according to Chapter and sequence of occurrence in that Chapter. (2) Photographs which have a reference number on their caption. All photographs apply to the Chapter in which they occur so that the reference figure pinpoints the [jertinent section and paragraph number. Procedures, once described in the text, are not normally repeated. If it is necessary to refer to another Chapter, the reference will be When given. forward.

the left or right side of the car Is mentioned. It Is as if looking

Great effort has been made to ensure that this book is complete and up to date. The manufacturers continually modify their cars, even in retrospect. Whilst manual is publishers omissions

every care Is taken to ensure that the information in this correct no liability can be accepted by the authors or for loss, damage or injury caused by any errors in or from the Information given.

Contents

Page

Acknowledgements

2

Introduction to the Porsche 914

2

About this manual

2

Buying spare parts and vehicle identification numbers

5

Routine maintenance

6

Towing, jacking-up and wheel changing

8

Recommended

lubricants and fluids

109

Chapter 1 Engine, cooling and exhaust system Chapter 2 Fuel system

38

Chapter 3 Ignition system

62 68

Chapter 4 Clutch Chapter 5 Transmission

74

Chapter 6 Rear suspension and driveshafts

92

Chapter 7 Front suspension and steering

98 108

Chapter 8 Braking system, wheels and tires 119 Chapter 9 Electrical system Chapter 10 Bodywork Conversion factors

and underframe

186 210

Safety first 1 211 Use of English

212

Index

213

1971 Porsche 914 (European Specification)

1973 Porsche 914 (North American

Specification)

Buying spare parts and vehicle identification numbers Buying spare parts Spare parts are available from many sources, for example; Porsche garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows: Officially appointed Porsche garages - This is the best source of parts which are peculiar to your vehicle and are otherwise not generally available (eg; complete cylinder heads, internal transmission components, badges, interior trim etc). It is also the only place at which you should buy parts if your car is still under warranty. To be sure of obtaining the correct parts it will always be necessary to give the storeman your car's engine and chassis number, and if possible, to take the 'old' part along for positive identification. Remember that many parts are available on a factory exchange scheme - any parts returned should always be clean! It obviously makes good sense to go straight to the specialists on your car for this type of part for they are best equipf)ed to supply you. Other garages and accessory shops ■ These are often very good places to buy materials and components needed for the maintenance of your car (eg; oil filters, spark plugs, bulbs, fan belts, oils and greases, touch-up paint, filler paste etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors ■ Good

factors will stock all of the more important

Identification plate (white arrow) and chassis serial number (black arrow)

1.8 liter engine number

2 .0 liter engine number

components which wear out relatively quickly (eg; clutch components, pistons, valves, exhaust system, brake cylinders/plpes/hoses/seals/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

Vehicle identification numbers When ordering spares, give the model identification, chassis and engine numbers to the storeman and take the vehicle, or the old part with you, whenever possible. The location of the various numbers is given below. Identification plate: This is in the front luggage compartment on the casing of the right headlamp. Chassis number: This is in the front luggage compartment on the top of the right wheel well. Engine number: For 1.7 and 1.8 liter models this will be found on the right crankcase behind the air filter. For 2.0 liter models It is on the rear upper part of the crankcase between the oil filler tube and the blower housing. Paint number: On later models this will be found on plate attached to the left door post.

1.7 liter engine number

Paint number

Routine maintenance In order to obtain the best of performance and reliability, it is essential tfiat a programme of routine maintenance is carried out. A maintenance summary is given below, and is based on the car

and the cooling fan drive belt (Chapter 1, Section 26). 3 Clean and adjust the contact breaker points. 4 Clean the spark plugs.

manufacturer's recommendations. In certain instances this is supplemented with additonal items which the author considers desirable. Where reference is made to items which are not on your particular vehicle, they should be ignored.

5 6 7

Every 300 miles (480 km) travelled, or weekly - whichever comes first

Every 12,000 miles (19,300 km) travelled or 12 months comes first

1 Check the engine oil level and top-up if necessary. 2 Check the battery electrolyte level and top>-up with distilled water if necessary. 3

Check the windshield washer fluid level and top-up if necessary.

4 Check the tire pressures (when cold). Don't forget the spare tire which supplies pressure for the windshield washers. 5 Examire the tires for wear, damage and stone chips in the tread. 6 Check the brake system reservoir fluid level and top-up if necessary. If a sudden drop in fluid level has occurred, examine the system for leaks (photo). 7 Check the brake operating during a test run. 8 Check the operation of all lights, instrument, warning devices, accessories, controls etc.

nozzles, and top-up the reservoir.

Note: This service should normally be carried out by your Porsche dealer. 1 Adjust the valve clearances wfien the engine is cold; renew the valve cover gasket if necessary. 2 Check the free play of the front wheel bearings and adjust if necessary. 3 Check the clutch play and pedal travel; adjust if necessary. 4 Change the engine oil; clean the magnetic drain plug and oil strainer. 5 6

Renew the engine oil filter. Check the engine and transmission for oil leaks.

7

Change the transmission oil and clean the magnetic drain plugs.

Every 3000 miles (4800 km) travelled or 3 months first 1 2 3

- whichever comes

Change the engine oil and clean the magnetic drain plug. Renew the engine oil filter. Check the engine and transmission for oil leaks.

Every 6000 miles (9700 km) travelled or 6 months first

- whichever

1 Run the engine until it is hot, then remove the spark plugs and connect a proprietary compression pressure gauge to each cylinder in turn. Crank the engine on the starter with the throttle wide open, and check the cylinder compression pressures. Refer to Chapter 1 Specifications for the pressure limits. 2 Clean or replace the fuel pump filter. 3 Replace the spark plugs. 4 Replace the contact breaker points. 5 Lubricate the distributor, applying a trace of general purpose grease to the distributor cam and a drop of engine oil to the contact breaker pivot and lubrication pad beneath the rotor. 6 Apply a few drops of engine oil to the pivot and linkage points of the throttle mechanism. 7

After the first 600 miles (970 km) travelled

Check the dwell angle and ignition timing; adjust as necessary. Check the engine idle speed and adjust as necessary. Check the adjustment of the windshield and headlight washer spray

Apply a few drops of engine oil to the door and bonnet hinges,

pivots, etc. 8 Renew the air filter cartridge, or clean the oil bath air cleaner and relubricate. This interval may be extended to 18,000 miles (29,000 km) on 1.7 and 1.8 liter engines if operating experience shows little accumulation of dirt, etc. 9 Check crankcase ventilation hoses for condition and security of fitment; renew as necessary. 10 Check the fuel system pip>es for condition and security of fitment; renew as necessary. 1 1 Check the brake pads for wear and renew as necessary. 12 Check/adjust the free play of the brake master cylinder pushrod. 13 Inspect all brake lines for damage and corrosion; renew parts as necessary. 14 Inspect the brake system for leakage; renew parts as necessary. 15 Examine the steering for oil leakage and play in the steering gear and linkage. 16 Check the clutch play and pedal travel; adjust if necessary. 17 Lubricate the clutch cable and roller with a general purpose grease. 18 Arrange for your Porsche dealer to check the headlamp beam aim. 19 Change the transmission oil and clean the magnetic drain plugs. 20 Check the condition of the door, hood and top rubber seals; renew as necessary. 21 Check the operation of the heating/ventilating system.

• whichever comes

1 Adjust the valve clearances when the engine is cold; renew the valve cover gasket if necessary. 2 Check the tension of the air pump drive belt (Chapter 2, Section 31).

first Every 24,000 miles (39,000 km) travelled or 2 years - whichever comes

1 Renew the fluid in the braking system and replace all the rubber parts. Refer to Chapter 8 for further information.

i

Engine oil dipstick nnarkings

max Brake fluid reservoir at rear of front compartment

mm

Dipstick and oil filler locations

Removing wrench

an oil filter using a special tubular

Transmission plug

Engine oil drain plug (A) and strainer retaining bolt (B)

filler/level plug (A), and drain

Distributor lubrication 1 Contact breaker pivot 2

Lubrication pad (beneath the rotor)

lowing, jacking-up and wheel changing Towing A towing eye is attached to the underfloor at the front of the car. At the rear there is a socket which can be used to install the towing eye which is supplied with the car tool kit.

Front and rear towing eyes

Jacking-up and wheel changing The jack is stowed in the rear luggage compartnnent, fastened to the forward panel by two quick-action locks. When changing a wheel, pry off the hub cap, or plastic wheel bolt covers (as applicable) and loosen the bolts by about one turn with the car standing on the ground. Insert the jack into the jack location in the rocker (sill) panel and raise the car. The wheel can now be removed and the replacement installed, tightening the bolts in a crosswise order.

Lower the car to the ground and finally tighten the bolts, then install the hub cap or wheel bolt covers. When carrying out maintenance and repair operations, the use of the car jack is not recommended. In these instances, jacks or supports should be used beneath the front axle (auxiliary support), rear radius arms or the underfloor members, using a suitable wood block on the jack head.

Typical jack and stowage point (1972 model shown)

Removing

a hub cap

Prying off a plastic wheel bolt cover

Using the jack (1975 model illustrated) the arrows show the direction of movement

r

Recommended

lubricants and fluids

Components

Gradfl

Castrol Product

Engine (1)

SAE 10 below -15°C (+5°F) SAE 20 from -15°C to 0°C (+5°F to +32° F)

Castrol CRI10 Castrol CRI 20

SAE 30 above 0°C (32*'F)

Castrol CRI 30

Transmission and differential (2)

SAE 90 hypoid oil

Castrol Hypoy B

Hubs (3)

General purpose lithium based grease

Castrol LM Grease

Constant velocity joints (4)

Molybdenum disulphide general purpose lithium based grease

Castrol MS3 Grease

Oil bath air cleaner, locks, hinges etc.

As engine

As engine

Brake fluid (5)

SAE J 1703a

Castrol Fluid Girling Universal Brake and Clutch

Chapter 1

Engine, cooling and exhaust system

Contents

16 7 25 18

Cooling system and cover plates Cooling systenn, fan and alternator - reassembly Cooling system - inspection Crankcase and contents - reassembly ... Crankcase, crankshaft and camshaft - inspection Cylinder heads - dismantling and decarbonisation ... Cylinders, pistons and rings - inspection Engine (and transmission) - removal and installation Engine dismantling - cooling systems, cylinder heads, cylinders and pistons, and lubricating systems ...

12 10 13 5

Engine dismantling - splitting the crankcase, removing the camshaft, and dismantling the crankshaft and connecting rods

27 11 17 8

Engine reassembly - final stages before installation ... Engine reassembly - general Engine - removal and installation of transmission and clutch

3 26 19 28 15 1 6

Exhaust system - removal and installation Fan and alternator drive belt - adjustment Fault diagnosis - engine General description Lubrication system - general description Lubrication system - inspection Oil cooler and filter - reassembly Oil seals, fan hub and flywheel - reassembly ... Pistons, cylinders and cylinder heads - reassembly Pushrods and rocker gear - reassembly The need for engine removal

...

Thermostat - removal, testing and adjustment (engine in the car) Valve clearance - adjustment

22 24 2 21 204 23

Valve gear and cylinder heads - inspection Valves and valve springs - reassembly to cylinder head

14 Specifications- Porsche 914

Engine • general Type

Horizontally opposed, 4 cylinder, air cooled, pushrod overhead valve

Weight (approx)

300 lbs (140 kg)

Bore Stroke (Capacity Code letter Compression Compression

ratio pressure (normal)

(minimum permissible) Maximum difference betvween cylinders Horsepower (DIN) at rpm

1.7 liter

1.8 liter

3.543 in (90 mm) 2.598 in (66 mm) 1679 cc

3.661 in (93 mm) 2.598 in (66 mm) 1 795 cc

W, EA, or EB W, EA, 8.2 : 1 ; EB

7.3 : 1

128 to 156lbf/in2 (9 to 11 kg f/cm 2) lOOIbf/in^ (7 kgf/cm2) 21 Ibf/in2(1.5kgf/cm2) W, EA, 80 at 4900 EB, 72 at 5000

Firing order (all engines) Lubricant capacity (all engines) Lubricant type

EC or AN EC, 7.3 : 1; AN, 8.6 : 1 128 to 156lbf/in2 (9 to 1 1 kq f/cm2) lOOIbf/in"^ (7 kg f/cm^) 21 lb f/in2 (i .5 kg f/cm^)

EC, 76 at 4800 AN, 85 at 5000

2.0 liter 3.70 in (94 mm) 2.79 in (71 mm) 1971 cc GAor GB GA, 7.6 : 1,GB,8.0

120to156lbf/in2 (8.4 to 1 1 kg f/cm2) 93 lb f/in2 (6.5 kg f/cm^) 21 lb f/in2 (1 .5 kg f/cm^)

GA, 95 at 4900 GB, 100 at 4500

1, 4, 3, 2 - also see Chapter 3 Specifications 7.4 US pint/6.1 Imp. pint/3.5 liters (approx) See Recommended Lubricants list

Cooling system Type Delivery volume Thermostat opening temperature

Radial fan on crankshaft 28.5 cu ft (800 liters) per second at 4600 rpm 65-70OC

(150- I6OOF)

Lubrication system Type Filter Capacity (approx): With filter change Without filter change Oil required to fill from the lower to upper marks of the dipstick Oil pressure Oil pressure ... ... ... ... ... ... ,.. Oil warning light comes on between ...

:1

Wet sump - pressure and splash Full flow - replaceable cartridge 3.5 liters/6.1 pints Imp/7.4 pints US 3.0 liters/5.25 pints Imp/6.3 pints US 1 liter/1.75 pints Imp/2.1 pints US SAE 30, 70OC at 2500 rpm/42 psi SAE 30, 70°C at minimum/28 psi 2 - 6 lb f/in2 (0.15 to 0.45 kg f/cm^)

11 Chapter 1 /Engine, coding and exhaust system Oil Oil Oil Oil Oil Oil

cooler pump pump gear/body end clearance pump gear/backlash pressure relief valve spring load pressure regulating valve spring load

Pressurized, multi tube, air cooled Twin gear Nil Nil 24.5 lb f at 0.921 in (1 1.1 kg f at 23.4 mm) 9.59 lb f at 0.661 in (4.35 kg f at 16.8 mm)

Crankshaft and main bearings No. of bearings ... Journal diameters: Nos. 1,2, 3 No. 4 Undersize main bearing shells Bearing shells type: Nos. 1,3, 4 No. 2 Bearing clearances: Nos. 1,3 No. 2 No. 4 Crankshaft endfloat limits Journals, maximum ovality Crankpin diameter: 1.7, 1.8 liter 2.0 liter

...

2.3609 - 2.3617 in (59.97 - 59.99 mm) 1 .5739 - 1 .5748 in (39.98 - 40.00 mm) 0.25, 0.50, 0.75 mm Aluminium, lead coated Split, 3 layer steel backed 0.0016 0.001 1 0.0019 0.0027 0.0011

- 0.007 in (0.04 - 0.18 mm) - 0.0066 in (0.03 - 0.1 7 mm) - 0.0074 in (0.05 - 0.19 mm) - 0.0051 in (0.07 - 0.15 mm) in (0.03 mm)

2.1646 - 2.1654 in (54.98 - 55.00 mm) 1 .9677 - 1 .9681 in (49.98 - 49.99 mm)

Crankcase Main bearing bore diameters: Nos. 1,2, 3 No. 4 Oil seal bore diameter (flywheel end) Oil seal bore diameter (fan pulley end) Camshaft bearing bore diameter Oil pump housing bore diameter Tappet (cam follower) bore diameter

2.7570 1 .9685 3.7401 2.4410 1 .0825 2.7560 0.9448

in (70.00 - 70.03 mm) - 1 .970 in (50.00 - 50.04 mm) - 3.742 in (95.00 - 95.05 mm) - 2.4429 in (62.00 - 62.05 mm) ■ 1 .0834 in (27.5 ■ 27.52 mm) - 2.7570 in (70.00 - 70.03 mm) - 0.9467 in (24.00 - 24.05 mm)

Camshaft and bearings

Camshaft drive Bearings Journal diameters Bearing radial clearance Endfloat Gear backlash

Light alloy gear from crankshaft White metal steel backed shells 0.9837 - 0.9842 in (24.99 - 25.00 mm) 0.0008 - 0.0047 in (0.02 - 0.1 2 mm) 0.0016 - 0.0063 in (0.04 - 0.16 mm) 0 - 0.0019 in (0 - 0.05 mm)

Connecting rods and bearings Type Big-end bearings Small end bush Undersize big-end shells Big-end radial clearance limits ... Crankpin endfloat limits Piston pin/bush clearance Connecting rod weight (1.7, 1.8 liter): White Black Maximum weight difference between connecting rods Crankpin, maximum ovality

Forged steel 3 layer thin vsrall shells Steel bush, lead-bronze coated 0.25,0.50,0.75 mm 0.0008 - 0.006 in (0.02 - 0.15 mm) 0.004 - 0.0276 in (0.1 - 0.2 mm) 0.0008 - 0.0016 in (0.02 - 0.04 mm) 746 - 752 grams 769 - 775 grams 0.0011 6 grams in (0.03 mm)

Cylinders Type Oversizes Distance between centers

Single barrel, finned, cast iron 0.020 in, 0.040 in (0.5, 1 .0 mm) 4.9 in (124.5 mm)

Cylinder heads Type Depth of cylinder seating

Aluminium alloy, 1 per pair of cylinders 0.21 2 - 0.255 in (5.4 - 6.5 mm)

Pistons and rings Type Cylinder clearance limits; 1.7, 1.8 liter 2.0 liter

Light alloy with steel inserts; domed crowns for fuel injection, flat crowns for carburetors 0.001 5 - 0.008 in (0.04 - 0.20 mm) 0.0008 - 0.008 in (0.02 - 0.20 mm)

12

Chapter 1 /Engine, cooling and exhaust system

Ring/groove clearance: 1.7, 1.8 liter: Top compression Lower compression Oil control 2.0 liter: Top compression Lower compression Oil control Ring gap width: 1.7, 1.8 liter: Top compression Lov\«r compression Oil control 2.0 liter: Top compression Lower compression Oil control Piston oversizes Maximum weight difference between pistons Piston pin Piston pin diameter

0.0024 - 0.0048 in (0.06 - 0.1 2 mm) 0.0016 - 0.0039 in (0.04 - 0.10 mm) 0.0008 - 0.0039 in (0.02 - 0.10 mm) 0.0016 -0.0048 in (0.04 - 0.12 mm) 0.0016 - 0.0039 in (0.04 - 0.10 mm) 0.0008 - 0.0039 in (0.02 - 0.10 mm) 0.0138 - 0.0216 in (0.35 - 0.90 mm) 0.01 18 - 0.0354 in (0.30 - 0.90 mm) 0.0098 - 0.0374 in (0.25 - 0.95 mm) 0.0138 - 0.0216 in (0.35 - 0.90 mm) 0.0138 - 0.0216 in (0.35 - 0.90 mm) 0.0098 - 0.0374 in (0.25 - 0.95 mm) 0.05 mm, 1.0 mm 10 grams Fully floating, secured by snap-rings 0.9477 - 0.9449 in (23.996 - 24.00 mm)

Tappets (cam followers) Type Diameter

Cylindrical, flat based 0.9433 - 0.9440 in (23.96 - 23.98 mm)

Pushrods and valve rockers Pushrodtype Rocker shaft diameter

...

Hollow cylindrical with hemispherical ends 0.7854 - 0.7862 in (19.95 - 19.97 mm)

Valves, valve seats and timing Inlet: Head diameter,

1.7 liter 1.8 liter 2.0 liter

Stem diameter Seat width Seat angle: 1.7, 1.8 liter 2.0 liter Guide bore diameter Maximum rock in guide Exhaust: Head diameter, 1 .7 liter 1.8 liter 2.0 liter Stem diameter ... Seat width Seat angle Guide bore diameter Maximum rock in guide Seat width correction angle: Inlet Exhaust Valve springs: Loaded length Load Valve clearances: Inlet (cold) 1.7 liter Exhaust (cold) 1.8, 2.0 I iter Valve timing: Intake opens Intake closes Exhaust ofjens Exhaust closes

1.540 in (39.0 mm) 1.613 in (41.0 mm) 1.654 in (42.0 mm) 0.3125 - 0.3109 in (7.94 - 7.9 mm) 0.07 -0.086 in (1.8 -2.2 mm)

0.3149 - 0.31 73 in (8.00 - 8.06 mm) 0.035 in (0.9 mm) 33.0 mm 34.0 mm 36.0 mm 0.3507 453°0-° 0.3491 in (8.91 ■ 8.87 mm) 0.08 - 0.98 in (2.0 - 2.5 mm) 0.3543 - 0.3567 in (9.00 - 9.06 mm) 0.035 in (0.9 mm)

1.18 4in 5° (3.0 mm) 1761b (80 kg) 0.006 0.006 0.008

in (0.15 mm) in (0.15 mm) 1in5°(0.20 mm)

120BTDC 75° 42° ABDC 43° BBDC 40 ATDC

Torque wrench settings

14.5 ft Ibf

2.0

Transmission support nuts Engine support nuts (body) Nuts securing engine to transmission Nut for small V-belt pulley Cooling blov

^ \■

/

Seating ring between

2 3

cylinder and cylinder tiead Cylinder Sealing ring between

4

cylinder Locking and ring crankcase

5 6 7

Piston pin Piston Piston ring {top)

8 9

Piston ring (bottom) Oil scraper ring

29

Chapter 1 /Engine, cooling and exhaust system into a bucket of water. The valve is sodium filled which provides additional cooling at high temperatures as it melts due to heat being transfered away from the valve head by the liquid sodium moving around. There will be a reaction, so do not stand too near. The valve may now be thrown in the scrap box. 8 During any major engine repair it is preferable to renew the valve springs. However, spring rates and loads are given in the Specifications and if equipment is available for checking them, those which are satisfactory may be used again.

803), may be required to pull the cover off. When this Is done the only inspection is a visual one of the housing and cover for scoring, particularly where the gears may rub on the housing and cover. If there is any scoring a new pump is required, (photo) 4 The two pressure valves must be inspected. The relief valve Is situated alongside the oil filter, and is removed by undoing the relief valve plug. Under this there is a sealing ring, a spring and the valve. The valve must not be ridged or worn; the spring rate is given in the Specifications but if there Is any doubt it is preferable to fit a replacement, (photo) 5 The regulating valve is found on the right-hand side of the block just under the oil breather. There is a similar arrangement to the relief valve; check or replace the spring. 6 Be careful not to get these springs and valves mixed up. If the valve is stuck do not tiy to pry it out, you will damage the bore. Screw a 3/8 in tap into the plunger and remove it that way. Be careful not to scratch the bores with the spring and do not use sealant on the thread of the plug or it will not come out next time. 7 The oil strainer should be checked for cleanliness and to see that the

15 Lubrication system - inspection 1 All oilways and passages should be checked carefully for blockages. An engine with a blocked oilway in the crankcase is a disheartening, expensive sight - it does happen, so check that rag, grease and sludge are absent from oilways. 2 If the oil cooler is functioning satisfactorily when the engine is dismantled, leave it alone; if it isn't, replace it with a new one. The old cooler can be tested by the agent on a special rig to a pressure of

delivery pipe joint is intact. 8 Always install a new oil filter when overhauling an engine. 9 1972 models onwards have a baffle plate in the crankcase, attached

85 lb f/sq. in (6 kg f/cm 2). it is unlikely that a suspect cooler will stand up to this. If there has been a bearing failure and the bearing has broken up, then it is essential to fit a new oil cooler as the oil cooler may harbour metal particles which will start the process all over again. 3 The oil pump is not easy to dismantle. An extractor (tool no. VW

to the oil pick-up tube, to ensure that the pick-up tube is always immersed. This can be added to engines from W 0 074 387 onwards; use a silicone adhesive around the contoured gasket when installing it.

-x^

Fig. 1.24. Lubrication system -component parts

1 8 41

42

44

39

19

7

6

5

4

3

27

2

26

25

18

24

11 17

«f J?/i 'x

•-^i^redal as necessary; tighten the locknut on completion.

6

Pedal controls - removal, dismantling, reassembly and installation

1

Remove

the floorboard from around the pedal assembly (photos).

2 Jack-up the front of the car and remove the cover plate for the steering and brake master cylinder. 3 Pull the accelerator pedal towards the rear to remove it. 4 Detach the ball socket from the ball, then disconnect the throttle cable and pull it out towards the rear. 5 Detach the clutch cable at the clevis (refer to the previous Section, if necessary). 6 Detach the mounting bracket (two nuts and spring washers: two nuts, spring and flat washers). 7 To dismantle the pedal controls, remove the cotter pin, washer, bushes and guide lever. 8 Remove the brake light switch (2 screws and washers). 9 Detach the return spring from the clutch pedal shaft. 10 Press out the pin and detach the clutch pedal lever. 1 1 Remove the nut and washer, and remove the bearing tube from the bracket. Remove the brake pedal and return spring. 12 Examine the parts for wear and deterioration, particularly the plastic bushes. 13 Assembly is the reverse of the removal procedure, all pivoting parts being lubricated with a little general purpose grease. Where necessary, adjust the clutch pedal (see previous Section), brake pedal (See Chapter 8), brake light switch (see Chapter 9) and throttle cable (See Chapter 2).

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Fig. 4.8. Removing

Fig. 4.7. Clutch pilot bearing installation depth

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the cable from the clutch withdrawal

6.1a One of the floorboard retaining screws

lever

Fig. 4.9. Installing the pedal end of the cable to obtain 0.4 in (10 mm) protrusion of the cable end

6.1b Removing the floorboard - Note the angle as it is difficult to manoeuvre out.

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