Equipment table

As from model 89 Engine type M 44 11/12 (2.7 I)

Electric fuel pump

Fuel filter

Fuel pressure damper

Fuel pressure regulator

944.608.102.06 Bosch No. 0580.464.042

928.110.253.00 Purolator No. 506.883.901.5

944.110.201.04 Bosch No. 0280.161.036

944.110.198.06 Bosch No. 0280.160.287

Air flow sensor

temperature sensor II

Throttle valve switch

Idle speed controller

944.606.121.01 Bosch No. 0280.202.064

944.606.125.00 Bosch No. 0280.130.026

944.606.113.01 Bosch No. 0280.120.308

930.606.161.00 Bosch No. 0280.140.501

Electric injection valve DME control unit

944.606.114.00 Bosch No. 0280.150.824

944.618.121.06 Bosch No. 0261.200.089

Equipment table

Printed in Germany - XVII, 1988

CHECKING TIGHTNESS OF EXHAUST SYSTEM FLANGES

1. Check tightness of hexagon nuts on exhaust manifold/cylinder head.

2. Check tightness of hexagon nuts on exhaust manifold/primary muffler flange.

3. Check tightness of hexagon nuts on primary muffler/final muffler flange.

Tightening torque for M 8 bolts and nuts: 20 + 2 Nm (2.0 + 0.2 kpm).

Checking Tightness of Exhaust System Flanges

REPLACING EXHAUST PIPE OR PRIMARY MUFFLER / CATALYTIC CONVERTER

No.

Description

Qty.

Removing

Note When: Installing

Special Instructions

1

Exhaust pipe

1

2

Sleeve

1

3

Primary muffler

1

26 - 2 Replacing Exhaust Pipe or Primary Muffler /

Catalytic Converter

REPLACING EXHAUST PIPE OR PRIMARY MUFFLER / CATALYTIC CONVERTER

1. Remove complete primary muffler or catalytic converter.

Mark cutting point and saw off exhaust pipe (cutting plane perpendicular to pipe axis, dimensions in mm).

2. Mount new parts on car, using old gaskets and nuts at first.

4. Remove exhaust assembly and weld sleeve all around.

3. Align exhaust assembly with connecting sleeve to be without stress and tack weld sleeve at several points to keep the parts in installed position.

5. Use new gaskets and mounting nuts for final installation.

Printed in Germany - III, 1983 Replacing Exhaust Pipe or Primary Muffler/ 26 - 3

Catalytic Converter

AUTOMATIC CRUISE CONTROL (TEMPOSTAT)

Automatic Cruise Control (Tempostat) 27 - 1

AUTOMATIC CRUISE CONTROL (TEMPOSTAT)

27 28 29 23 30

27 - 2 Automatic Cruise Control (Tempostat)

No.

Description

Qty.

Installing

Special Instructions

M 6 x 25

2

2

Washer

4

3

Spacer

3

4

Rubber grommet

3

5

Nut M 6

2

6

Cable

1

7

Plug holder

1

8

Plug

1

M 6 x 10

4

10

Drive holder

1

11

Drive holder

1

12

Drive

1

13

Screw

2

14

Washer

2

15

Plug

1

16

Control unit

1

17

Switch

1

18

Lock washer

5

Printed in Germany - 111,1983

Automatic Cruise Control (Tempostat) 27 - 3

No.

Description

Qty.

Installing

Special Instructions

19

Washer

4

20

Roller

1

21

Sleeve

2

22

Operating lever

1

23

Pull spring

1

24

Sleeve

2

25

Accelerator lever

1

26

Accelerator pedal

1

27

Nut

2

28

Clutch switch

1

29

Plug

1

30

Rubber stop

1

Automatic Cruise Control (Tempostat)

Printed in Germany

REMOVING AND INSTALLING CONTROL

1. Turn off ignition.

2. Unscrew trim panel in footwell on driver's side.

3. Unscrew control unit mounting bolts.

FOR CRUISE CONTROL

4. Pull off multiple pin plug after pulling out control unit slightly.

5. Remove control unit.

Removing and Installing Control Unit 27 - 5 for Cruise Control

REMOVING AND INSTALLING CRUISE CONTROL SWITCH (STEERING COLUMN SWITCH)

1. Disconnect battery. 4. Unscrew steering column switch and take off casing.

3. Unscrew casing mounting screws.

5. Pull off multiple pin plug on steering column switch.

Pull out four-pin plug of control switch from underneath the instrument panel and disconnect.

27 - 6 Removing and Installing Cruise Control Switch

(Steering Column Switch)

REMOVING AND INSTALLING CONTROL UNIT FOR CRUISE CONTROL

1. Turn off ignition.

2. Unscrew trim panel in footwell on driver's side.

3. Unscrew control unit mounting bolts.

4. Pull off multiple pin plug after pulling out control unit slightly.

5. Remove control unit.

Removing and Installing Control Unit 27 - 5 for Cruise Control

REMOVING AND INSTALLING CRUISE CONTROL SWITCH (STEERING COLUMN SWITCH)

1. Disconnect battery.

2. Pull off cover by hand.

5. Pull off multiple pin plug on steering column switch.

Pull out four-pin plug of control switch from underneath the instrument panel and disconnect.

4. Unscrew steering column switch and take off casing.

5. Pull off multiple pin plug on steering column switch.

Pull out four-pin plug of control switch from underneath the instrument panel and disconnect.

27 - 6 Removing and Installing Cruise Control Switch

(Steering Column Switch)

6. Cruise control switch and turn signal switch make up a single unit. Two retaining tabs must be disengaged and the switches pulled apart, in order to separate the turn signal switch and wiper switch.

3. Press off cable on ball head of operating lever.

4. Unscrew lock nut on cable adjusting screw completely and disconnect cable.

REMOVING AND INSTALLING DRIVE

1. Turn off ignition.

2. Open holder for multiple pin plug and disconnect plug.

5. Unscrew mount on body and holder on drive.

Printed in Germany - III, 1983 Removing and Installing Cruise Control Switch 27 - 7

(Steering Column Switch) Removing and Installing Drive

REMOVING AND INSTALLING CRUISE CONTROL CABLE

1. Press off cable on ball head of operating lever.

2. Unscrew lock nut on cable adjusting screw completely and disconnect cable.

3. Press off cable on control lever above accelerator pedal.

Cable mount has no additional lock.

4. Press rubber grommet out of compartment wall and pull out together with the cable.

Adjusting

2. Unscrew lock nut and remove switch.

Requirements:

Adjusting

Accelerator pedal cable and, if car has automatic transmission, control cable must be adjusted as specified.

Adjust clutch switch that distance between end of threads and clutch pedal in neutral position is 4 mm.

Adjust cruise control cable that control lever with roller rests on accelerator lever above the accelerator pedal without stress. Operate lever on drive by hand. The operated throttle must return to idle position afterwards, since otherwise coasting shutoff would malfunction among others.

REMOVING AND INSTALLING CLUTCH SWITCH

Note:

Cars with automatic transmission do not have this switch.

1. Pull off two-pin plug on clutch switch.

Points are closed in neutral position.

Printed in Germany - III, 1983 Removing and Installing Cruise Control Cable 27 - 9

Removing and Installing Clutch Switch

TROUBLESHOOTING CRUISE CONTROL

First check the following points if automatic If a defect is not found while checking these cruise control malfunctions. points, troubleshooting must be continued on the control unit multiple pin plug and drive.

1. Check cable for damage and correct adjustment.

2. Check fuse no. 8 on central electric board (stop light uses same fuse).

3. Check function of stop lights.

Terminal 8 of control unit for cruise control will have ground potential from the stop light bulb filament when brake pedal is not operated.

Should both stop light bulbs de defective simultaneously, the control unit cannot function because the connection with car ground is interrupted.

4. Check function of clutch switch.

Switch must be closed in neutral position (ground switched to control unit terminal 14).

See "Removing and Installing Clutch Switch" for adjustments.

27-10

Troubleshooting Cruise Control

Printed in Germany

TESTING MULTIPLE-PIN PLUG FOR CONTROL UNIT FOR CRUISE CONTROL WITH AN OHMMETER

l.With ignition off, pull multiple-pin plug on control unit.

4.Connect tester to term. 12 and term. 4.

Reading = 0 volt Operate "ON/ACCELERATE" Reading = battery voltage

5.Connect tester to term. 12 and term. 6.

Reading = 0 volt

Press "MEMORY" button

Reading = battery voltage

2.Connect tester to term. 1 (+} and term. 12 (ground) on multiple-pin plug. Switch on ignition.

Reading = battery voltage

3.Connect tester to term. 12 and term.3.

Reading = battery voltage

Operate "off" switch on control switch.

6.Connect tester to term. 12 and term. 8.

Reading = 0 volt

Operate brake

Reading = battery voltage

/.Connect tester term. 1 (Postive) term. 14.

Reading = battery voltage Operate clutch (switch breaks). Reading = 0 volt

Reading = 0 volt

Printed in Germany-VII,1986 Checking Multiple-Pin Plug 27 - 11

Control Unit for Cruise Control

8.Connect tester to term.12 and term.11 (Hall pulse generator) transmitter.

Turn left front wheel slowly by hand. Voltage must rise and drop from less than 1 V to greater than 6 V per wheel revolution (rectangular pulse).

4.Connect tester to term. 2 and term. 4 (potentiometer +).

Reading = 2 to 4 kohm

5.Connect tester to term.2 and term. 3. (potentiometer sliding contact).

Reading = 2 to 4 kohm

CHECKING MULTIPLE-PIN PLUG ON CRUISE CONTROL DRIVE WITH AN OHMMETER

1.Switch off ignition.

2.Disconnect plug in engine compartment.

6.Connect tester to term. 5 and term. 6 (clutch actuator).

Reading = 30 to 40 Ohm

If no defect can be detected by these tests, check wire harness to control unit for cruise control. If necessary, replace control unit.

3.Connect tester to term. 1 and term. 7 on plug half of drive (engine resistance).

Reading = 3 bis 15 ohm

27 - 12 Checking Multiple-Pin Plug of Cruise Printed in Germany

Control Drive

AUTOMATIC CRUISE CONTROL (TEMPOSTAT) FROM 85/2 MODEL

Printed in Germany - VI 1,1986 Automatic Cruise Control 27 - 13

(Tempostat)

AUTOMATIC CRUISE CONTROL (TEMPOSTAT) FROM 85/2 MODEL

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