Technical info

Technical information about:

*General.*	Engine.	Transmission.
Suspension.	Electrical installation.	Torque settings.

Dimensions and weight

A flat 4 boxer with two overhead camshafts. Camshafts driven with toothed cam belt. Liquid cooling with pump, radiator, thermostat and thermo-switched ventilator.

General	*Other info*
Cylinder size:	102 x 76 mm
Ccm:	2484
Compression rate:	9 : 1
Maximum power:	140 Bhp / 5400 rpm
Maximum torque:	208 Nm / 3000 rpm
Tire size:	185/70 HR14 or 195/60 HR15
Tire inflation normal:	1.8 bar on all tires
Tire inflation under heavy load or high speeds:	2.1 bar on all tires
Petrol tank contents:	63 liters inclusive reserve
Oil capacity:	6.1 liters inclusive oil filter
Transmission / differential:	3.5 liters
Cooling system capacity:	9 liters
Place engine number:	on the block above crankshaft on radiator side
Place identification plate:	in the front, in the engine bay

Dimensions and weight	*Other info*
Wheel base:	2670 mm
Track front/rear:	1450/1440 mm
Length:	4580 mm
Width:	1730 mm
Overhang front/rear:	895/1015 mm
Height:	1424 mm
Turning circle:	11.7 m
Kerb weight:	1320 kg
Weight fully loaded:	1770 kg
Tow able weight:	1150 kg

Valve system	*Piston*	Crankshaft and bearings	Camshaft
Oil pump	Carburetor	Cooling system	Ignition system

Valve system	*Other info*
Valve clearance (cold) inlet	0.30 mm
exhaust	0.35 mm
Marks can be found on:	flywheel and on the camshaft pulley's
Valve diagram:	intake opens 15° BTDC
	intake closes 47° ABDC
	exhaust opens 53° BBDC
	exhaust closes 9° ATDC
Valve seats angles in and outlet	44°55' - 45°5'
Valve guides outside diameter	0.02 mm oversize 15.060 - 15.078
	0.20 mm oversize 15.140 - 14.158
inner diameter	8.015 - 8.030 mm
Valve head diameter intake	44.50 - 44.80 mm
exhaust	39.05 - 39.30 mm
Valve clearance in- and outlet	0.028 - 0.058 mm
Inner valve spring free length	41.80 - 42.80 mm
length under pressure	21.5 mm by 269 - 293 N
Outer valve spring free length	36 mm
length under pressure	26.5 mm by 570 - 620 N

*Piston*	*Other info*
Piston diameter class A	101.945 - 101.960 mm
class B	101.960 - 101.975 mm
Available oversize pistons	0.050 / 0.20 / 0.40 / 0.60
Liner inner diameter class A	102.000 - 102.015 mm
class B	102.015 - 102.030 mm
Available oversize liners	0.050 / 0.20 / 0.40 / 0.60

*Crankshaft and bearings*	*Other info*
Front and intermediate journals	class 1 63.012 - 63.021 mm
	class 2 63.002 - 63.011 mm
	class 1 62.885 - 62.894 mm
	class 2 62.875 - 63.884 mm
Rear journal	class 1 75.048 - 75.057 mm
	class 2 75.038 - 75.047 mm
	class 1 75.921 - 75.930 mm
	class 2 75.911 - 75.920 mm
Available under sizes	0.127 / 0.254 / 0.381 / 0.508 mm
Crankpins diameter:	class A 59.973 - 59.981 mm
	class B 59.965 - 59.973 mm
	class A 59.846 - 59.854 mm
	class B 59.838 - 59.846 mm
Available under sizes	0.127 / 0.254 / 0.381 / 0.508 mm

*Camshafts*	*Other info*
Diametric clearance	0.014 - 0.046 mm
Bearing diameter	32.009 - 32.025 mm
Journal diameter	31.979 - 31.995 mm

Oil pump
Oil pressure regulator valve
length free spring	68.4 mm
length off spring under load 107 Nm	39 mm
Oil pressure on 3000 rpm 85° C	4.5 tot 6 bar

Carburetor	*Other info*
Brand: Weber	38 ADLD-2/150
Venturi	26/30
Auxiliary venturi	4.5/4.5
Main jet	1.50/1.60
Idling jet	0.50/0.50
Idling air jet	1.40/1.10
Pump jet	0.50
Fast idling throttle opening	0.35 - 0.40 mm 950 - 1000 rpm
Needle valve	1.75
CO- percentage max.	3.5% with 950 - 1000 rpm
Electric fuel pump
pressure	0.28 tot 0.32 bar with 20° C

Cooling system	*Other info*
Thermostat opens at	84° C ± 2° C *unless* *with our conversion*
fully open at	96° C
Thermo-switch
active at	93 - 97° C
non-active at	88 - 92° C

*Ignition system*
Brand: BOSCH	without breaker
Ignition sequence	1 - 3 - 2 - 4
Cylinder location	1ste cylinder front right
Ignition timing at 3000 rpm	29° on flywheel (without vacuum)
Idle speed	950 - 1000 rpm.
Coil primary resistant	1.9 Ohm with 20° C
secondary resistant	9500 Ohm with 20° C
ignition resistor	0.9 Ohm
Spark plugs	Champion N7Y
	BOSCH W5DC
Electron clearance	0.6 - 0.7 mm

Transmission

Manual	*Other info*
Fully synchronized 5-gears
Gear ratios (:1)	I 3.462
	II 2.105
	III 1.458
	IV 1.126
	V 0.921
	A 3.214

Suspension.

Front wheel alignment

Rear wheel balance

Brakes	*Other info*
Front- and rear discs
Front disc diameter	251 mm
Front disc thickness when new	18.5 ± 0.1 mm
minimum	17.3 mm
Brake pad thickness front new	18.5 mm
minimum	7 mm
Rear disc diameter	251 mm
Rear disc thickness new	10.0 ± 0.1 mm
minimum	9 mm
Brake pad thickness rear new	16.5 mm
minimum	7 mm

Front wheel alignment
Camber	0° ±20'
Castor	2°10' -2°50'
King-Pin Incl. (KPI)	9°30'
Toe out	0 -3.5 mm

Rear wheel alignment
Camber	1° ± 20'
Toe in	0.5 - 4 mm

Electric installation.

Battery	*Alternator*	Starter motor
Fuses	Bulbs list	*Other info*

12 V / 60Ah

Alternator
Brand: BOSCH	type K1-14 V/55A - 20 of K1-14 V/65 A - 21 (whit air-conditioning
With 6000 rpm maximum amperage
Maximum velocity 12000 rpm
Stator resistance	0.26 Ohm ± 10%
Rotor resistance	3.4 Ohm ± 10%
Current regulator	build in
Regulated current	14 V ± 0.2 V
Belt tension for alternator	10 - 15 mm under 50Nm thumb pressure

*Starter motor*	*Other info*
Brand: BOSCH	000131117
1979:	000131132
Amperage taken without load	38 A / 11.5 V
Rotation direction	Clockwise (view from dog end)

Bulbs
Head light and dipped light halogen	55 W
Park lights	4 W
Turn signal lamps front and rear	21 W
Rear lights	5 W
Stop lights	21 W
Reversing lights	21 W
License plate light	4 W
Interior lights	3 W
Side indicator lights	5 W
Engine bay lumination	5 W
Glove compartment light	4 W
Turn signal control light	4 W
Panel lights bulbs	3 W

Other info