Club 80-90 Forums

hi all, i need to set the timing on my recently purchased dualcab but i am unable to find the info. it is a 1990/1 with a 2.1 mv engine. any help would be greatly appreciated. cheers, dave.

capacity 2109cc³
number of cylinders/type 4/overhead valve
production run 02/1985 - 10/1992
output 70kW - 95bhp DIN @ 4800RPM.
Torque 160Nm @ 2800 RPM.
Bore 94 mm
Stroke 76 mm
Compression ratio. 9:1
minimum octane rating 91
ignition system ECU controlled with hall effect trigger
trigger location distributor
fuel system Bosch Digifant injection - combined ignition and fuel ECU
type multi point fuel injection - intermittent
air metering flow
Valve timing at 1mm lift.
Inlet opens. 10° BTDC
Inlet closes. 48° ABDC
Exhaust opens. 50° BBDC
Exhaust closes. 0° ATDC
Valve dimensions.
Inlet head diameter. 40 mm
Inlet stem diameter. 7.96 - 7.97 mm
Inlet overall length. 122.5 mm
Inlet valve seating face angle. 45°
Exhaust head diameter 34mm
Exhaust stem diameter 8.91 - 8.92 mm
Exhaust overall length 122.5
Exhaust valve seating face angle 45°
Tuning and Emission
ignition coil supply voltage 11 volts
primary resistance coil green label .5-.8 ohms - coil grey label .6-.8 ohms
secondary resistance coil green label 2400-3500 - coil grey label 6900-8500 ohms
firing order 1 - 4 - 3 - 2
distributor part number Bosch - 0 237 520 007
ignition timing 5°±1° BTDC @ 2250RPM with vacuum see note***
Ignition advance checks ECU controlled
idle speed 880±50 RPM see note
oil temp for CO test 80°C
CO content @ idle .5 % volume MAXIMUM see note***
HC content @ idle 100 parts per million
Service checks and adjustments.
Spark plugs Bosch W5DCO/ W7CC0
electrode gap .7mm
valve clearance hydraulic
compression pressure 10-13 bar (150 psi-195psi)
oil pressure 2 bar @ 2000RPM
Lubricants and capacities.
Engine oil grade 15W/40 (SF) VW Quantum Blue or equivelent mineral based
engine oil capacity with filter 4.5 litres
gearbox oil grade 80W-90W
gearbox oil capacity 3 litres (syncro 4.5 litres)
autobox oil grade dexron (final drive type 90W)
autobox capacity 3 litres (final drive capacity 1.25 litres)
Fuel system.
System pressure without vacuum 3 bar
regulated pressure with vacuum 2.5 bar
coolant temperature sensor 275-375 ohms @ 80°C
injector resistance 15-20 ohms
idle speed control valve 2-10 ohms
oxygen sensor heater resistance 10-15 ohms
Tightening torques.
Cylinder head stage 1 10Nm
cylinder head stage 2 25Nm
cylinder head stage 3 50 Nm
big end bearings 45Nm (1987 onwards 30 Nm +180°)
flywheel use new bolts with locking compound - 60Nm + 90°
clutch to flywheel 20Nm
crank pulley single pulley 60Nm - 3 belt pulley 350Nm
rear hub nut 500Nm!
steering track rod end 30Nm
brake caliper to hub 35Nm
brake caliper carrier to hub fixed type caliper 160Nm - sliding caliper 270Nm
spark plug 25Nm
oxygen sensor 50Nm
Brake disc and drum dimensions.
Minimum brake disc thickness 11mm
maximum drum diameter 253.5mm

Cylinder head tightening sequence

8 2 4 6
5 3 1 7

Notes***

Disconnect engine crankcase breather and clamp when setting CO level and idle speed.

Disconnect lambda sensor with ignition switched off when setting CO level and idle speed.

Disconnect temp sender on thermostat housing when setting ignition timing

Side Note....if you haven't stripped/messed with engine or distributor then it is unlikely that the ignition timing will need any adjustment (it just never changes to be honest)
Martin

Like Red says unless the distributor has been moved the timing never goes adrift, but if you have moved it proceed like this.

thanks for the quick replies and alot of use full info. i fitted a new cap and rotor and gave the cap a wiggle to make sure it was seated correctly and the dissy moved as the bolt was loose i will be setting with strobe light so just to confirm the notch on the pulley is tdc, and set to 5°±1° BTDC @ 2250RPM . cheers, dave.

mark nearest you is tdc, one nearest the block is the timing mark 5degrees btdc

thankyou