Club 80-90 Forums

Hi folks,
After some more advice, have ordered and fitted some plugs (whilst doing an annual service)from just kampers for my camper and they are Bosch WR7DC+ single electrode (0.8mm gap), but the original ones fitted were champion triple electrode. I spoke to somebody at just kampers and they said the bosch ones are correct for my vehicle and also in the little catalogue it notes that they replace the triple electrode plugs. In my haynes manual it states that there is a difference of plugs if the coil has a green or grey sticker (mine has a green sticker). Just wondered are these the right plugs, and is that gap correct, or am I barking completely up the wrong tree! Just not sure if I have done right fitting these as the van has been running very well and after fitting them I took it a short run and it cut out a couple of times (when idling). Did not want to start adjusting things if the plugs are not right to start with, any help much appreciated.

Thanks,

Glenn

Originally (when new) VW used Bosch W7DC in the 1.9 wasserboxer it then went to the W7DC+ then W7DTC and also W7CCO which has now gone to W7CCO+. As you can see as technology improved so did the plug choice.
The main reason for VW going Triple electrode was longer service intervals and cheaper servicing costs as upto the introduction of the multi-electrode and special metal types, spark plugs were changed every 12,000 miles.
Single electrode gap says 0-7mm but triple and quad electrode plugs come fixed and cannot be adjusted, their gaps are definately more than 0-7mm but this doesn't seem to effect the running infact I'm convinced mine runs better with multi electrode plugs fitted, it seems to be smoother pulling from low revs.
Of course there is nothing wrong with fitting the single electrode type (W7DC+) or the resistor ones you have.
The plugs with 'R' in them have built in resistors for radio supression....when you consider yours already have supressed leads/rotor arm and spark plug caps you don't necessarily need supressed plugs as well but thats up to you.



Common 1.9 DG
capacity 1913cc³
number of cylinders/type 4/overhead valve
production run 10/1982-10/1992
output 57kW - 78bhp DIN @ 4600RPM (swiss - 54kW - 73bhp DIN@4000 RPM)
Torque 141Nm @ 2600 RPM. (swiss - 150 @ 2600 RPM)
Bore 94 mm
Stroke 68.9 mm
Compression Ratio. 8.6:1
minimum octane rating 91 RON
ignition system transistorized hall effect
trigger location distributor
fuel system pierburg carburettor
type 2E3 (possible 2E4 depending on equipment fitted)
description carburettor - twin venturi
Valve timing at 1mm lift.
Inlet opens. 5° BTDC (1° from 01/86)
Inlet closes. 34° ABDC( 30° from 01/86)
Exhaust opens. 38° BBDC (36° from 01/86)
Exhaust closes. 4°ATDC (8° from 01/86)
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 Emmisions
ignition coil supply voltage 11 volts
primary resistance .57 to .75 ohms (.52-.76 1985-1992)
scenery resistance 2400 - 3500 ohms
firing order 1 - 4 - 3 - 2
distributor part number Bosch - 0 237 024 011 (0 237 024 035 - 1985-1992)
ignition timing 5°±1° BTDC without vacuum see note at bottom of page
ignition advance checks 0°-2° @ 1500RPM w/o vacuum and basic timing (0-1 @1160)
10°-14° @ 2400RPM w/o vacuum and basic timing (13-17 @2400)
24°-28° @4200RPM w/o vacuum and basic timing (24-28 @4200)
vacuum advance range 12°-16° engine degrees
idle speed 900±50 RPM see note at bottom of page
oil temp for CO test 60°C
CO content @ idle 1.5±.5 % volume
HC content @ idle 300 parts per million
Service checks and adjustments.
Spark plugs Bosch W7DTC ( W7CCO 1985-1992)
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 10W30 (SF) although most use 15W40 which quietens the hydraulic tappets down
engine oil capacity with filter 4.5 litres
gearbox oil grade 80W-90W
gearbox oil capacity 3 litres
autobox oil grade dexron (final drive type 90W)
autobox capacity 3 litres (final drive capacity .75 litres)
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
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.

When setting ignition timing with DIS (digital idle stabilisation) the two connectors of the DIS unit must be removed and plugged together.

2 different distributors were fitted to this engine, the data for the later engine is in brackets.

Thanks for the reply. So out of interest what make and model of triple electrode plug do you use/would reccommend?

Thanks,
Glenn

vwmonkeyboy wrote: So out of interest what make and model of triple electrode plug do you use/would reccommend?

Thanks,
Glenn

Bosch W7DTC

like he said Glenn... come on mate it's a google away

oh yeh. Thanks for making it that plain and simple, obviously just overwhelmed with all the info supplied!! or just being thick!!

Thanks for the help.

Glenn.

Just to add to this, I recently fitted NGK BP6ET to mine - from http://www.spark-plugs.co.uk

They list it as the NGK equivalent of the Bosch W7DTC.

Bus is running well (though changed lots of other stuff at the same time!).

Cheers,
Stu

Thanks for that will keep them in mind for next time maybe. Have ordered some of the W7DTC bosch plugs to try. Am still running on the WR7DC+ bosch plugs and since that first run it has not cut out again, so might see how it runs on these for a bit longer and then try the others when they arrive and see if I can tell any difference.

Thanks again,

Glenn

I use the single electrode plugs because Gasure etc say they are better when running on LPG (Oh, and gapped a bit tighter too, mine were at .5mm when I last checked).

vwmonkeyboy wrote:manual it states that there is a difference of plugs if the coil has a green or grey sticker (mine has a green sticker).

Our van has no sticker on the coil

It is a 85 / 86 on a C plate and so is right at the crossover point, it has the later cooling pipes, stat, brakes etc.

Is there any way of knowing which ignition system a van like this has ?

I don't have a problem by the way, just advancing my (and any readers of this) knowledge

Hi All,

Can anyone comment on the Bosch WR78 spark plugs? In South Africa we can't order the W7DTC's anymore.

These are the specs from Bosch South Africa:


Regards,
Michael

I have Bosch Super 4's fitted to my 1.9 watercooled Petrol. Tried to find the triple diode, but to no avail. The super 4's work really well anyway.

Hi,

Thanks for replying - sorry I forgot to mention I've also got a 1.9 (1984). Have you used them before and can comment on how long they last?

Cheers, Michael

The Supa 4's appear to be identical apart from the extra electrode, so there shouldn't be any issues there. As for lonevity....I have heard users reporting no visable wear after 30K plus...these plugs are designed for long service changes ie: 40,000 mile change intervals.

Martin

Hi Martin,

Thanks for that - I'll give them a try and report back!

Cheers, Michael

My two penneth....
As far as ignition systems were concerned the 80's were a transition period from low powered CB (contact breaker) setups to high powered Hall effect triggered systems and several designs in between and although the T25 never had points there were differences in what was fitted as regards coil ouput etc.
My opinion is that later ignition systems (on T25's) with the higher powered (forgive me for not knowing this..green labled coils?) work very well wilh multi electrode spark plug types I cannot vouch for earlier air cooled stuff and would still recommend single electrode plugs for these.

Martin

The plugs seem to work quite well but I've run into some other problems so it's hard to evaluate them on their own.. Hoping that once I've got my timing working properly I can comment..