Gas Drive Adjustment
Caution: The gas actuator must be handled with particular care during installation. The slightest kink can lead to subsequent rupture during operation. Cables that have been bent should not be installed.
Press the gas pedal all the way (full throttle) and fix the pedal in this position with a plank.
Cold start drive adjustment
All AUDI 80/90 diesels are equipped with a cold start device. By means of a cable drive, the injection metering device inside the injection pump is set to an earlier position by 2.5°. This makes cold starts easier. During repair work, the drive cable must be connected as follows:
Install washer -1- on drive cable. Insert the cable through the rubber grommet into the holder on the fuel pump. At the same time insert the drive wire into the clamping bolt -3-.
Fit lock washer -2-.
Set the drive lever to position 0 by pushing the lever in the direction of the arrow as far as it will go.
Pull on drive cable and tighten with clamping bolt -3-.
Checking and adjusting the idle speed and maximum speed
Because diesel engines do not have an ignition system, a special tachometer is required (VDO). It can be connected to the W terminal of the generator.
Warm up the engine to operating temperature. Engine oil temperature 60°C.
Connect tachometer.
The cold start cable must not be pulled out.
Electrical consumers (radio, light) must be turned off.
Check the idle speed: diesel 1.6 l - 875±25 rpm; diesel 1.9 l and turbodiesel 1.6 l - 900±30 rpm. If necessary, set the idle speed with the adjusting screw -1-.
Turning to the right: rpm increases.
When turning to the left: the speed drops.
Attention: If the idle speed cannot be set below 900 rpm or 980 rpm. stop rests against stop bolt -3-. Loosen the stop bolt and unscrew it. Set the idle xsshch with the adjusting bolt -1-, screw in the limiting bolt up to the stop and lock it.
Checking the increase in speed
Pull out the cold start actuator 1 click. The speed should increase by 60 rpm.
Pull out the cold start drive completely. The number of revolutions should increase to 1050±50 rpm.
If the required values are not obtained, the cold start drive must be adjusted.
Attention: If the value of 1050 rpm is not achieved despite the correct installation of the cold start drive, unlock the stop screw, with the cold start drive pulled out, set the speed using the stop screw and lock it.
Checking the maximum speed
Give full throttle. Measure speed: diesel 1.6 l: 5350±50 rpm; 1.6 l turbodiesel: 5100±50 rpm; 1.9 l diesel: 5050±100 rpm.
If necessary, loosen the locknut of the adjusting screw -2 and set the maximum speed. Then tighten the locknut.
Attention: The protruding part of the adjusting screw -5 is protected by a cap.
The screw must not move. If the screw is significantly misaligned, the following problems may occur:
- 1. Screw in = protrusion too high, idle speed too high, not adjustable.
- 2. Screw turned out = protrusion too small, jerks when starting off or accelerating due to too low speed. If necessary, make the main adjustment, for which the cap is removed and the screw is locked.
Protrusion too small: Slowly screw in the screw until the number of turns increases, then back off ½ turn.
Protrusion too large: Loosen the screw until the speed stops dropping. Then turn the screw in slowly until the number of turns increases, then turn the screw ½ turn back.
Lock the adjusting screw and close with a new cap.
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