kt~-Elektrik

Enghe-Ehtrical '
Moteur4leeQricN&
Motore-hnpimto elttrico
MaQor-equipoekctffco
Motor - Elsptm
Motor&klrisch
14 12 Engine .Electrical System
S~ecificatlons ............................................................ Paae

.
Dlstrlbutor-removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
060
Dislrlbutorcap -renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
091
Dlstrlbutor rotor-renewlng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
Breaker polnts-renewlng ..............................................
7 41
Pulsetransmkerln distributor-checklnglrenewlng .....................
15t
Condenser- renewing ..................... .........................
171 .
.
201 Vacuumignitib~oontrolunit lor dlstrlbutor-renewtng ....................
209 Distrfbutor cap/lgnllion leads . checking ................................
trouble-shooting-dlstrlbutor ..........................................
1213011 Coil-renewing .............................. : . . . . . . . . . . . . . . . . . . . . . . . . .
061 Llne reslslw for Wl . renewlng .........................................
111400B Contrd unit tor fr&nslsforlzedlgnitlon -checking .........................
070 Canlrol unlt foriranslstorized lgnltlon -renewing .........................
Trouble-shooting-contactless transislorired ignition system ............
5231009 Alternator and regulator-checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
020 Anernelot-remo~lngand Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101 Beitpuiley/fan wheel-renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201 Carbon brusbes-renewing .............................................
301 V-beH-renewing ......................................................
569 Sllprlnw-sklmmlng to Hne flnlsh .......................................
671 Rotor-renewing .......................................................
581 Bath deep-gmve ball bearings-renewing ..............................
691 D l d e bocnd-renewing ................................................
123200T Regulator-renewing .......................... ..
....... .. ..........
Trouble-shootlrtg-alternator ...........................................
1241009 Starter-checklngwlthout removing from vehicle ..................... . . .
-
020 Starter removing and Installing ........................................
511 Solenold swllch-renewing .............................................
513 Starter -sfrlpplng and assembling ......................................
551 Carbon brushes- renewing .............................................
602 Starter-reconditioning ................................. .............
701 Exciterwlndlng . renewing .............................................
 Specifications
Engine - electrical system
Model
32016 323 1
320/6 A 323 l A "l
1211 . . . Distributor
Manufacturer Bosh
.
T v. ~ e I
PFUD 6 I
I
PGPUD 6
Bosch Na. I 0231 309 007 0 237 302 006 '1
BMW partnumber I 12111360659 I 1211 1266723
Distributor rator with speed
governor
Cutout speed (wankshdt) llmin 1 6600 + 150
Cutout speed (camshaft) llmin I 3300 f 75
1211 . . . D!strlbulor rotor with
s p e e d governor
Manufacturer Bosch
Bosch No. 1 234 332 196
S u ~ ~ r e s s resistor
or ka 5
') Version for Sweden
1) wlth Inductive (contactless) transmitter. Warnlng: never work on the contactless transistorized coil lgnllon system unless Ihe
engine Is stopped and the lgnltlon switched off. Rlsk of fatal electrlc shock.
 Specifications
Englue - e#ectrhf system
32016 323 1
Model 32016 A 323 1 A * )
12 11 . . . Condenser
Manufacturer Bosch -
Bosch No. 1 237 330 303 -
Capacitance /IF 0.18. ..0.22 -
Insulation resistance k(Z min. 200 -
12 11 . . .Position Indicator
Manufactumr Bosch
Bosch No. 0335541 010
Resistance measured between
leads at temperature I2 80 f 10
at OC (Tj 25 (m
Air gap between posttion Indicator
and vibration damperr mm (In) .
0.2. .2.0(0.008. . .0.8)
*) Verslon for Sweden
 Specifications
Engine - electrical system
32016 323 1
Model 32016 A 323 l A ')
.
12 11 .. IgnRIon timlng

D ~ ~angle
I I
-
Dlstrl.krlor Bosch No.
deg-
0 231309 007
35 ...41
0 237 302 066

% Mi... 68
at 4500/mln deg. 52 . . . D
% 86.7. . .95.0
Breaker polnts gap mm (In) 2 0.35 (0.014) -
Spark plug electrode gap mm (in) see 1212. ..Spark plugs
Flrlng order 1-5-3-6-2-4
S tatlc lgnltlon Hmlng 1)
with englne cold 10" before TDC -
Dynamic Ignition timing 2)
wlth englne running at
normal operating temperature
(vacuum lgnltlon control
out of acllon, dwell angle
tester swllched otfJ T S 22' before TDC n° before TDC
- a t englne speed 1 Imln 1500 1600
*) Version for Sweden
1) Gulde value only. Always time the ignlllon dynamically.
2) Wlih BMW digital tester. using TDC positlon indlcatorlnstalledonenglne or If necessarymarks orvibratlon darnper(V-beltpulley) or ball
mark on flywheel, Illuminated wlth stroboscopic lamp. Onautomatlctransrnisslon cars,TDC = shortpln, lgnltion llming mark = l o n g pln
 Specifications
Engine - electrical system
32016 323 I
Model 32016 A 323 i A ')
1211 . . . fgnftlon tlrnlng (continued)
Centrlfuga! lgnllion advance QCS beforeTDC
(measured wlth vacuum
ignltion control out of
actlon and engine at normal
operating temperature, uslng BMW digltal
or dwell angle tester1) ~000 lmln I0 . . . 14-
1500 /rn in 220

2400 /min I 27 . . . 33" (ends)

2500 /mln 25. . . 31'
3000 /min .
27 . .33O
3500 /mln 30 . . .36*(ends)
Max. ignltion advance (wlthoui
vacuum advance) VS 33 +3 30*3
')Version for Sweden
9 ) If necessary. illuminate TDC mark with strobe lamp
 Specifications
Engine - etectrical system
Model

12 11 . ..lgnitkn timing (continued)

Vacuum Ignttton control
Bosch distributor number 0 23 1 309 007 0 237 302 006
Vacuum control dlrectlon advance retard advance retard
Starf: mbar
I 1 5 0 . . . 190
(153 . . . 1 8 O ) l )
1 4 0 . . . 280
(73 . . 113)l)
1 170 ... 230 140...290

- .. . .
1
- 9
L

End: mbar
2 4 0 . . -260 340. . . 420 310. . ,320 450.. .540

7.09.. . 7.68 10.04.. 12.40 . . .g.45 . .15.94

In Hg
(6.89. . . 7.28)q ..
(3.54 .4.13)')
9.13 . 13.27.

Range of contrcl 'CS 10 10 14 16

') Verslon for Sweden
1) Previous values (until 8/77)
Engine - electrical system ---
320/6 323 i
Model
320/6 A 323 i A *)
Centrifugal advance graphs - Ignition contrd values for distributor test bench measurement
A = Dlstrlbutor shaft movement in degrees
B = Distributor shaft speed In l/mln
1, = Tolerance band with dlstrlbutor In new condition
1, = Tolerance band when distributor has been run

-7

B 500 1000 1500 2000

Bosch dlstrlbutor number 0 231 309 007 B& dleMbutor number 0237 302006 4

*) Version for Sweden

 Specifications
Engine - electrical system

Model

12 12 . . . Spark plugs
Make Beru Bosch Cham~lon

Electrode gap mm (In) I

1213.. . Coll
Make Bosch
Bosch-Nr. 1 0 221 119 0171) 1 0221 122 010
TYPe 1 KW 1 2 V KW 12 V
Primary wlndlng resistance ja .
1.7. .2.1 I 0.4
12 13 .. .
Llne redstor
Make '1 Bosah
Bosch No. '1 0227 900 101
Nornlnal resistance R 'I 0.4 und 0.6
-

*) Version for Sweden

1) Coil 0221 119017 only In conjunctlan with llne resistor rated 0.9 f 0.05Sr. (Reslstor lead in engine wirlng harness).
Specifications
 Specification$
Engine - dectrkel system
Model 3 20 /6 323 1
-
- --
32016 A
- -
323 i A *I
-- -

j231 . . . Alternator wlth attached

regulator (conllnued)
Min. sliprlng diameter mm (In) 31.5 (1.24)
Min. projection mm (In) Z S (0.10)
12 31 ...V-belt
- --

~arrow-~=on V-belt 9.5 x £60 LA

Make
.
1232 . . Regulator
(atlached
lo alternator)
Bosoh
-

Y
Bosch No. 01920!j2OM

cut-in voltage v I 14.1 + 0.2

ControUed w a g e range v I ' 13.7.. . 14.5
*) Venf on far Sweden
 Specifications
Engine - electrical system
1214. .. Control unlt for translstorlzed
coll ignltlon
12 41 . .. Starter
Make II Bosch
-

Bosch number 0 001 311 125

TYpe GF+ 12 V 1.1 kW
Direction of rotaflon clockwise
Number of teeth on pinlon 9
Armature axial play ..
0.05. 0.3 (0.002. . .0.012)
Min. length of carbon brushes mm (in) I t 1 (0.433)
Owmtlng voltage v I 6...12
T e a voltage V I 1 3 f a26
Tgitt temperature
-. WF) I -k 204 {+ 68)
.
1241 . .Solenoid switch
Current consumption (with
nomlnirl voltage at termlnal SO)
Engagementand hold-In wlndlngs A
Watd-in winding A 7.5
") V.ersion for Sweden
Model
32016 323 1
32016 A 323 l A *)

15.9 . ..17.3
') Version for Sweden
I . .

...
wfiocw n w
- #m@m wmvl
m1 operahg temperature -
The f e h d q Rems must be correct before the
lgnltlon can be tlmed accurately:
a) breaker polnts In good condltlon
b) dwell angle correct
c) Tt)C posltion Indicator correctly located.
Connect the BMW dlgltal lester to the round-
pln plug and the current dlstrlbutor lor the TDC
posltlon Indicator.

Version with contactless transistorized coll ig-

nltton:
Warn~ng:the dwell angle Is a fixed feature and
cannot be varied.
Dwell angle at 1500/mln = 42'f TO"
a t 4500Imln = 5-2- f 5D
- check these settlngs.
Detach the tube.

Verslon wlth breaker polnts:

Adjust dwell angle:
Overcome the spring-loadlng and turn the
catch to the tefl to remove the dlstrlbutor cap.
Take out the distributor rotor and dust cover.
When insfdttng: make sure that the dust cover
dddr9rliaHrpr cap are properly secured and
Um rratcheb m c t l y seated.
 Turn the englne over wilh the starter.
Turn the brealter pbids c d u all(Ils h e l l
1
.
angle Is 35'. . 41".
Alm for the lower value.

Detach the vacuum hoses for ignition advance

(1) and retard (2).
Vacuum advance =black hose
Vacuum retard =white hose

1' -; --. -- -----3

Start the engine.
Program the BMW dlgltal tester to 1500 f 501
mln at the speed control -3,.
L"T--: * -- --- . See also operating lnstrustlons for BMW digi-
. ! '
-
I
. tal Lester.
M, Accelerate untll engine speed Is a t least
1500/rnln.
Read off the lgnlllon control angle (22' +I") at
Ihe dlgltal tester.
 m1 m C position lndlcaior - renew-
Iw
Pull lhe m & p i n plug downwards out of the
h&mr.
0-k the from the plug.

Utl the position indicator out of Its clip.

When installing: make sure that the position
kndlcatar Is cwrectly seated. f he gap between
thapoglilorr iadkalor and the vlbratlon damper
.
ahould be 0.2.. 2.0 mm (0.008.. . 0.08 in). B
12 $1 091 Dlatrfbutor cap - renewing
Pult off the lgnitlan leads. Take off the dls-
trlbutw ow and attach the new cap.

12 1 4 111 Distributor rotor - renewtng

Take off the Clldttlbutor cap.
PuR out Me dlstrbutor rotor.
Resfstance of suppressed rotor I).
Importent: the cutout speed1) of the dislrlbutor
rator b stamped underneath.

12 11 141 Breaker points - renewing

Take aff the dlstrlbutor cap.
Remove the dlstrlbutor rotor and dust cap.

1) Sw sp&flcallons
R e m m screw (2).
Pull out the breaker points assembly.
When installing: clean new points to remove
1
grease.
Apply B-ch Ft 1 v 4 grease to cam and Iltt sec-
llon ($1 of breaker arm.
Adjua dwell angle and Ignition timing -
1 2 11004.

12 11 151 Pulse transmitter In distributor-

checklnglrenewlng
lmpoftanr: no work is to be performed on the
contactless transistorized coil ljnitlon system
unless the engine is stopped and the lgnltlon
switched off. Rlsk of fatal electrlc shock.
The pulse transmitter delivers an A C signal
varylng between app. 0.3 and I00 V according
t o running speed. This is used as a control slg-
nal to interrupt the lgnltlon spark.
a) Testing
Disconnect the transmitter lead at the plug be-
tween the dlstrlbutor and the control unit.
Connect the Program tester.
Test lead red to termlnal 7, black to termlnal
31 d.
Set range switch to x0.1 V.
Operate the starter.
If a readlng of at least 0.05 V Is obtained, the
pulse transmitter Is In good worklng order.
If not, the fault Is In the control unit.
b) Renewing
Pull out plug (1).
Remove the dlstrlbutor - 12 11 060.
I L

I
A=0.35.. . 0.70mm (0.014 ... 0.028 in).

Carefully press up the pulse transmitter wheel

(4) with two screwdriver blades on opposite
sides.
Note: locatlng pln (5).
When Insralling: cutout In pulse transmitter
wheel must engage In groove on distrlbotor
shaft.

Take out thrust washer (6).

Remove thethree retainlng screws with a 3 mm
AHen key.
Remove Seeger clrcllp (7).

Remove screw (8) and take OH retaining ptate

(9).
Pull out plug (10).
Loosen screws for mountlng and take off car-
rier plate.
Unsctew pulse transmmer from carrler plate.

ing: lugs face cutout for plug-in.

control unit for d i 6

VW&W V#I60-&8S8 fMtBd$&dZd Cd! ig-
nMm:
Warnjng: mv0r wmk on the ~ e t b m ~ l t e t n s -
istorbdcoUIgnlCIcmsy~fern unl-tA*e*
Is stoppod anXl tHs ig&n awImEhnd off.
Danger d fasl d&(: ah*
-
Ramova the dlaqfbmsr f2 11 080.
Take.wt ttra rettaiatkg ~ W and I itl@cmW
the m m m cpntml wit @rewbcmnWhgllnk
-1.
Whgn fnstallfn~: the bmnmng Hhk.
and connect to MarnaL
 Trouble shooting - distributor (with contact breaker)
Fault
Engine will not start, o r misfires
and stops
Engine runs erratically and misfires
Engine misfires under part load
Engine power output drops
Engine backfiring - noise developed
Engine will not accelerate
Engine starts, but cuts out
immediately
Engine misfires - fuel
consumption too high
1) Determine with BMW Program tester 1100 005
I I
I Cause11
Burned or dirty breaker points I Remedv
Renew breaker points
Stray currents across distributor cap Clean distributor cap, renew if necessary
Defective suppressor resistor i n Renew distributor rotor
distributor rotor
Dwell angle incorrect. Contact gap Adjust dwell angle. Renew distributor
not identical at all lobes of cam
- uneven cam wear
Contact breaker plate for vacuum Renew distributor
ignition control is worn or loose
No centrifugal ignition control - cam Free distributor cam on shaft (oil): if
seized or rusted to shaft necessary, renew distributor
Open or short circuit at condenser Renew condenser
-
Defective ignition lead Renew ignition lead
Defective spark plug cap Renew spark plug cap
Defective suppressor resistors Renew suppressor resistors
 -
12,s 011 @dl r%qf$wlng
Warning.- never work on Ihe ~ n i s d m - t m n -
~~ a d l'gnltton aystdm nleas the en-
gine 15 ahoppsd and the lgrtitfon swttched off.
Rlah of fatal e t m c dtock.
C h d d l t e d l - 3 1 00009.
I)effaeh the reeds.
Data* thrS mil from Its mtdnlng plat*
When Instattin@:black/red b a d to termmall6
black read ta termhat 1
,Wm/ng: db not ecddwrilly anfurre the ~ n f l
tor tfre Manderd IgnWtt system (with brmkur
pol&) and fbe roll for ihe TSZ tr8nststortzed
mntaetteas oall Nnltlon ayetern.
Bas& number 0 221 119 017 fur call with
breaker pdnts ay8tm
8usd number 0 221 122 610 for w&ctlwu
tranet8tarbd system
If these Items are oopfusmd, !here wlll be sev-
ere d o n st tfre breaker poi* even after
only a short dktance has been covared, and
mtsflrfng a d poor odd starting wIll m u r .

-
12 13 053 Une msbtor for cdl rsnedng
Warnlng: never werk on the c o n W e # 8 Wan-
M a r k e d wII QnWn syatem unless the en-
glne I m stopped and the tgnfil~nawltched off.
Wdr of fatal decttk shock
Veralon without breaker potnb
Remove Re bsftery.
Detach tbe leads.
Detach the dne redstor hwn the mWhlng
plate,
Nhen lnstctlllng:
bktWrod bad Yo 0.8 Ohm redWor
g w m Jmd lo 0.4 Ohm redotot
blaaWred Lead to OA Ohm redstor.
12 14 068 C a n W unit far WmHllsWbed
- chw-
IWIOII - - - - -~

Warning: new work an the c e r r t b ~ l e s strans-

Istortredo d l lgnlthn e y A m uldeasthclmglne r
la Wpped nad the Ignlllonrwltchedoff. Risk p l
Md el-k ekmk
A] Cenrtect the Program twtw
S w k h pkltlon U 1.

Wth the Egnitbrr ~Mehend MI, tint madlng must

be bedm 20V.
Ii thpn 2,9 v b f e Mown, UIS CU-OI d¶
bas a feoli.
II no &e# e q l e reading Ls shown, &st the
pulse tmnemltter - I2 11 151.

19 Cd c Wambg-up tegul~tur LIVd = b k k

28 DMbutst d Ad&lonal a t snde RT =red
a2 Englrae plug 4 Dlade relay GN =green
27 sta~er f Fuel pump mley Bf? -blawo
t Them-thne s a c h fl Tmna2stotlred I g n b fTSZ) abniral urnit
b Startlng W ~ I V ~ h Reskwa
t2 14 010 Control ulilt h r treinalstom
ignltlon - renewlng
Warning: Naver work oh the wntactlesa ban-
slstorfzed $nMon eystorn unless the englns le
stopped and ttre I g n h ewttched off. Rfak of
fatal fAwtrIc shaek
Pull out plug.
Detach contrd udt frm wheel arch.
InstaU only cunhl unlt wfth Boscb n u m b
B 227 010 236.
 Troul

I Starter runs but engine will not s t a h

Fuel system working correctly I
I
Detach lead 4 from distributor and hold against earth .- NO - ~etachblack/redcable from str
(ground). Operate the starter. Spark length must be app 0.4 Ohm. Connect a voftmetei
10 mm (0.4 In) Readlna Is etrllbaler
I
Yea
I

cap, distributor rotor red to terminal 7, black to termln

end lgnltlon reads In

Voltage below 2.0 V at cell terminal 1

I
Yes

Voltage agalnst earth Defee€lveIlne

(ground) st call terminal resistor or
15 exceeds 3.0 V
signal present in pfug at.
control unlt
terminal 15
I Enalne starts 1

IgnHlon tlmlng correct 1 Stgnal pre-M in

plug at c o n t d unlt

YC
Pulse trans-

worklng order c~nnectlonto earth

Renew control unlt I Renew control unit

I) measured with BMW Program tester

 Warning: never work on the cantactleas tran-
sistorized col lgnltion system unless the en-
and the Ignftion swltched off.
gine is s t ~ p e d
Rlek of fatal electric shack.

rk length must be app.

No - DetachOhm.
0.4
blaeklred cable from starter
Connect a vohnefer into clrcult Run the sterter.
Rlaadlng in equhslent to battery voltage

pqii

1 7 1Renew defecnve

Pulse transmkter In working

order

Defective tine
resistor or

comol unit

Yf'm
I

1 Signal present In
plug at m t m l unlt terminal 1

Pulse trans-
mitter in NO Make connectton to earth
(ground)

w
I
Renew contrd unit

tester
 1 Wsrnlng: never work on the mnt-ss tnn-
1 Ustorlzed coll tgnltlon system unless the en-
gine Is stopped and the ignition switched off.
1 Risk of fatal electrk shock.

Break In lead from starter Illne r%sl&or or starting relsy

Adjust alr gap batween rotor and stator to 0.35. .. 0.70 rnm (0.014. . .0.
I connector and Insert a vofimeter
Transmltfer lead interrupted

Renew pulse bansmltter

Yse,
Pulse transmitter In worldng
order

here and

.;N6 -4 Lead to coil

I
termlnal 1
Interrupted 1
transistorized ignition
actless tran-
]less the en-
switched off.

Break in lead from starter to line resistor or starting relay

] Adjust air gap between rotor and stator to 0.35 . . . 0.70 Fm (0.014. . . 0.028 in) I

-No -4 Transmitter lead interrupted I

'No
\
Renew pulse transmitter
 PO9 Alternator and regulamr
-12checking
31

For test procedure, $e Program Test

11 00 #&
12 31 O M AlternPrtor - removlng and in-
eta11lng
Warning: Do nof disconnect the leadsbetween
the battery and the alternator unless the en-
glne k stopped.
If the battery Is rwharged wtthout remuvtng It
ftcrm the vehicle, h e podUve end negatlvabat-
tery leads must be &awnngctsdu
When src welding on the vehbte, the ground
(earth] terminals d the wsMW aqulpment
should be attached Qlredy to the vehlcle
component being welded.
Disconnect the nag8rlvs lead at the battery.
Detach the leads st the alternator.
B+Red
D f Blue

Remove the boft holding the alternator at the

tensioning strap.
Loo~enthe upper mwntfng and llft out the al-
ternator.
When Insfafling;It ohauld be posslbls to presc
In the V-belt by 5-10 mm (02-3.4 In).

-
12 31 101 Belt pulleylcooling fan renew-
ing
-
Remove the alternator 12 31 020.
Prevent the cooling fan from turning, and de-
tach it.
When installing: note correct tlghtenlng ior-
quell.

InWlatton order: nut (I), corrugated washer

(2), waeher t3), belt pulley (4 -I6),
- codlng fan
(61, #.
 -
I
12 31 201 Carbon brushes renewing
Take off the regulator and remove complete
wlth carbon brush holder.

L - Unsalder the carbon brushes and solder In the

a- - -
When instslli ng: It should be! posa
in the V-belt by 5 ...10 mm (0.2 .

12 31 569 Sllprlngs - skimmlng

- alternator strlpped - c
To skim the sliprlngs, tallstock sptndle EFAW I
L 75 or GDF 85 R 3 must be used.
7
.
Remove only enough material to smooth out
the scored areas.
Warning: Minimum sliprlng diameter 31.5 mrn
(1.24 in).
After skimmlng, check that sliprlngs still run
true. Max. permissible runout 0.03 mm (0.0012
in).

520 I 2 038 1) See apectfkatlons.

 -
12 31 !371 Ratot renewing r
- alternator strlpped -
Press #e rotor out of the bearlng plate.
When Installing: The cellar on dl= (1)feees L e
ball bearing.

Pufl the ball bearing (2) away from Me rotor.

When installing: Grease the bearlng wlth Ft
1v 34 grease.
The open slde of the bearing faces the how-
I
*Y
n
i.
piice the corrunatedwasher 131 Into the hous-
ing before lnstalllng the ball bearing.
M

-
L

JJ
12 3f581
-., 00th ball beeulngs - renewing
- alemator strlpped -
Take off the retalnln~plate (2).
Prebs the ball bearlng (3) out of the bearlng
plate.
When installing: The open slde of the bearlng
laces the rotor.
The shoulder on dlac (1) faces the ball bearlng.
Pull the ball bearlng (4) away from the rotor.
Use only C 3 bearings.
The open stde of the bearlng faces the rotor.
lnserl corrugated washer (5) Into the housing
before Installing the baU bearlng.

12 31 Wt D W e board - renewing
Detach the regulator.
Mark the correct Installed position of the hous-
ing (1) In reiatlon to the sllpring bearing (2).
Detach the housing (1)from the sliprlng bear-
Ing (2).
When installlna: Attach corrugated washer (3)
wlth Ft 1 v 34 grease before listalling the ball
bearlng.
1

Detach dlode board (9) and stator (10) from

ii~pringmount (2).
Note eonect Installed posMon of washer 03)
hnd lnsulstlng bushing (12).

I
r--

:
7
-v I a

Unaalder the diode board h r n the rlatorwh?d-

a Ing.
 1 2 3 3 3 901 Regulator - renewing
The mgulalcnr -canody be renewed fogether
wlth the carbon h s h holder.
Remove and Inatal the mgulator.
When installing: use only Basch regulator
0 182 052 WU.

L
P-rn tester b nqt livail-ablsr:
vohfge musf be wallable$
ArhU:'ba€€ery
ConnW a vdtrnder batween D+ and ground
fearik).
AEW dnnl,,a rmdtnq of 13.8-14.8 v must be
p
bt
r
im ' r

we WlrittM Is defecztvs If the ceadlng a- I

. e,epMb a#:&V.
I

.-
43 41 618
M[m
.3m w - w and asaem*
RvWQ:, -
milenoidswWh 12 43 611.
Tak. malt the mt&dmtnp WrewbIl)*
rake art ths d p a WP m.
Rmmovettw WWIBLW~~), shbwW end +@
iB)L
When InsWIng: u# ahtmd ta WWf m W V
.. .
eladplay to 810 , & I 5 mra fQ.004,. .OAW hs)
(4).

R e m v e the pole bouslng screwrr (8) and pull

off cap (7).
Uft out the pmitlve brushes fB) and detach the
brush holder board (9).
When installing: note correct installed posMen
at brush hddet board (S)* Pole houslng acrewa
(6) must be inserted *rough the locating sfota
In the brush holder board (9). Pass the exclter
winding lead through the rubber seal.
Check candMon of commutator tbearlngs.

af r t e houef& The slat 14 tho pole haudng

P E d l O r w ~ W P I m e ~ d l k b ~
Rsnravuthe! ! S m s r n -I It$),
When Installing: insert the engagement lever
(13) tothatthe engagement rlng (14) rests be-
twaen tho projections on the engagernenf
Iwer,
m a s 9 the engagement lever with Basch Ft 2
v 3 8llhno grease.

1 2 41 551 Carbon brushes

- starter removed -
- renewing
T a k e outthe reWo4-m~
rorewr {I).
Take 8fl the dust cap @&
Remave th* 1- wpsin9r(5), dima {qmd-1
 Remove the pole housing screws (6) a n d pull
o f f the cap (7).
LIH out the posltlve brushes (8) and take off the
brush holder plate (9).
6 When installing: note correct posltlon of brush
holder board (9). The pole houslng screws (6)
must be placed through the retalnlng slots In
the brush holder board (9). insert the exciter
wlndlng lead Into the rubber seal. Check the
commutator bearlng.

-- --
Unsolder end resolder the carbon brushes to
. . the exclter wlndlng end the brush holder
board.

1 2 41 602 Starter - reconditioning

I - starter s t r i p p e d down -
Check armature and fteld wlndtngs with 220 V
test lamp.
Check the commutator a n d larnlnatlons wlth

.-
I wlll Ilght up. I n this case. renew .-
the armature.

Introduce an ammeter wlth 60 A measuring

range Into the current circuit, and test each
lamination of the commutator i n turn by touch-
.
Ing brlefty wlth the test probe. Test voltage 2 . .
4 V. The needle deflection o n the meter should
be the same between all laminations.
Severe floctuatlons Indicate an open clrcuit.
Renew armature If an open clrcult ISfound.
Ch& the exclt'w wbdlng far shun to earth
(grouna
a r
ty mt 8 WhaI Inapec2lm.
Renew burned or dheralke wetheated wllrb
lngs.

Sklm the commutator surface to a tine finish.

However, do not skim below the mlnlmum
commutator diameter (A) of 33 mrn (1.3 In).

Cut back the lnsulatlon between the corn-

mutator plates.
The insulation should be 0.5 mm (0.02 In) below
the surface of the plates.

Press out bushing If worn.

When installing: before inserting new bush-
ing, soak I! for at least half an hour In engine
011, then press In untll flush.
Pfeos the bushlng aut of the Intermediate
bearkg cap H worn.
When installing: soak the new bushing for at
least hall an hour In englne oil, then press in
until flush.

12 41 701 Exciter winding - renewing

- starter strlppeddown -
Mark the positions of the pole shoes so that
they can be Installed again In the same posl-
tlons as before. Take out the four pole shoe
screws and remove the pole shoes and the ex-
clter winding from the pole houslng.
When installing: before flnally tightening the
pole shoe screws alter Insertion, allgn the pole
shoes exactly parallel with the longitudinal ax-
is.