Hello from America !

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berlintourist
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Re: Hello from America !

Ungelesener Beitragvon berlintourist » Samstag 8. September 2018, 03:44

man könnte ja auch mal über den teich fliegen - ne unterhose und die zahnbürste sind schnell eingepackt.... :lol:

:-|
Wartburg - aus freude am schrauben ...

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Montag 10. September 2018, 23:59

I'll be installing the engine tomorrow. I have a few questions:

What is the clutch pressure plate to flywheel bolt torque?

What are the engine to transmission bolt torque values?

Can you guide me to the proper way to set, or adjust, the shifter (circuit)?

Thanks in advance. -Kerry

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Warre 1000
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Re: Hello from America !

Ungelesener Beitragvon Warre 1000 » Dienstag 11. September 2018, 21:14

The clutch screw shall have a torque of 21,6 Nm or 2,2 kpm.
The motor-gear box screws shall have a torque of 44,1 Nm or 4,5 kpm.
I did not found the torque for the starter motor, but those are even bigger screws than the motor-gearbox screws.

Nm stands for Newtonmeter and Kpm for kilogrammeter. What that are in poundfoot or poundinches I do not know.

In fact I attach those screws with only a good feeling for those type of screws.
Stig
Wenn man alles weiß, hat man sicher etwas missverstanden.

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Tomtom
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Re: Hello from America !

Ungelesener Beitragvon Tomtom » Dienstag 11. September 2018, 21:34

I did not found the torque for the starter motor, but those are even bigger screws than the motor-gearbox screws.

=4.6kpm
Hast Du einmal etwas Gutes gefunden, mußt Du es pflegen!

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Dienstag 11. September 2018, 22:31

Thanks guys!

My torque wrench covers all forms of measure so the conversion is not necessary. I agree Warre, sometimes I go by the "experience torque wrench" :lol: The screws that most concern me are the clutch screws.

Do you have any help for adjusting the gear shifter (circuit)? I have it adjusted based on what Wartburg Peter has suggested on his website. However it feels vague. All the parts are new and in good shape. I wonder if I have missed something?

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Warre 1000
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Re: Hello from America !

Ungelesener Beitragvon Warre 1000 » Freitag 14. September 2018, 20:55

Do the car have the gear level at the steering column or on the floor?
Stig
Wenn man alles weiß, hat man sicher etwas missverstanden.

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Dienstag 18. September 2018, 01:18

The engine is back in and everything works well! I drove 120km over the weekend. It's very reliable and quite a conversation piece. It has some vibration at 100kph but that goes away at 120kph :smile:

I will post pictures of the clutch and disc. The VW 180mm "40hp" friction disc had to have 3.25mm taken off the length of the center hub to mate well with the transmission shaft.

Warre, The shifter is at the steering column. Every linkage from the firewall to the transmission is new, purchased from LDM by the owner. I have it adjusted fairly well. However 2nd gear is difficult to engage at speed. Every other gear is easily shifted. Every gear is selected easily at idle. I think that the 1st to 2nd shift plane needs to be adjusted a bit.

The LED tachometer no longer works now that I have everything together. I do not know why. I re-checked all of my connections. I'm missing something.

-Kerry

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MarkusH
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Re: Hello from America !

Ungelesener Beitragvon MarkusH » Dienstag 18. September 2018, 20:37

Hi!

The LED tachometer no longer works now that I have everything together. I do not know why. I re-checked all of my connections. I'm missing something.

What do you mean? There is no tachometer, from stock. Was a tachometer additionally installed?
Or do you mean this one?
The curved LED-display on the left side shows the current fuel consumption.

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Warre 1000
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Re: Hello from America !

Ungelesener Beitragvon Warre 1000 » Dienstag 18. September 2018, 21:05

Kerry Chadderton hat geschrieben:.....The shifter is at the steering column. Every linkage from the firewall to the transmission is new, purchased from LDM by the owner. I have it adjusted fairly well. However 2nd gear is difficult to engage at speed. Every other gear is easily shifted. Every gear is selected easily at idle. I think that the 1st to 2nd shift plane needs to be adjusted a bit....


I might be you have figured the shifter adjustment out by yourself. But here how I adjust the shifter at the steering column.

The important thing is that the reverse should not be possible to engage by mistake. The shifter should be pulled out about 5 mm towards the passenger. Then it will be possible to pull the shifter towards the steering wheel one step more and engage the reverse gear. This can be adjusted at the last vertical joint to gear box shifter shaft (6mm thread with a 10 mm nut width). Appropriate adjustment is when the reverse gear cannot be engaged by mistake, but the 1 and 2 gear are easy to engage.

There is a small possibility that the reverse gear preventing system also might interfear, when changing from third to second gear. When changing from first gear to second gear there should not be any problem because the gear box are alredy connected to 1-2 gear shifter rod. You can try adjust the link a little bit shorter (or do I get it wrong and should it be a little longer?)

If parts falling out, when pulling the shifter towards the passenger one small fork has broken, and the adjustment becomes impossible, but the gear box is still manouverable. That have happened a few times at my Wartburg.

Nice that the clutch is working!
Stig
Wenn man alles weiß, hat man sicher etwas missverstanden.

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Mittwoch 19. September 2018, 01:06

MarkusH,

Thank you! I was completely mistaken. It makes sense now. I thought it was the strangest tachometer I had ever seen! I switched the ground wire when reassembling. The schematics you have provided are priceless. I need the wiring diagram to fix the fuel gauge as well. What does the 3 position switch below this gauge do?

Warre1000,

You might have it figured out. The 1st to 2nd shift does feel like it is passing through the reverse lockout. I'll try minor adjustments.

Thanks my friends!

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MarkusH
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Re: Hello from America !

Ungelesener Beitragvon MarkusH » Mittwoch 19. September 2018, 09:23

What does the 3 position switch below this gauge do?


left position
partial switch off the gauge. Then only the red LEDs of temperature and fuel level will light on, if the motor run hot or fuel comes to end.

mid position
normal function

right position
test of "brake fluid low level warning lamp"

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MarkusH
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Re: Hello from America !

Ungelesener Beitragvon MarkusH » Mittwoch 19. September 2018, 12:35

in left switch position:
Imho also the last 4 LEDs of the consumption gauge will light on, if you give full throttle.
I have another gauge, so by that I have to rely to the wiring diagram.

have a look here:
http://wartburgpeter.de/te_kmva.htm

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Freitag 21. September 2018, 14:16

Warre 1000,

You were right. The 1st/2nd shift was hitting the reverse lockout in it's travel. A minor adjustment. It shifts perfectly now. Thank you.

Markus,

Thanks for the link. The description of operation cleared up most of the mysteries. The 3 position switch is working. However the fuel level gauge was not working. The encoder was dirty and stiff. I cleaned it well and tested it. It is okay. The gauge shows a yellow LED at all times until the tank reaches empty, at which time only the red LED shows:

20180919_142515_resized.jpg


This is with a full tank. Is this normal?

-Kerry

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MarkusH
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Re: Hello from America !

Ungelesener Beitragvon MarkusH » Freitag 21. September 2018, 16:02

Hello!

There seems to be a small defect in the electronic.
Normally, the red and yellow LED only light up single.
The green LEDs can light up together, depending on how much fuel is in the tank. (full = all green on)
When the first (left) green LED lights up, the yellow turns off.

With some effort, you can fix that.
But you can still buy the whole display instrument, relatively cheap.

bye
Markus

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Freitag 21. September 2018, 17:29

Markus,

Okay. It is good to have that knowledge. I will explore a bit and see if it is something that I can fix.

Have a good weekend. I am looking forward to beer and sausages myself! {beifall}

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Dienstag 2. Oktober 2018, 14:39

Hello again! I hope everyone is well. I've been sidetracked with family obligations and have not had as much time to spend with the Wartburg. The clutch repair was a great success. I have put 240 trouble-free kilometers on it since.

There is a new issue. The temperature gauge flickers in and out and has a generally sporadic operation now. This began as soon as the engine was installed. I have checked the temperature of the engine with IR thermometers and the engine is running at the right temperature. I have done much diagnosis and have come to this observation; If the system voltage is below 13.5v then the gauge works fine. When the engine is above idle the system voltage rises to 13.85v and the temperature gauge either shuts off or blinks different LEDs sporadically.

Have any of you experienced this problem? Have I done something wrong with the engine replacement?

-Kerry

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Warre 1000
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Re: Hello from America !

Ungelesener Beitragvon Warre 1000 » Mittwoch 3. Oktober 2018, 21:31

To me it sounds like a loose contact at the motor temperature sensor. Changing the speed over idle the vibrations changes and causes short interruptions in contact. Of course, it might be something else, I am not familier with the LED intruments.
Stig
Wenn man alles weiß, hat man sicher etwas missverstanden.

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Mittwoch 3. Oktober 2018, 22:23

Warre,

Your logic is sound. I thought of that and replaced the spade connector at the temperature sensor. There was no change in the gauge behavior. Since I have a fault in the LED fuel gauge these all could be signs that the entire gauge assembly is going bad. I can live with a faulty fuel level, or consumption gauge, but I do not like driving without knowing my engine temperature!

It's been a couple of days since I first posted this problem. You are the only one to respond. Maybe no one else has had this issue. I might just have to roll up my sleeves and dive deep into this problem the hard way.

Thanks my friend!

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Tomtom
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Re: Hello from America !

Ungelesener Beitragvon Tomtom » Donnerstag 4. Oktober 2018, 00:33

Never heard about such an issue.
At first I recommend the pages of "Warburgpeter" and especially this one with the values of the "Geber"
http://www.wartburgpeter.de/te_tank_temp_anzeige1.htm#

I dont believe that the instrument is broken. They are very robust...
I assume that the sensor has a damage itself.
So try to check it the following way. Take a resistor with 150 Ohm or somethin like that and connect it instead the sensor against the ground.
The value shown by the instrument should be stable all over your way.
If not the instrument may have an error, if yes its a problem of the temp sensor...
Hast Du einmal etwas Gutes gefunden, mußt Du es pflegen!


Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Donnerstag 4. Oktober 2018, 22:02

Once again you have saved me from stress!

I performed the 150ohm resistor test and the problem lies in the sensor itself. I am relieved. However temperature sensors are hard to come by here. I am attempting to find a cross-reference part, such as the 40hp VW clutch disc and the 2.8 litre GM thermostat. If anyone has a solution please speak up. If I find one I'll post the results here. Many thanks!

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Tomtom
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Re: Hello from America !

Ungelesener Beitragvon Tomtom » Freitag 5. Oktober 2018, 10:44

Could you post a (marco) picture from the sensor from above?
Pic. limits are max 1000px here in the forum.
Hast Du einmal etwas Gutes gefunden, mußt Du es pflegen!

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Freitag 5. Oktober 2018, 15:19

Tomtom,

Will this do?

20181005_090943_resized.jpg


If this is not good enough I can remove, clean it and take better pictures.

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Tomtom
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Re: Hello from America !

Ungelesener Beitragvon Tomtom » Freitag 5. Oktober 2018, 18:54

Thank you Kerry,
my idea was to see the welding point and the contact.
They both look okay.
I think you could not move at left/right the contact tag and it is fixed?
Was the contact loose and somebody set the welding point to fix it again?

Here something about the inner construction.

Cimg1218.jpg


The sesnsor itself is some ceramic plate at the ground of the brass cartrigde. If the ceramic plate is broken there is no chance to fix it.
Than there is a spring and a capsule with some resistor inside.
In the most of the cases I know the resistor or the wires of the resistor are broken.
So you could replace this resistor.

If you want to invest 1 hour you could try to check it and may be you have a chance repair it.
Unweld the contact point and open the brass flanging above on the top to get out the black plastic part.
Than you could take the resistor out of the cartridge.

PS.
Do not buy in hurry any similar items at ebay until my next post. There are a lot of similar looking sensors with another temperature characteristics...
Hast Du einmal etwas Gutes gefunden, mußt Du es pflegen!

Kerry Chadderton
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Registriert: Freitag 31. August 2018, 00:48
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Montag 8. Oktober 2018, 13:25

tomtom,

In the picture is how I received the car, so a previous owner or mechanic has welded the connection. I do not know why.

Your information is good and gives me confidence to attempt a repair. It is possible that the connection beneath the weld has corrosion, making a bad contact point. I have seen this in computer boards. I will remove it and have a look over this week. Thank you for the picture and information.

Kerry Chadderton
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Re: Hello from America !

Ungelesener Beitragvon Kerry Chadderton » Freitag 12. Oktober 2018, 22:54

Well I have removed the sensor (encoder) and tested it in a pot of water on the stove. As the temperature increased I began to see liquid oozing from around the plastic cap. There's water inside. This is my fault! I was so happy to have the Wartburg running well that I treated the engine area to a good washing. I have filled the sensor with water {Du Du}

I'm going to take it apart as you have suggested. Maybe it is not a lost cause. Maybe I can clean and dry it. I would rather have another good sensor but that is not looking hopeful.

I'll post my results. Thanks again!

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bic
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Re: Hello from America !

Ungelesener Beitragvon bic » Samstag 13. Oktober 2018, 01:39

Kerry Chadderton hat geschrieben:... I would rather have another good sensor but that is not looking hopeful....


c120.JPG
Lieber Old School als gar keine Erziehung.

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Tomtom
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Re: Hello from America !

Ungelesener Beitragvon Tomtom » Samstag 13. Oktober 2018, 22:01

Kerry
There's water inside. This is my fault!

It's not your fault. These sensors were waterproof in the past. But this is 30 years behind us...
So try out to fix it just for some personal interest and satisfaction... :smile:
You can fix the housing with some 2K glue. I use normally "JB weld 300°" Very good stuff.

If you have to buy a "new one"... I had checked in this interim time all the sensors I have.
These types wont fit:
- C120-2
- 3.1101/02
-. Any combination of 2 letters with "/02" at the end will not fit -> like "AB 1/02" "YF 1/02" etc.
All these "x2" sensors have a similar housing / shell but another values.

So the link above is okay.

Good luck {top}
Hast Du einmal etwas Gutes gefunden, mußt Du es pflegen!


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