DF Engine - 1.9l Waterboxer.
 

 

Vehicle identification
Capacity 1913cc³
Number of cylinders/type 4/overhead valve
Production run 10/1982 - 12/1990
Output 44kW - 60bhp DIN @ 3700RPM
Torque 140 Nm @ 2200 RPM
Bore 94mm
Stroke 68.9mm
Compression ratio 8.6:1
Minimum octane rating 91 RON
Ignition system transistorized hall effect
Trigger location distributor
Fuel system solex carburettor
Type 34 PICT
Description carburettor - fixed jet
Valve timing at 1mm lift.
Inlet opens 4° ATDC
Inlet closes 26° ABDC
Exhaust opens. 36° BBDC
Exhaust colses. 14° BTDC
Valve dimensions.
Inlet head diameter. 35.5 mm
Inlet stem diameter. 7.94 - 7.95 mm
Inlet overall length. 122.5 mm
Inlet valve seating face angle. 45°
Exhaust head diameter 30mm
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
secondary resistance 2400 - 2500 ohms
firing order 1 - 4 - 3 - 2
distributor part number Bosch - 0 231 023 013
ignition timing 5°±1° ATDC (with crankcase breather disconnected) with vacuum.
Ignition advance checks 0°-2° @ 1500RPM w/o vacuum and basic timing
  6°-10° @ 2400RPM w/o vacuum and basic timing
  20-24 @3800RPM w/o vacuum and basic timing
vacuum advance range 14°-18° engine degrees
idle speed 750±50 RPM
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
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)
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

 
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