924 Turbo
New dimension, measured from cylinder head mating face to valve head:
Intake 5.0mm Wear limit: Intake 5.3mm
Exhaust 4.7mm Exhaust 5.2 mm
Carry out check with new valve. Keep material loss to a minimum.
Tightening Specifications - Cylinder Head Bolts • 924
Tightening sequence for cylinder head
Tightening specifications using the turning angle method-924-inductlon engine
Tightening is performed in two stages, following the sequence shown in the diagram at each stage. Reverse sequence when undoing the bolts.
Turning angle tightening method
Tightening in two stages (with screws with internal serrations)
1st stage 65 Nm
2nd stage 180°= 1/2 tum
Tightening specifications for cylinder head bolts - 924 turbo
1. Tighten cylinder head bolts in prescribed sequence, in stages, to 40 Nm, 80 Nm and 110 Nm.
2. Retighten cylinder head bolts after at least 60 minutes (to allow for settling of cylinder head). To do so, loosen bolt no. 1 (see tightening sequence) approx. ½ a turn and tighten to 110 Nm. Repeat this procedure with the remaining bolts in the prescribed sequence. Bring engine up to operating temperature (oil temperature approx. 80° С). Allow engine to cool and give cylinder head bolts a final tightening as described under 2.
Machining the Cylinder Head Mating Face
Permissible unevenness of mating face: 0.1 mm
Max. reworking depth 0.4 mm
Peak-to-valley height = 0.015 mm
Size Worn A = 139.55mm
Main Testing and Adjusting Values for Engine
Engine type 924 |
Engine type 924 turbo |
||||||
|
XK,XJ |
XG,XE |
VC |
|
M31/D1/02 |
M31/03/04 |
Mod. 81 (Sweden, Australia) |
Electric fuel pump Delivery rate |
Min. 750 cm3/30 s |
as XK, XJ |
as XK, XJ |
Electric fuel pump Delivery rate |
min. 1050cm3/30s |
as 01/02 |
as 01/02 |
System pressure test value |
4.5...5.2 bar |
as XK, XJ |
as XK, XJ |
System pressure test value |
5.8...6.5 bar |
as 01/02 |
as 01/02 |
Adjust, value |
4.7...4.9 bar |
as XK, XJ |
as XK, XJ |
Adjust, value |
6.0...6.3 bar |
as 01/02 |
as 01/02 |
Control pressure cold (approx. 20° C) |
1.3...1.7bar |
as XK, XJ |
1.7...2.1 |
Control pressure cold (approx. 20° C) |
2.0...2.4 bar |
2.4...2.8 |
1.3...1.7 |
Control pressure warm |
3.4...3.8 bar |
as XK, XJ |
as XK, XJ |
Control pressure warm without overpressure |
3.45...3.85 bar |
as 01/02 |
3.1 ...3.5 |
Leakiest |
|
|
|
Leak test |
|
|
|
Min. pressure after 10 min. |
1.7 bar |
as XK, XJ |
as XK, XJ |
Min. pressure after 10 min. |
2.0 bar |
as 01/02 |
as 01/02 |
Min. pressure after 20 min. |
1.5 bar |
as XK, XJ |
as XK, XJ |
Min. pressure after 20 min. |
1.7 bar |
as 01/02 |
as 01/02 |
Opening pressure of inject valves |
2.5...3.6 bar |
as XK, XJ |
as XK, XJ |
Opening pressure of injection valves |
2.7...3.8 bar |
as 01/02 |
as 01/02 |
Ignition timing with vacuum hose disconnected |
10° CA before TDC for 950 ± 50 rpm |
|
|
Ignition timing with vacuum hose disconnected |
M31/01 25° CA before TDC at 2000 rpm M31/02 20° CA before TDC at 2000 rpm |
Digital advance unit (DZV) |
|
Ignition timing with vacuum hose connected |
|
3° CA after TDC for 950 ± 50 rpm |
0° CA = TDC for 950 ± 50 rpm |
|
|
|
|
Test |
Testing and Adjusting values 924 |
Special notes |
Idle speed setting Idle speed rpm |
950 ± 50 rpm 750...800 rpm (from mod. 81 USA, California, Canada) 1000 + 50 rpm (from mod. 81, Japan, automatic) |
All consumers switched off |
CO content % |
1.0...2.0% USA and Canada Mod. 78 0.5... 1.0 % * (measured upstream of cat.) Mod. 79 0.7... 1.1 % * (measured upstream of cat.) Mod. 80 0.6...1.0 % (measured upstream of cat.) from mod. 81 0.5...1.0 % (measured upstream of cat.) |
*Air pump and activated charcoal container not connected Plug connector for oxygen sensor not connected |
|
California Up toMod.79 max. 0.7 %* (measured upstream of cat.) Mod. 79 0.8... 1.2 %* (measured upstream of cat.) Mod. 80 0.6...1.0 % (measured upstream of cat.) Frommod.81 0.5...1.0 % (measured upstream of cat.) |
Plug connector for oxygen |
|
Japan Mod. 78 0.5...1.0 %* (measured upstream of cat.) Mod. 79 0.7... 1.1 %* (measured upstream of cat.) Mod. 80 0.6....1,0 % (measured upstream of cat.) From mod. 81 0.6... 1.0 % (measured upstream of cat.) |
Plug connector for oxygen sensor not connected |
Test |
Testing and Adjusting Values 924 turbo (GT) |
Special notes |
Idle speed setting |
|
from mod. 81 (DZV ignition system) with cold intake airtemp. Sensor |
Idle speed rpm |
900 ± 50 rpm Mod. 79/80 (Europe, USA, Japan and Canada) < 900 rpm from mod. 81 |
ignition marking in insp. aperture |
CO content % |
0.5...1.0 Mod. 79/80 (Europe, USA, Japan and Canada) 0.5...1.5 from mod. 81 1.0. ..2.0 Australia, Sweden |
measured upstream of cat., plug connector for oxygen sensor not connected |
Measuring Boost Pressure 924 turbo
Model 79/80 |
from Model 81 |
Europe USA |
Europe USA |
0.67...0.73bar 0.43...0.47bar |
0.62...0.68 bar 0.43...0.47 bar |
924 Саггега GT 0.72...0.78 bar
V-Belt Dimensions
924 V-belt for alternator |
mm 9.5 x 888 LA without teeth |
V-belt for alternator as from mod. 81 |
mm 9.5 x 888 LA with teeth |
V-belt for air-conditioning compressor |
mm 12.5х900 LA without teeth |
V-belt for compressor as from mod. 79 |
mm 13/12.5 x 875 la with teeth |
V-belt for air pump (air injection) |
mm 9.5 x 771 LA |
924turto V-belt for alternator as from mod. 81 |
mm 9.5 x 1048 LA without teeth mm 9.5 x 1050 LA with teeth |
Coolant Mixing Table
Frost protection to |
Antifreeze |
Water |
Antifreeze |
Water |
-25°С |
40% |
60% |
2.81 |
4.21 |
-30°C |
45% |
55% |
3.21 |
3.81 |
-35°С |
50% |
50% |
3.51 |
3.51 |
Page Transmission and clutch
Torque Specifications Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (4-speed transmission type 088)
Location |
Thread |
Tightening torque Nm (ftib) |
Side transm. Flange |
M8 |
25(18) |
Side transm. cover |
M8 |
27 (20) |
Cover for shifting shaft |
M6 |
8(6) |
End shield |
M8 |
24(18) |
Drive shaft |
M8 |
24 (18) |
Drive shaft |
M8 |
24(18) |
Oil filler screw |
M24 |
25(18) |
Oil drain screw |
M24 |
25(18) |
Reverse gear pin |
M8 |
25(18) |
Reversing lever bearing |
M10X1.5 |
35(26) |
Shifting lock |
M14X1.5 |
30(22) |
Reversing lever |
M18x1.5 |
30(22) |
Crown gear |
M10x1 |
85...100 (63...74) |
Flanged shaft to diff. gear |
M8 |
25(18) |
Protective tube to transmission case |
M7 |
10...16 (7.5...12) |
Joint shaft |
M8 |
42(31) |
Shifting lever mounting |
M8 |
21 (15) |
Joint rod to intermediate shifting lever |
M8 |
21 (15) |
Joint rod to transmission case |
M8 |
14(10) |
Reversing light switch |
M18x1.5 |
30(22) |
Exhaust line to transmission |
M10 |
45(33) |
Exhaust line to Transaxle system |
M8 |
10 (7.5) |
Front muffler to exhaust pipe |
M8 |
20(15) |
Central tube housing to transmission case |
M12 |
85 (63) |
Central housing to transmission case |
M10 |
42(31) |
Shift lever plate to central tube |
M8 |
21 (15) |
Central shaft to transmission shaft |
M8x35 |
30 (22) |
Central tube flange to clutch housing |
M10X35 |
42(31) |
Clutch housing to engine flange |
M10x1.5 M12x1.5 |
45 (33) 75(55) |
Transmission bearing to body |
M10 |
42(31) |
Bearing bracket to transmission |
M8 |
25(18) |
Clutch lever |
M8 |
15(11) |
Clutch to flywheel |
M8 |
32 (24) |
Guide tube to clutch housing |
M7 |
10...16(7.5...12) |
Support strut to tans-mission (USA) |
M10 |
42 (31) |
Arrester to central tube (USA) |
M8 |
20(15) |
Torque Specifications - Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (5-speed transmissions type 016 Z and 016 Y)
Location |
Thread |
Tightening torque Nm (ftib) |
Drive shaft |
M30 x 1.5 |
220...240 (161 ...175) |
Drive shaft |
M22 x 1.5 |
160...180 (110...133) |
Driving shaft |
M24 x 1.5 |
200...220 (147...162) |
Flange shaft to diff. gear |
M10X1.5 |
47...50 (35...37) |
Shift lock/rear axle and wheel housing |
M10X1.5 |
15...18 (11 ...13) |
Mounting of casing and cover |
M8х1.25 |
22...25(16...18) |
Crown gear/diff. Gear |
M12 x 1.25 |
150...160 (111 ...118) |
Locking pawl/rear axle casing |
M6x1 |
8...10(6...7.5) |
Reversing light switch/ wheel housing |
M18X1.5 |
25...32 (18...24) |
Oil filler screw/wheel housing |
M24 x 1.5 (tapered) |
20...25 (15...18) |
Oil drain screw/rear axle casing |
M25X1.5 (tapered) |
20...25(15...18) |
Tension plate, rear axle casing, wheel housing |
M8х1.25 |
22...25(16...18) |
Joint shaft |
M8 |
42(31) |
Exhaust tine to transmission |
M10 |
45(33) |
Exhaust line to transaxle system |
M8 |
10(7.5) |
Front muffler to exhaust pipe |
M8 |
20(15) |
Central shaft to transmission shaft |
M8x35 |
35 (26) |
Central tube flange to clutch housing |
M10X35 |
42 (31) |
Clutch housing to engine flange |
M10x1.5 M12x1.5 |
45(33) 75(55) |
Clutch lever |
M8 |
15(11) |
Clutch to flywheel |
M8 |
32 (24) |
Guide tube to clutch housing |
M7 |
10...16 (7.5...12) |
Transmission bearing to transmission |
M10 |
42(31) |
Transmission bearing to rear axle transverse tube |
M10 |
42(31) |
Central tube to transmission case |
M12x1.5 |
85 (63) |
Shifting rod to inner shifting rod/transmission |
M8 |
18(13) |
Bearing bracket to floor unit - center |
M6 |
9(7) |
Angled linkage to guide rod |
BM10 |
23(17) |
Torque Specifications - Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (5-speed transmissions type 016/8 and 016/9)
Location |
Thread |
Tightening torque Nm (ftib) |
Oil filler screw to transmission case |
M24 |
25(18) |
Oil drain screw to transmission case |
M24 |
25(18) |
Protective tube to transmission case |
M7 |
10...16 (7.5...12) |
Shifting shaft to transmission case |
M6 |
6...10(4.5...7.5) |
End shield to transmission case |
M8 |
24 (18) |
Ball bearing to drive shaft |
M10 |
50(37) |
Cover to end shield |
M8 |
25(18) |
5th gear wheel to driving shaft |
M10 |
50 (37) |
Shifting lock to end shield |
M18 |
30 (22) |
Shift travel limiter to |
M18 |
30(22) |
End shield |
M14 |
|
Reverse transfer lever to end shield |
M10 |
35(26) |
Reverse gear pin to end shield |
M8 |
20(15) |
Flanged shaft to diff. gear |
M8 |
25(18) |
Side transmission cover to transmission case |
M8 |
25(18) |
Crown gear to diff. casing |
M10 |
85...100 (63...74) |
Reversing light switch to transmission case |
M18 |
30(22) |
Joint shaft |
M8 |
42(31) |
Joint rod to transmission case |
M8 |
21 (15) |
Joint rod to transmission case |
M8 |
14 (10) |
Shift lever plate to central tube |
M8 |
21 (15) |
Exhaust line to transaxle system |
M8 |
10(7.5) |
Front muffler to exhaust pipe |
M8 |
20(15) |
Central tube housing to transmission case |
M12 |
85 (63) |
Central tube housing to transmission case |
M10 |
42 (31) |
Shifting rod mounting |
M8 |
21 (15) |
Central shaft to transmission shaft |
M8x35 |
35(26) |
Central tube flange to clutch housing |
M10x35 |
42(31) |
Clutch housing to engine |
M10x1.5 M12x1.5 |
45(33) 75(55) |
Clutch bearing to body |
M10 |
42(31) |
Bearing bracket to transmission |
M8 |
25(18) |
Clutch lever |
M8 |
15(11) |
Clutch to flywheel |
M8 |
32(23) |
Guide tube to clutch housing |
M8 |
10...16 (7.5...12) |
Clutch 924
Design
Pressure plate Contact pressure Clutch disk Clutch drive plate with riveted on lining Thickness untensioned (new) Wear limit
Lateral runout Clutch play at clutch pedal |
Single-plate dry clutch with disk spring, compact design MF215K 4810.. .5490 N 215mm
10.1-0.4 mm 8.5 mm with asymmetrical wear Max. 0.6 mm with 2OO mm 20-25 mm |
Clutch 924 turbo
Design
Pressure plate Contact pressure Clutch disk Clutch drive plate with riveted on lining Thickness untensioned (new) Wear limit Lateral runout Clutch play at clutch pedal
|
Single-plate dry clutch with disk spring, hydraulically actuated, extended design MFZ225 7200.. .7900 N 225 mm
8.1 ± 0.3 mm 6.3 mm with asymmetrical wear Max. 0.6 mm with 225 mm Approx. 3 mm |
Technical Data 4-Speed Manual Transmission Type 924 YR (924 XT*)
Ratios 1st gear 2nd gear 3rd gear 4th gear R.gear |
10:36 i=3.60 16:34 i=2.125 25:34 i = 1.360 30:29 i = 0.966 12:42 i=3.50 |
Final drive |
Hypoid drive, 12 mm offset |
Final drive ratio |
9:35 i= 3.8888 |
Climbing ability in % 1st gear 2nd gear 3rd gear 4th gear |
54 (49.5) 28 (26) 16 (14.5) 9.5 (9) |
Power transmission |
Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (20 mm Ø) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels |
Transmission weight (dry) |
45 kg (99 Ibs) |
Filling capacity |
Approx. 2.6 liters multi-grade transmission oil, SAE 75 W-9O, API classification GL 5 (or MIL-L 2105 В) or 80 W90-GL 4 |
Technical Data 5-Speed Manual Transmission Types 016 Z and 016 Y *
Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear R. Gear |
14:39(14:39) i= 2.7857 (2.7857) 18:31 (19:32) i = 1.7222 (1.6842) 23:28(27:30) i= 1.2174 (1.1111) 29:27 (31:25) i = 0.9310 (0.8064) 34:24 (35:21) i = 0.7059 (0.6000) 46:21-16:14 i= 2.5034 |
Final drive |
Helical bevel gear differential |
Final drive ratio |
7:33 i= 4.7143 (7:35 i= 5.000) |
Power transmission |
Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø20 mm) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels |
Getriebegewicht (trocken) |
45 kg (99 Ibs) |
Filling capacity |
Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-9O, API Classification GL 5 (orMIL-L2105B) |
"Specifications for USA in brackets |
|
Technical Data 5-Speed Manual Transmission Types 016/8 and 016/9 *
Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear R. gear Final drive |
10:36 i= 3.600 16:34 i=2.125 24:35 (25:34) i = 1.458 (1.360) 28:31(30:29) i= 1.107 (0.966) 35:30 (37:27) i = 0.857 (0.729) 12:42 i= 3.500 Hypoid drive, 12 mm offset |
Final drive ratio |
9:35(9:37) i= 3.889 (4.111) |
Climbing ability in % 1st gear 2nd gear 3rd gear 4th gear 5th gear |
59 (57) 32(30) 21 (18) 14(11.5) 9.5(7) |
Power transmission |
Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 20 mm) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels |
Transmission weight (dry) |
55 kg (121 Ibs) |
Filling capacity |
Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-9O, API Classification GL 5 (or MIL-L 2105 В) or 80 W90-GL4 |
"Specifications for USA in brackets |
|
Torque Specifications - Automatic Transmission 924
Location |
Thread |
Tightening torque Nm (ftib) |
Oil filler transmission case |
M24X1.5 |
20 (15) |
Flange shaft to differential |
M8х1.25 |
25(18) |
Locking plate to adjusting ring |
M6x1 |
8(6) |
Planetary gear to axle drive |
M8х1.25 |
29(21) |
Governor cover to axle housing |
M8х1.25 |
9(7) |
Cover for diff. pinion to axle housing |
M8х1.25 |
25(18) |
Cover of axle housing to axle housing |
M8х1.25 |
25(18) |
Crown gear to differential |
M10x1 |
78...93 (58...69) |
Governor shaft to governor housing |
M5х0.8 |
3.5 (3) |
Screw plug tor measuring connection |
M10x1 |
15(11) |
Lever for hand slide valve to transmission case |
M6x1 |
3.5 (3) |
Detent segment to lever for hand slide valve |
M16X1.5 |
20.5 (15) |
Lever of kickdown valve to shaft of accelerator rod |
M8х1.25 |
17(13) |
Detent spring to transmission case |
M8х1.25 |
20.5 (15) |
Pump to transmission case |
M6x1 |
7.0(5) |
Slide valve case to transmission case |
M6x1 |
3.5(3) |
Oil strainer to slide valve case |
M5х0.8 |
3.5(3) |
Oil pan to transmission case |
M8х1.25 |
20.5 (15) |
Intermediate plate to transmission case |
M5х0.8 |
3.5(3) |
Facing plate to slide valve case |
M5х0.8 |
3.5(3) |
Supporting plate to duct plate |
M5х0.8 |
-3.5(3) |
Intermediate and duct plates to slide valve case |
M5х0.8 |
3.5(3) |
Cover plate to pump housing |
M4х0.7 |
1.4(1) |
Adjustment brake strap 2nd gear |
M12X1.5 |
19.6(14) |
Converter to drive plate |
M8 |
21 (15) |
Torque Specifications -Automatic Transmission Actuating Elements 924
Location |
Thread |
Tightening torque Nm (ftib) |
Shift lever guide to shift bracket |
M6 |
9(7) |
Locking segment to shift bracket |
M6 |
10 (7.5) |
Mount of shift actuation and side seal guide |
M6 |
10(7.5) |
Retaining bracket to transmission |
M8 |
21 (15) |
Cable to bracket |
M8 |
8±1 (6±1) |
Cable to retaining bracket |
M8 |
8±1(6±1) |
Cable to transmission lever |
M8 |
5±1(4±1) |
Torque Specifications -Accelerator Actuation (Automatic Transmission) 924
Location |
Thread |
Tightening torque Nm (ftib) |
Guide pulley to bracket |
M6 |
9(7) |
Guide pulley bracket to intake pipe |
M6 |
9(7) |
Control cable to bracket |
M8 |
5(4) |
Control cable to transmission |
M10 |
30(22) |
Control cable to central tube |
M4 |
1.4(1) |
Rubber to lever for accelerator actuation |
M6 |
9(7) |
Rubber to lever |
M6 |
9(7) |
Support to bracket for guide pulley |
M6 |
9(7) |
Support for guide pulley to crankcase |
M8 |
21 (15) |
Accelerator pedal to floor plate |
M6 |
5(4) |
Torque Specifications-Central Tube (Automatic Models) 924
Location |
Thread |
Tightening torque Nm (ftib) |
Torque converter mounting to rear bell |
M8x25 |
21 (15) |
Mounting of central shaft to flange shaft |
M8 |
35 (26) |
Central tube flange to clutch bell |
M10x35 |
42(31) |
Central tube housing to transmission case |
M12X1.5 |
85 (63) |
Central tube housing to transmission case |
M10x-1.5 |
42(31) |
Torque converter to driver plate |
M8x12 |
21(15) |
Mounting of central shaft to clamper |
M8 |
35 (26) |
Damper to flywheel |
M8x18 |
21 (15) |
Cover to clutch housing |
6.3х19 |
5(4) |
Stop basket to damper |
M8x25 |
21 (15) |
Technical Data - Automatic Transmission 924
Internal designation |
RK(RL) |
|
Number of speeds |
3 forward, 1 reverse and parking lock |
|
Ratios: |
Driving position 1 i = 2.5517 Driving position 2 i= 1.4483 Driving position D i=1.0000 Driving position R i= 2.4615 |
|
Clutch |
Hydrodynamic torque converter |
|
Torque converter ratio |
2.2 (up to mod. 79 = 2.1 from mod. 80 = 2.44) |
|
Stall speed |
2600 ± 200 (up to mod. 79 = 2100 ± 200 from mod. 80 = 2450 ± 200) |
|
Torque conv. code letter |
К (up to mod. 79 = J, from mod. 80 = M) |
|
Final drive |
Hypoid drive set |
|
Hypoid offset |
44mm |
|
Axle ratio |
11/38(11/41) |
|
Filling capacities Final drive |
approx. 11 multi-grade gear oil, SAE 75 W-90, API classification GL 5 (or MIL-L 2105 В) |
|
Automatic section |
61 total filling capacity with ATP Dexron, torque converter capacity 2.51, change quantity approx. 2.81, observe marking on top-up reservoir |
|
Specifications for USA in brackets
Pressure-Testing Hydraulic Control Unit
Up to model 80
|
From model 81 |
||||||
Selector Lever. Pos. |
Accel. pedal pos. |
Main press. In bar Overpressure (kg/cm2) |
Test con-dition |
Selector lever pos |
Accel.. pedal pos. |
Main press. In bar Overpressure (kg/cm') |
Test-condition ) |
D |
Idle (zero accel.) |
2.95 ± 0.05 |
|
D |
Idle (zero accel.) |
2.95 ± 0.05 |
|
|
|
|
Speed more than 50 km/h* |
|
|
|
Speed more than 50 km/h* |
D |
Full accel. |
6.85 ± 0.05 (590+005) |
|
D |
Full accel. |
6.85 ± 0.05 (5,90 ± 0,05) |
|
R |
Idle (zero accel.) |
7.35 ± 0.3 |
Vehicle stationary |
R |
Idle (zero accel.) |
9.6 ± 0.3 (9.4 ± 0.3) |
Vehicle stationary |
R |
Full accel. |
over 18 |
at stall speed |
R |
Full accel. |
over 18 |
at stall speed |
•Specifications for USA in brackets
Torque Specifications - Manual Transmission 924 turbo (Types G31/01, G31/02, G31/03)
Location |
Thread |
Tightening torque Nm (ftib) |
Drive shaft |
M 30 x 1.5 |
220 (162) |
Driving shaft |
M 24 x 1.5 |
220 (162) |
Flange shaft to diff. gear |
M10x1.5 |
46(34) |
Shift lock/rear axle and wheel housing |
M10x1.5 |
18(13) |
Mounting of casing and cover |
M 8х1.25 |
25(18) |
Crown gear/diff. gear |
M 12 x 1.25 |
150(111) |
Locking pawl/rear axle casing |
M6x1 |
10 (7.5) |
Reversing light switch/ wheel housing |
М18х1.5 |
30(22) |
Oil filler screw/wheel housing |
М24Х1.5 (tapered) |
25(18) |
Oil drain screw/rear-axle casing |
М25х1.5 (tapered) |
25(18) |
Tension plate, rear axle casing, wheel housing |
M 8х1.25 |
25(18) |
Joint shaft to joint flange |
M 8х1.25 |
42(31) |
Torque Specifications - Clutch, Central Tube, Transmission Suspension, Shift Actuation 924 turbo (Type G31/01, G31/02, G31/03)
Location |
Thread |
Tightening torque Nm (ftib) |
Clutch |
|
|
Guide tube to clutch housing |
M7 |
12(9) |
Clutch and ring gear mounting |
M8 |
25(18) |
Flywheel to crankshaft |
M12 |
100 (74) |
Clutch housing to engine |
M12 M10 |
75(55) 45 (33) |
Clutch release shaft with clutch casing |
M6x35 M6 |
9.5 (7) 7.5(5) |
Clutch operating cylinder to clutch housing |
M8x28 |
21 (15) |
Central tube |
|
|
Central shaft to transmission input shaft |
M10x46 |
80 (59) |
Central tube flange to clutch housing |
M10x35 |
42(31) |
Central tube flange to transmission case |
M12 |
85 (63) |
Transmission suspension |
|
|
Transmission bearing to rear axle transverse tube |
M10 |
42(31) |
Transmission bearing to transmission |
M10 |
42(31) |
Shift actuation |
|
|
Bearing support to center of floor unit |
M6x10 |
9(7) |
Shifting rod to transmission |
M8 |
18(13) |
Angled joint to guide rod |
BM 10 |
23(17) |
Torque Specifications - Manual Transmission 924 turbo (Type 016G)
Location |
Thread |
Tightening torque Nm (ftib) |
Oil filler screw to transmission case |
M24 |
25(18) |
Oil drain screw to transmission case |
M24 |
25(18) |
Cover for shifting shaft to transmission case |
M6 |
6...10 (4.5...7.5) |
End shield to transmission case |
M8 |
24(18) |
Bait bearing to transmission input shaft |
M10 |
50 (37) |
Cover to end shield |
M8 |
25(18) |
5th gear wheel to driving shaft |
M10 |
50(37) |
Shifting lock to end shield and transmission case |
M18 |
30(22) |
Shift travel limiter to end shield |
M18 M14 |
30(22) |
Reverse-transfer lever to end shield |
M10 |
35(26) |
Reverse gear pin to end shield |
MS |
20(15) |
Flange shaft to differential |
M8 |
25(18) |
Transmission side cover to transmission case |
M8 |
25(18) |
Crown gear to differential casing |
M10 |
85...100 (63...74) |
Reversing light switch to transmission case |
M18 |
30 (22) |
Joint shaft to joint flange |
M8 |
42(31) |
Torque Specifications - Clutch, Central Tube, Transmission Suspension and Shift Actuation 924 turbo (Type 016G)
Location |
Thread |
Tightening torque Nm (ftib) |
Clutch Guide tube to clutch housing |
M7 |
12(9) |
Clutch and ring gear mounting |
M8 |
25(18) |
Flywheel to crankshaft |
M12 |
100 (74) |
Dutch housing to engine |
M12 M10 |
75(55) 45(33) |
Clutch release shaft with clutch housing |
M6x35 M6 |
9.5 (7) 7.5 (5) |
Clutch operating cylinder to clutch housing |
M8x28 |
21 (15) |
Central tube |
|
|
Central shaft to transmission input shaft |
M10x46 |
80 (59) |
Central tube flange to clutch housing |
M10x35 |
42(31) |
Central tube housing to transmission housing |
M12x75 M12x80 M10X60 |
85(63) 85(63) 42(31) |
Transmission suspension |
|
|
Transmission bearing to body |
M10 |
42(31) |
Bearing to support bracket |
M8 |
23(17) |
Support bracket to |
M8 |
25(18) |
Transmission Shift actuation |
|
|
Joint rod to transmission case |
M8 |
14(10) |
Joint rod to intermediate shifting lever |
M8 |
21 (15) |
Shifting rod mounting |
M8 |
21 (15) |
Shift lever plate to central tube |
M8x12 |
21 (15) |
Intermediate shifting lever to shifting shaft |
M8 |
22.5 (17) |
Technical Data- 5-Speed Manual Transmission G 31/01, G31/02* and G31/03
Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear R.gear |
10:36 i= 3.6000 16:34 i= 2.1250 24:35 i=1.4583 28:31 i=1.1071 37:27 i = 0.7297 12:42 i= 3.5000 |
Final drive |
Hypoid drive, 12 mm offset |
Final drive ratio |
9:35 i = 3.8889 |
Power transmission |
Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 25 mm) to transmission mounted in 3 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels |
Transmission weight (dry) |
55 kg (121 Ibs) |
Filling capacity |
Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-90, API classification GL 5 (or MIL-L21O5 B) |
Technical Data - 5-Speed Manual Transmission 016G
Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear R.gear |
12:38 i= 3.1666 18:32 i=1.7777 23:28 i=1.2174 29:27 i = 0.9310 34:24 (35:21) i = 0.7059 (0.6000) 12:16-22:48 i= 2.9091 |
Final drive |
Helical bevel gear differential |
Final drive ratio |
8:33 i = 4.1250 (7:33 i= 4.7143) |
Power transmission |
Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 25 mm) to transmission mounted in 3 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels |
Transmission weight (dry) |
45 kg (99 Ibs) |
Filling capacity (specifications for USA in brackets) |
Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-90, API classification GL 5 (orMIL-L2105B) |
Torque Specifications - Front Axle 924/924 turbo
Location |
Thread |
Tightening torque nm (ftib) |
Control arm to cross member |
M12x1.5 |
65 ± 10 (48 ± 7.5) |
Clip to control arm |
M10 |
46(34) |
Control arm to steering knuckle |
M10 |
50+10 (37+ 7.5) |
Cross member to body |
M10 |
42(31) |
Track rod to steering knuckle |
M12x1.5 |
30+20(22+15) |
Clip for stabilizer to |
M8 |
13(10) |
Body (up to Oct. 81) |
M8 |
20(15) |
Stabilizer suspension to control arm (up to Oct. 81 ) |
M10 |
20 ± 5 (15 ± 4) |
McPherson strut bearing to shock absorber strut |
M14x 1.5 |
77+3(57+2) |
Fillister head screw to clamping nut |
M7 |
13+3(10+2) |
Cover plate to steering knuckle |
M7 |
10(7.5) |
Floating caliper to steering knuckle |
M12x1.5 |
85 (63) |
McPherson strut to steering knuckle |
M12x1.5 |
100 (74) |
McPherson strut to body |
M8 |
25 ± 4 (18 ± 3) |
Spoked wheel to brake disk (LA wheel) |
M14X1.5 |
130 (96) |
Disk wheel to brake disk (st. Wheel) |
M14X1.5 |
110(81) |
Guide joint to control arm |
M7 |
25(18) |
Stabilizer suspension to body |
M8 |
23(17) |
Clip for stabilizer to suspension |
M8 |
23(17) |
Stabilizer bearing to control arm |
M8 |
23(17) |
Torque Specifications - Steering 924/924 turbo
Location |
Thread |
Tightening torque Nm (ftib) |
Track rod to steering knuckle |
M12X1.5 |
30+20(22+15) |
Universal shaft to steering gear |
M8 |
30+5(22+4) |
Steering gear to cross member |
M8 |
20+4(15+3) |
Cover for pinion bearing |
M6 |
7±1(5±1) |
Cover for thrust piece bearing |
M6 |
7±1(5±1) |
Check nut for adjusting bolt |
M10x1 |
25 ± 5 (18 ± 4) |
Track rod to steering rack |
M22X1.5 |
50 ± 7 (37 ± 5) |
Track rod joint to track rod |
M14X-1.5 |
30+10(22+7.5) |
Steering wheel to steering column |
M16X-1.5 |
45 ± 10 (33 ± 7.5) |
Steering column switch to jacket tube |
M8 |
15±4(11 ±3) |
Support bearing to body |
M6 |
5 (4) |
Universal shaft to steering column |
M8 |
30 ± 5 (22 ± 4) |
Torque Specifications - Rear Axle 924/924 turbo
Location |
Thread |
Tightening torque Nm (ftib) |
Bearing flange to transverse tube |
M10 |
46(34) |
Bearing flange to body |
M12x1.5 |
70(52) |
Thrust bearing to bearing flange |
M10 |
46 (34) |
Thrust bearing to body |
M10 |
46(34) |
Support bearing to body |
M10 |
46(34) |
Support bearing to strut |
M8 |
23(17) |
Axle control arm to rear axle strut |
M12X1.5 |
90(66) |
Axle control arm to rear axle strut |
M12X1.5 |
103(76) |
Axle control arm to transverse tube |
M12X1.5 |
61(45) |
Vibration damper to axle control arm and body |
M12X1.5 |
61(45) |
Universal shaft to final drive and rear wheel shaft |
M8 |
42(31) |
Adjusting lever to spring strut |
M16x1.5 |
245 (180) |
Stabilizer suspension to rear axle strut and stabilizer |
M10 |
46(34) |
Fastening clip to transverse tube |
M8 |
23(17) |
Wheel bearing cover to axle control arm |
M10 |
58(43) |
Wheel hub to rear wheel shaft |
M24 x 1.5 |
380 + 70 (280 + 52) |
Brake drum to rear wheel shaft |
M24X1.5 |
350 ± 50 (258 ±37) |
Cover plate to brake carrier |
M6 |
10(7.5) |
Floating caliper to brake carrier |
M12X1.5 |
85 (63) |
Brake line to floating caliper/ slave cylinder |
M10x1 |
14(10) |
Mounting bracket for brake line to brake carrier |
M6 |
10(7.5) |
Brake disk to wheel hub |
M6 |
5.0 (4) |
LA wheel to wheel hub |
M14X-1.5 |
130 (96) |
Steel wheel to wheel hub |
M14X-1.5 |
130 (96) |
LA wheel to brake drum |
M14х1.5 |
130 (96) |
Steel wheel (4-hole) to brake drum |
M14X1.5 |
110(81) |
Technical Data - Front Axle 924
Wheel suspension |
|
Wheels independently suspended on control arms and spring struts (McPherson design) |
Springing |
|
One coil spring per wheel, coaxial with spring strut |
Shock absorbers |
|
Double-acting hydraulic shock absorber struts |
Stabilizer |
Up to end model 77 Model 78 Model 79 Model 80
Model 81 some of model 82 up to end Sept. 81 In model 82 from Oct. 81 |
Standard Optional extra — 20 mm — 22 mm — 23 mm — 23 mm (21 mm) (23 mm)* 21 mm 23 mm**
20mm 21.5mm |
|
|
|
Specifications for USA, Canada, Japan in brackets *Not as indiv. optional extra M 404 **0nly for export in conjunction with optional extra M 471
Technical Data - Front Axle 924 turbo
|
Rest of world (USA, Canada, Japan- opt. extra) |
USA, Canada, Japan- basic model(from model 81 see row) |
|
Wheel suspension |
Wheels independently suspended on control arms and spring struts (McPherson design) |
||
Springing |
One coil spring per wheel, coaxial with spring strut |
||
Shock absorbers |
Double-acting hydraulic shock absorber struts |
||
|
VW (Opt. extra Koni) |
VW (Opt. extra Koni) |
|
Stabilizer Ø |
23 mm USA, Canada Japanlrommod.81 21 mm (opt. extra for USA, Canada, Japan from mod. 81 23mm in conjunction with Koni shock absorber and 14 mm rear stabilizer) from mod. 82 21.5mm |
21 mm |
|
Technical Data - Steering 924
Steering wheel |
2 spokes 383 mm up to end model 81 3 spokes 380 mm from model 82 Optional extra 4 spokes 362 mm 3 spokes 380 mm |
Steering wheel ratio in the middle |
19.15:1 |
Turning circle diameter |
10.08 m |
Track circle diameter |
9.21 m |
Steering wheel turns from lock to lock |
4.02 |
Technical Data - Steering 924 turbo
|
Rest of world (USA, Canada, Japan - opt. extra) |
USA, Canada, Japan - basic model (from model 81 see row) |
Steering wheel Ø |
380mm 360 mm (opt. extra) |
380mm 360 mm (opt. extra) |
Steering wheel ratio in the middle |
22.39:1 |
19.15:1 |
Turning circle Ø |
10.3 |
10.08 m |
Track circle Ø |
9.5m |
9.21 m |
Steering wheel turns from lock to lock |
4.02 |
4.02 |
Technical Data - Rear Axle 924
Wheel suspension
Springing
Torsion bar
Shock absorbers
Stabilizer up to end model 77 from model 78
Spring strut adjustment (angle of spring strut) up to end model 77 From model 78 With 22 mm torsion bar with 23.5 mm torsion bar (for relevant models see above)
|
Independent wheel suspension on semi-trailing arms One round torsion bar per wheel, transverse
22mm 23.5 mm in conjunction with stabilizer 14 mm 23.5 mm from model 81 USA, Canada, Japan from chassis no. 92 АО 430199 (Sept. 79) Double-acting hydraulic shock absorbers Standard Opt. extra 018 mm Standard Opt. extra 014 mm*
23°
23°40' 19°
|
* Model 80 for USA, Canada, Japan not as individual optional extra (M 404)
Model 81 and some of 82 (up to end Sept. 81 ) only export in conjunction with M471
Technical Data - Rear axle 924 turbo
|
Rest of world (USA, Canada, Japan - opt. extra) |
USA, Canada, Japan - basic model (from model 81 see row) |
Wheel suspension Springing Shock absorbers
Torsion bar Ø Spacers Stabilizer Ø
|
Independent wheel suspension on semi-trailing arms One round torsion bar per wheel, Transverse Double-acting hydraulic shock absorbers F+S F+S (Opt. extra Koni) (Opt. extra: Koni) 23.5 mm 23.5 mm 21mm per wheel - 14mm - USA, Canada, Japan from model 81 — (Opt. Extra for USA, Canada, Japan from model 81 14 mm in conjunction with Koni shock absorbers and 23 mm front stabilizer) |
|
Checking Rims
Points for measuring vertical and lateral runout on outer and inner rim shoulders. Dimension "a" = 8mm
Max. permissible vertical and lateral run-out With light alloy rims = 1.0 mm With steel rims = 1.25 mm Note It is not permitted to straighten twisted rims. |
|
Tires, Wheels, Tire Pressures
Information about permitted lire/wheel combinations is contained in the vehicle documents or Technical Information bulletins.
Tire pressures (summer and winter tires) measured with tires cold