Workshop Manual Porsche K Jetronic Type17 Ch-Books Pdf

WORKSHOP MANUAL Porsche K Jetronic type17 ch
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Test Equipment 4, Component Location 5, Vacuum Diagram 9. Trouble Shooting Chart 10, Vacuum Leaks 11, Component Tests. Air Flow Sensor 12, Fuel Pump 17, Cold Start System 18. Warm Up Regulator 19, System Pressure 22, Leakage Test 23. Testing Injectors 23, Comparative Test 24, Idle Speed and CO Adjustment 26.
Mounting Pressure Tester 30, Component Repair, Fuel Distributor Repair 911 914 32. Fuel Distributor Repair 928 33, Fuel Pump Repair 34. Pressure Regulator Repair 35, Warm up Regulator Repair 911 35. Injector Removal 928 36, Throttle Activated Valve 36. Electric Wiring Diagram 37, Parts List 39, Test Sheet 40.
2 ROBERT BOSCH Porsche K Jetronic, INTRODUCTION, Testing Procedures The construction and opera Always use new gaskets seals and 0 rings when. tion of the K Jetronic CIS fuel injection system is installing components or fuel lines . different from other fuel injection systems The, technical instruction booklet Fuel Injection Con When installing the mixture control unit tighten the. tinuous Injection System CIS at the back of the fastening screws uniformly . manual describes the components and operation of, the K Jetronic fuel injection system in detail A Whenever work is performed on the fuel injection. thorough understanding of the various compo system the idle and CO must be adjusted . nents is required before working on K Jetronic fuel. systems How to use this manual Use the trouble shooting. chart to find the cause s for a given symptom The. Before trouble shooting testing or adjusting the cause column will indicate what component s . K Jetronic fuel injection system the ignition sys should be tested Each component test instruction is. tem and the mechanical system of the engine a complete instruction One component may be. compression valve timing etc must be within checked by following the test instructions for the. specification and operating properly Verify that specific component or the entire system can be. these systems are in proper working order before checked by following all the component instructions. proceeding further in order , K Jetronic fuel systems have an electric safety The Tool List and Component Location sections will. circuit which prevents the electric fuel pump and help identify the necessary tools and help locate. other electrical devices from operating unless the vehicle components to be tested Specific compo . engine is running or being started The electric nent removal and installation information can be. safety circuit can be bridged to apply voltage to any found in Mounting the Pressure Tester and Com . electrical component without running or starting ponent Repair The Electric Wiring Diagram section. the engine This procedure can be found in the shows how to bridge the electric safety circuit to. Electric Wiring Diagram section of the manual apply voltage to electrical components without run . ning the engine Replacement parts lists and com , In addition 911 SC models use a thermo valve plete test specifications can be found at the end of.
which enriches the fuel mixture during starting by the workshop manual . blocking the warm up regulator vacuum which de , creases control pressure After starting the valve. opens by means of an electric heating element ,Several component tests Auxiliary Air Valve and. Warm up Regulator require that the engine is cold . For cold tests the engine must not have been run,for several hours preferably overnight . Most vehicles since 1978 have fuel distributors,which use push valves in the system pressure. regulator to maintain pressure Several component, tests require special testing procedures for fuel.
distributors with push valves The Fuel Pump sec , tion describes in detail how to identify a fuel dis . tributor with a push valve in the system pressure. regulator , Thoroughly clean the fuel fittings before removing. any fuel lines Dirt must not enter the fuel system. under any circumstances Do NOT bend the steel,fuel lines When removing fuel lines always hold. the hex fitting on the component with one wrench, while loosening the fuel line with another wrench . Do not bend the steel type fuel lines ,K Jetronic Porsche ROBERT BOSCH 3.
TEST EQUIPMENT, TOOL PART NUMBER APPLICATION, Pressure Tester KDEP 1034 tests all working pressures. Connecting Parts KDEP 1034 10 pressure tester fuel line adapters. KDEP 103411013 for various engines, KDEP 1034 11, Wrench KDEP 1035 adjusts idle mixture CO all except. manufacturer tool adjusts idle mixture CO for 928. Guide Rings KDEP 1040 10 for 80 mm diameter sensor plates. KDEP 1040114 for 110 mm diameter sensor plates, Comparative Tester KDJE 7451 tests injectors and fuel distributor. for equal delivery, Accessory Set KDJE 7451 25 for use with KDJE 7451 when engine. is fitted with steel fuel lines, Valve Tester KDJE 7452 tests injectors.
1500 cc Graduate commercially available measures fuel pump delivery. Tachometer commercially available measures engine speed for idle and. CO adjustment, CO meter commercially available measures CO for fuel mixture adjust . Vacuum Pump commercially available for testing full load enriched warm . up regulators,4 ROBERT BOSCH Porsche K Jetronic, COMPONENT LOCATION 911T 911 911S. through model 1975, Mixture Control Unit 1 Injectors 2 The Start Valve is located on back. of intake manifold below the venturi assembly The Thermo time. Switch is located on engine block below the secondary air pump . Warm up Regulator 1 Fuel Pump Test Point arrow Bridging Electric Safety Circuit. Electric Fuel Pump Secondary Air Pump Pressure Hose arrow . K Jetronic Porsche ROBERT BOSCH 5, COMPONENT LOCATION 911 911s 911SC. beginning model 1976, Mixture Control Unit with Air Filter Removed 1 Throttle Valve As Injectors 5 Auxiliary Air Valve 6 .
sembly 2 Intake Housing 3 Secondary Air Pump 4 , Fuel Pump Protective Cover above Fuel Pump Fuel Pump Test Point arrow CO Test Point for Vehicles with Catalytic Con . 6 ROBERT BOSCH Porsche K Jetronic, COMPONENT LOCATION 924. 1 Start Valve hidden , 2 Warm up Regulator, 3 Auxiliary Air Valve. 4 Injectors, 5 Fuel Filter, 6 Mixture Control Unit. Nv p, Thermo time Switch aii viewed from Fuel cumulatois Noise Exhaust Gas Ac ii il itiun b.
underneath engine Dampers 3 arrow , Fuel Pump and Fuel Accumulator 1976 model Fuel Pump Test Point arrow Secondary Air Pump Pressure Hose arrow . K Jetronic Porsche ROBERT BOSCH 7, COMPONENT LOCATION 928. Start Valve 1 Auxiliary Air Valve 2 Thermo time Switch 3 Injector Mixture Control Unit. 4 Warm up Regulator 5 , Fuel Pump Protective Cover above Fuel Fuel Accumulator and Fuel Filter located in. Pump No 1 below right rear wheel well, Fuel Pump No 2 located under right rear Fuel Pump Test Point arrow Bridging Electric Safety Circuit relay No XVII. fender arrow ,8 ROBERT BOSCH Porsche K Jetronic, VACUUM DIAGRAM.
Lzz z 6, 911 since 1976, 1 Throttle Valve Assembly. 2 Electro Air Valve, 3 Auxiliary Air Valve, 4 Thermo valve only 911 SC . 5 Warm up Regulator, 6 Ignition Distributor, 7 Exhaust Gas Recirculation Valve only California . 8 Changeover Dump Valve, 9 Vacuum Limiter, 10 Vacuum Takeoff for Auxiliary Air Valve and Auxiliary Air Device. 11 Vacuum Takeoff Power assisted Brake System, K Jetronic Porsche ROBERT BOSCH 9.
TROUBLE SHOOTING CHART, 0 , c r o h, h, P, o a, o y c. s clb o J0 , y y sc a y y, a a y Q, c 0 , L c by, a a. 10 0 t t 0 0 Vacuum system leaking see Vacuum Leaks . Air flow sensor plate and or control plunger not moving. smoothly see Air Flow Sensor Movement , Air flow sensor plate stop incorrectly set see Air Flow. Sensor Position , Auxiliary air valve does not open see Auxiliary Air Valve . Auxiliary air valve does not close seeAuxiliaryAir Valve . mo Electric fuel pump not operating see Fuel Pump . Defective cold start system see Cold Start System . IN Leaking cold start valve see Cold Start System . 0 Incorrect cold control pressure see Warm up Regulator . Warm control pressure too high see Warm up, Regulator .
11 Do 0 IIN No Warm control pressure too low see Warm up Regulator . 0 Incorrect system pressure see System Pressure , Fuel system pressure leakage see Fuel Leaks . 10 , 11o Injection valve s leaking opening pressure too low see. Testing Injectors , 00 Unequal fuel delivery between cylinders see. Comparative Test , No No Basic idle and or CO adjustment incorrect see Idle and. CO Adjustment , Throttle plate does not open completely.
10 ROBERT BOSCH Porsche K Jetronic,VACUUM LEAKS, There must be no air leaks in the air intake system . Any air drawn into the engine without passing, through the air flow sensor will cause a lean air fuel. mixture condition and improper engine operation , To test for air leaks remove the outlet hose from the. auxiliary air valve and pressurize the hose with com . pressed air Hold the throttle plate open and coat all. air fittings arrows below with soapy water Bubbles. indicate a leak ,Replace any defective hoses gaskets or seals . K Jetronic Porsche ROBERT BOSCH 11, AIR FLOW SENSOR updraft only .
Sensor Plate Plunger Movement Engine temperature, must be above 20 C 68 F Remove the rubber boot. from the air flow sensor Bridge the electric safety. circuit see Electric Wiring Diagram Switch the igni . tion on for 10 seconds to apply control pressure to the. Fully lift the sensor plate up by hand to its maximum. deflection as shown Even resistance must be felt over. the entire lever movement If not the air flow sensor. plate is not moving freely see below , Now push the sensor plate down rapidly almost back. to its rest position The plunger will not follow the. rapidly moving sensor plate but the shock of the, plunger hitting the sensor plate lever when it does. come down must be felt If this cannot be felt the. plunger is not moving freely see below , Fully lift the air flow sensor plate up to its maximum. deflection When released the sensor plate must fall. back to its rest position after bouncing once or twice. on the spring stop If not the air flow sensor plate is. not moving freely see below , If the air flow sensor plate does not move freely .
loosen the mounting screws around the air flow, sensor housing to check if housing warpage is caus . ing the lever to bind If necessary replace the gasket. under the air flow sensor and uniformly tighten the. fastening screws , If the plunger does not move freely remove the fuel. distributor from the air flow sensor see Fuel Dis . tributor Repair Remove the plunger from the fuel, distributor If it is necessary to blow compressed air in. the control pressure connection hole to free the, plunger hold the plunger with your hand as shown to. prevent the plunger from falling out of the fuel dis . tributor Clean the plungerwith an appropriate solvent . If the plunger still binds in its barrel replace the fuel. distributor ,12 ROBERT BOSCH Porsche K Jetronic,Air Flow Sensor Plate Position Remove the rubber.
boot from the air flow sensor The sensor plate must. be flat and pass through the narrowest part of the. funnel without touching the sides , If the sensor plate touches the sides of the funnel . loosen the sensor plate fastening screw Insert the. appropriate guide ring see Too List Hold the fasten . ing screw with pliers to prevent the plate from moving. down as shown When the guide ring is in place , tighten the fastening screw to 5 0 5 5 Nm 3 7 4 0 ft. Ibs Then loosen the screw and retorque the fasten . ing screw again to the same value The air flow sensor. plate must not now be able to be turned by hand , Bridge the electric safety circuit see Electric Wiring. Diagram Switch the ignition on for 10 seconds to,apply control pressure to the plunger . The upper edge of the sensor plate should be flush. with the beginning of the upper cone as shown The, upper edge of the sensor plate may be as much as 0 5.
mm below the beginning of the upper cone but must. NOT project up into the cone at all , Adjust the sensor plate position by removing the air. filter and bending the wire loop on the spring stop. arrow or turning the adjusting screw 1 Tighten the. lock nut before rechecking the sensor plate position . K Jetronic Porsche ROBERT BOSCH 13, AIR FLOW SENSOR downdraft only . Sensor Plate Plunger Movement Engine temperature, must be above 20 C 68 F Remove the air filter from. the air flow sensor Bridge the electric safety circuit. see Electric Wiring Diagram Switch the ignition on. for 10 seconds to apply control pressure to the, Fully push the sensor plate down by hand to its. maximum deflection as shown Even resistance must, be felt over the entire lever movement If not the air.
flow sensor plate is not moving freely see below . Now pull the sensor plate up rapidly almost back to. its rest position The plunger will not follow the. rapidly moving sensor plate but the shock of the, plunger hitting the sensor plate lever when it does. come down must be felt If this cannot be felt the. plunger is not moving freely see below , Fully push the air flow sensor plate down to its. maximum deflection When released the sensor plate. must fall back to its rest position after bouncing once. or twice on the spring stop If not the air flow sensor. plate is not moving freely see below , If the air flow sensor plate does not move freely . loosen the mounting screws around the air flow, sensor housing to check if housing warpage is caus . ing the lever to bind If necessary replace the gasket. under the air flow sensor and uniformly tighten the. fastening screws , If the plunger does not move freely remove the fuel.
distributor from the air flow sensor see Fuel Dis . tributor Repair Remove the plunger from the fuel, distributor If it is necessary to blow compressed air in. the control pressure connection hole to free the, plunger hold the plunger with your hand as shown to. prevent the plunger from falling out of the fuel dis . tributor Clean the plunger with an appropriate solvent . If the plunger still binds in its barrel replace the fuel. distributor ,14 ROBERT BOSCH Porsche K Jetronic, Air Flow Sensor Plate Position Remove the air filter. from the air flow sensor The sensor plate must be, flat The chamfered edge of the sensor plate must face. down The word top or five punch marks are,stamped on the top of the sensor plate .
The sensor plate must pass through the narrowest, part of the funnel without touching the sides If the. sensor plate touches the sides of the funnel loosen. the sensor plate fastening screw Insert the appropri . ate guide ring see Too List Hold the fastening screw. as shown to prevent the sensor plate from moving,down When the guide ring is in place tighten the. fastening screw to 5 0 5 5 Nm 3 7 4 0 ft Ibs Then . loosen the screw and retorque to the same value The. air flow sensor plate must not now be able to be,turned by hand . Bridge the electric safety circuit see Electric Wiring. Diagram Switch the ignition on for 10 seconds to,apply control pressure to the plunger . The upper edge of the sensor plate should be flush. with the beginning of the upper cone as shown The, upper edge of the sensor plate may project up as.
much as 0 5 mm above the beginning of the upper, cone but the lower edge of the sensor plate above. the chamfer must not project down into the lower, cone at all . If the sensor plate is too high very carefully tap the. guide pin arrow deeper into the housing Caution , Make this adjustment very carefully Adjustment sev . eral times in both directions will loosen the press fit of. the pin possibly causing engine damage K,K Jetronic Porsche ROBERT BOSCH 15.


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