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Old 11-20-2009, 10:30 PM
panzerwagen80 panzerwagen80 is offline
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Join Date: Oct 2009
Location: Palm Beach Gardens
Posts: 50
PROGRESS REPORT

I have had the car out of the garage and around the parking lot now twice.

I even let it run the whole time I was washing it night before last.

I changed the spark plugs and made the mistake of trying to adjust the air/fuel mixture and boy did I goof it up good!

I managed to adjust it just far enough out of whack that it died from either over fueling or starving... don't really remember which way I was tweaking it when it died.

So I thought that a good way to find the mid point would be to turn it all the way clockwise until it stopped, and then back it out a half turn at a time trying the ignition until it came back to life.

NOT MY PROUDEST MOMENT!

Then I learned something really important!

Apparently when the screw is all the way down it gets tight enough to strip the end of the little stock spring loaded extension.

(That cute little aluminum doohickey that lets you adjust it without removing the breather)

So in my moment of panic I immediately assumed the worst and thought perhaps the screw had com all the way out.

AGAIN NOT MY FINEST MOMENT.

So after an hour or so of trying to get some one to loan me a scope and a magnetic or pincer grabber I started looking online for any info that might help.

I was killing time waiting for a friend of mine to call me back with the scope when I came across a Bosch K-Jetronic manual PDF I could download.

After reading the manual thoroughly I finally understood exactly what I was dealing with.

Out to the car again and I discovered there was a large machine screw on the right side of the extension and what looked like a large brass rivet on the left side of the stock extension. So my first inclination was to try to gently pry the rivet up through the plate. Slow going and patience revealed what I was looking at was not a rivet at all but a smooth button top machine screw!!

This was the first glimpse of light at the end of what I thought would be a very long dark tunnel.

So with a little persuasion and a very small set of needle nose pliers i managed to remove this extension and not have any little pieces of metal in the air intake where they definitely do not belong.

First catastrophe averted!

Now when I inspected the business end of this thing I discovered it was the problem and not a large Allen stud rattling around in the intake.

I picked up the phone and called my friend back as he was pulling up the driveway with the scope. (We both had a good laugh over the mess I had caused)

So now the extension is off and stud was in the lever run all the way down. MAX FUEL DELIVERY!! Not a good place to have it. If I intend to adjust the air fuel a little at a time until it will start.

So i backed the stud out all the way to its stop point. Yes it has one where the threads are peened to prevent the exact problem I was afraid I had caused.

So I am now starving the engine of fuel and adjusting a little at a time so I don't flood it and have to wait.

A STRONG CAUTION!!!!

Just because these threads are punched to prevent you from pulling the stud all the way out doesn't mean it cant be done!

Back it out only until you begin to feel resistance then start adjusting clockwise in very small increments 1/8th turn at a time and try to start it with each turn until it try's to fire.

Be careful to make sure the key is OFF when you turn the adjusting screw and don't press the flap down or you may get false signs of life.

As soon as it shows it is trying to fire turn the screw clockwise in VERY tiny increments like 1/32 of a turn at a time until it starts and idles without dying.

When you have a solid idle, gently turn the stud clockwise 1/32 more and stop take your hand off the 3mm allen and listen for a 30 or so seconds. (this will give the system a chance to recover from any pressure you were applying with the tool.

These things are really touchy... A light touch and patience is a must have to adjust these K-Jetronc CIS systems.

I can't stress this enough.

Still getting a pretty lumpy idle even with the new plugs.

I have a brand new set of OEM wires coming in Monday.

I will install these as soon as I get 'em and hopefully this will solve the missing and crummy performance.

As soon as this is fixed were on to setting the timing (and possibly a new cap and rotor)

Until then I am looking into making a small aluminum plate with a 4mm rubber gromet in the center to cover the obvious vacuum leak that removing the bad extension is causing.

I can make this myself and use the bottom of the old extension as a template and two stock screws to hold it down.

I might even try to repair the extension itself with piece of a 3mm Allen.

I'm a little fuzzy on how best to attach the steel Allen to the brass plug on the bottom of the extension.

Drill & Tap a fine thread then epoxy it into place with some solid metal to metal high temp adhesive?

Any thoughts?
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