Thank you for your reply, The engine is hot right now and the rains are moving in. First thing in the morning I will check out the system with your suggestions. So the engine should run even with the ECU and ICV disconnected? What you're doing is using the O2 sensor to determine the optimum air/fuel mix? Makes perfect sense.

Got the new O2 sensor installed this morning. The OE unit was covered with soot. Using the original ECU and the engine cold, the engine would fire and then die. Repeated several times and was finally able to get it to run, but only by pumping the throttle until the RPMs got above 1K RPMs then I was able to limp it up to 6k and it ran a little rough, but it ran. Until I let the RPMs drop under 1K and the engine died.


So I dropped the sensor plate 1/8 turn. Some good. Dropped another 1/8 turn and again it started a little better but died again. So I nursed it again and was able to get some RPMs and get the engine up to speed. Ran the engine at 5-6K and got it up to 90deg C. Let off the gas, the engine hit 1K and died. I can not get a warm start.


The entire fuel system has been replaced. FD has been rebuilt. Everything went back together using only finger pressure, Nothing was forced. I have not done a detailed flow test of the FD, but fuel delivery was equal at each outlet. There is a 0.4 BAR difference between System and Control pressures.


When I researched the FD rebuild, it was noted that the FD Plunger Nut is set at 0.6mm, "to start." Per the Bosch KE-Jetronic manual. From what I get out of the manual, if the Plunger drops too far down, the Metering Edge of the plunger will shut the fuel off. At least with my limited knowledge, that seems what would happen. Could the Plunger Nut need to be moved up? It would seem like the Metering Edge of the FD Barrel and Plunger has to be as close together as possible. Foot off the gas and engine off, and the Plunger and Nut would shut off all fuel. The metering edge would shut down the fuel to the injectors and the seal of the Plunger Nut would seal the bottom of the Plunger. Any movement up, due to the Sensor Plate dropping, would open the fuel to allow the engine to run either thru the ICV or the Throttle. Does that make any sense?