Cleaning Mechanical Injectors
12-24-2003 | 10:54 AM
#1
Thread Starter
Addict
Rennlist Member
Rennlist Member
Joined: Jul 2002
Posts: 2,673
Likes: 35
From: AZ
Cleaning Mechanical Injectors
For those who have K-Jetronic injection (US 1977 - 79, ROW 1977 - 83) and wish to clean the injectors. This is the procedure is per "Troubleshooting Guide K-Jetronic, 4533.2 printed 2/78.
The instructions for cleaning injection valves are:
Cleaning will only be successful if the injection valve is flushed out in the direction opposite to the normal flow [note: not in text ... there is a screen inside the injector that can get plugged up].
Tools and spare parts:
1 Bosch nozzle tester No. EFEP 60 H or locally made unit
1 pressure gauge 0 - 6 kp/cm^2 Cl. 1.0 100 mm dia.
1 reducing piece RSI 1/2" on 1/4"
(obtainable from Steinbronn, 7 Stuttgart-Feuerbach,
Kruppstrasse 34-36) to mount pressure gauge on nozzle tester
1 locally made tool
1 valve plate
1 plastic hose (80 mm long, 8 mm inside dia.) ET no. 911 201 228 00
2 hose clips ET No. 999 512 160 02
Locally made tool:
Saw open defective injection valve (approx. 7 - 10 mm from outlet aperture)
Remove spring with pincers
Clean sawn-off valve at cut section, wipe down and connect to plastic hose (8 mm inside dia.). Use hose clip No. 999 512 160 02 to secure
The fouled injection valve is inserted in the opposite free hose section and also fixed with a hose clip.
For safety reasons do not use carburettor fuel for cleaning; use only test oil.
Sequence for cleaning operations:
a. Lift needle of valve to be cleaned with pincers so that the valve spring plate is located between the raised needle and needle seat. The valve is now open and can be rinsed in the desired flow direction.
b. Fit the valve together with the locally made tool and screw on to nozzle tester.
c. Actuate nozzle tester several times thus rinsing the injection valve against flow direction (at least 15 times).
d. Unscrew locally made tool with injection valve from nozzle tester and blow out with compressed air (max. 4 bar).
Check the injection valve for tightness, spray pattern and operating efficiency after cleaning.
Opening pressure: 2.6 to 3.6 bar
In one set, the variation in pressure must not be greater than 0.6 bar. If the variation is too great, the injector with the lowest opening pressure is to be replaced. The spray pattern is to be cone shaped (angle of spray 10 - 20 degrees); a side deflected pattern is incorrect.
Leak test: no drops should form within 15 seconds of pressure being applied that is 0.5 bar below the opening pressure.
The instructions for cleaning injection valves are:
Cleaning will only be successful if the injection valve is flushed out in the direction opposite to the normal flow [note: not in text ... there is a screen inside the injector that can get plugged up].
Tools and spare parts:
1 Bosch nozzle tester No. EFEP 60 H or locally made unit
1 pressure gauge 0 - 6 kp/cm^2 Cl. 1.0 100 mm dia.
1 reducing piece RSI 1/2" on 1/4"
(obtainable from Steinbronn, 7 Stuttgart-Feuerbach,
Kruppstrasse 34-36) to mount pressure gauge on nozzle tester
1 locally made tool
1 valve plate
1 plastic hose (80 mm long, 8 mm inside dia.) ET no. 911 201 228 00
2 hose clips ET No. 999 512 160 02
Locally made tool:
Saw open defective injection valve (approx. 7 - 10 mm from outlet aperture)
Remove spring with pincers
Clean sawn-off valve at cut section, wipe down and connect to plastic hose (8 mm inside dia.). Use hose clip No. 999 512 160 02 to secure
The fouled injection valve is inserted in the opposite free hose section and also fixed with a hose clip.
For safety reasons do not use carburettor fuel for cleaning; use only test oil.
Sequence for cleaning operations:
a. Lift needle of valve to be cleaned with pincers so that the valve spring plate is located between the raised needle and needle seat. The valve is now open and can be rinsed in the desired flow direction.
b. Fit the valve together with the locally made tool and screw on to nozzle tester.
c. Actuate nozzle tester several times thus rinsing the injection valve against flow direction (at least 15 times).
d. Unscrew locally made tool with injection valve from nozzle tester and blow out with compressed air (max. 4 bar).
Check the injection valve for tightness, spray pattern and operating efficiency after cleaning.
Opening pressure: 2.6 to 3.6 bar
In one set, the variation in pressure must not be greater than 0.6 bar. If the variation is too great, the injector with the lowest opening pressure is to be replaced. The spray pattern is to be cone shaped (angle of spray 10 - 20 degrees); a side deflected pattern is incorrect.
Leak test: no drops should form within 15 seconds of pressure being applied that is 0.5 bar below the opening pressure.
Last edited by Rich9928p; 12-24-2003 at 11:13 AM.
12-24-2003 | 08:13 PM
#2
Rennlist Member
Joined: Dec 2002
Posts: 5,283
Likes: 49
From: Australia
Rich,
Thanks for this, will file for reference. Cant quite visualize the tool though. While my local wrench cleans and tests for $9 a unit though, its unlikely I will need to do it this way. A process to back flush the WUR filters would be useful though, and the O ring specs (section thickness) would be good to have.
jp 83 Euro S AT 47k
Thanks for this, will file for reference. Cant quite visualize the tool though. While my local wrench cleans and tests for $9 a unit though, its unlikely I will need to do it this way. A process to back flush the WUR filters would be useful though, and the O ring specs (section thickness) would be good to have.
jp 83 Euro S AT 47k
