K-jetronic problem

Hello,
I have a big problem with my Golf 1 convertible 1800cc with mechanical k-jetronic
Will start from the beginning.
I had started restoring her a few years ago but was unable to continue due to circumstances. Result she has stood still for a few years. Now I have finally been able to get back to it and try to start her. She started but came to a halt after a few seconds and didn't want to start after that. The starter also had trouble getting the engine around. The cylinders, inlet and oil were full of petrol. After looking no further I thought of piston rings broken after standing still for so long so I searched and put another engine but still have the same problem




 after looking further and testing my injectors I saw that as soon as the petrol pump is running all started spraying without me lifting the air valve so I checked the distributor and it was completely blocked. Then bought overhaul kit after everything was nicely cleaned and reassembled i have still the same problem, then i tried other injectors but no difference. As soon as i on the petrol pump all the injectors give petrol I no longer know what to do hope that maybe there is someone here who could help me. Pls.




Kind regards

https://www.vwgolfmk2.co.uk/forum/viewtopic.php?f=37&t=41350

https://www.facebook.com/joeyribbens1981  seems a well nice fella


some info on these pages and links..

Fuel Injection - The Mk1 Golf Owners Club

dont worry plenty of advice and ideas will come along, to me sounds great that you have fuel reaching injectors so really you need spark and then should start.  if no fuel there then id be more concerned.  did you have part number for cis unit maybe you can swap that for a working 1  if you find that's the issue.   But i suspect its more of spark issue…Timing, or ignition coil or ignition module that's my guess since pumps seem fine.

 

I have spark, if i stop my fuelpomp and start he wil go and burn whats left, but h
The moment i put my pomp again he stops. I am getting to much fuel in the engine

I just took the whole fuel system out of the car and connected it all together on a table to try and test it. There i can really see thar the distributor is not working like he is supposed to if i on my gaspomp the injectors spray and whistle its like the distributor is not even there i don't get it everything inside it is new. If i was sure it was really broken i would buy a new one but they are a little to expensive to just buy one to try 😔 

All help is welcome and i thank you already

Get a metering head refurb kit and follow this tutorial
Bosch K-Jetronic Fuel Distributor Seal Replacement - YouTube


 

I'd suggest you get hold of a fuel pressure test gauge and check your control and system pressure. It could be the warm up regulator that is causing the issue.

How did you get on with this? I am having the same problem. I was getting no fuel (mk1 had sat for a decade with popped Conrod) My fuel pump only got the system to 2.5 bar. This was one problem. Replaced it and now system is getting 5 bar. New fuel filter. Accumulator hold pressure at 2.5 bar for over 20 minutes after shut down. The fuel lines were horrible, tank filled with crud so replacing both (Once I get engine running) I have removed the injection system and am currently bench testing it. I have disassembled the metering head and replaced all seals. Replaced plunger spring. WUR Feed is showing 5 bar injectors are injecting wiht AFM plate at rest. 5th injector also injecting, return also filling. Cylinder 1, 3 and 4 all full flow. Cylinder 2 flows in lifting AFM plate. Changed injectors around 1 and 2 to see if it could be injector it is not. I also modified the retaining clip in the  plunger slightly to allow it to drop further as i thought it was maybe not dropping enough making it seem like resting position of AFM was higher in the barrel. I am going to remove the washers in the pressure regulator tomorrow and other than that I’m stumped. Looks like a new metering head is needed. Any help would be appreciated. Thanks Jim 

Hi Jim, the injectors shouldn't be spraying with the AFM plate in the rest position, so your fuel plunger could be stuck in the metering head or your mixture adjustment screw needs backed off until the injectors stop spraying. If I was you, I'd replace tank and lines first so you know the system is clean, then focus on the engine running.

Thanks Pistol, I am replacing the tank and lines but want to ensure the replacement engine is okay first. The injection system is out of car and I will not be using the lines or tank again. Th above symptoms are on the bench. The plunger is not stuck but i am worried that fuel is passing the rings. The issue is the metering head is seeing system pressure all the time and I'm not sure why. The mixture adjustment is something to look at thanks but until the metering head see's cold pressure they will operate when they are seeing 5.2 bar……
Playing with it all now    

I'd be interested to see your bench test set-up!

You really wouldn't! It's totally the reverse of Heath Robinson…… I only have a photo from when i was setting it up not the end product. I have just put the injection system back in the car.

HERES THE PHOTO: Caveat::: no need to comment on the fire risk….

I since added fuel line to separate fuel pump and battery, I also added some wood framing to hold the bottles up and a better return. It done the trick. I bought a pressure gauge from local hydraulic shop with valve so I could check pressures.

Got the rebuild kit complete on the metering head and loctited the seal and it works good, ballanced the injectors and it all works as it should on AFM lift. Back in car now but still wont start but least I know that parts are good. Now to run through WUR, 5TH injector and all wiring to see where the problem is for starting…..

Finally got her running tonight!

Let me know how you got on I have had two weeks of playin Gand am well versed at the moment on what worked for me and what did not!

Thank you for the comments who took the time to give advice

jim 

I like the fuel filter holder!

Good job in getting it running. Always good to have more knowledge on here - especially on the dark arts of K-Jet!

J

Thanks! Yeah its a bit rudimentary but certainly done the trick for me. Managed to fault find and set it up to standard factory settings and it worked.

Happy to help where I can with my opinion to anyone else having troubles and happy to physically help too in the NE of Scotland!!

Jim

Lucy750Y said

I since added fuel line to separate fuel pump and battery, I also added some wood framing to hold the bottles up and a better return. It done the trick. I bought a pressure gauge from local hydraulic shop with valve so I could check pressures.

Got the rebuild kit complete on the metering head and loctited the seal and it works good, ballanced the injectors and it all works as it should on AFM lift. Back in car now but still wont start but least I know that parts are good. Now to run through WUR, 5TH injector and all wiring to see where the problem is for starting…..

Hi,
I was wondering how you balanced the injectors and how you finally got it running!

I have tried new, pumps, accumulator, relays, 3 metering heads, new distributor and new fuse board.  Now have one injector with a strong spray (maybe too strong) one not bad but and the others with just a trickle.

Also had a little engine bay fire. Oops. but all ok.
Any info appreciated
thanks
Con

hi i would look at the adjustment on the sensor
plate as if it is not set correct the plunger will
allow fuel to go directly to the injectors just a
thought maybe looking in the wrong direction