Oh boy, what have a let myself in for? As I'm slowly fixing my oil leak source (on the thread by the same name) by rebuilding my engine, my mind has wandered towards my long term thought of taking my 78 US spec camper mechanically back to original engine spec..that's right fuel injection. A few days ago, I saw an add on here for a complete FI system for my model and year and so I went for it. To say I'm a novice in the field is kind, but once my engine is back in and running, I hope to have the rest of the year using the camper for fun, then come next winter, I'm intending/hoping to fit the FI. Pictures of the bits and bobs below. It's going to be a slow build which will give me time to refurbish the parts, so any hints and suggestions would be welcome. Wish me luck!
Cool, I have quite a few pics of wiring locations from when I removed ours back at Easter, close ups of what plugs where. Leave it with me and I’ll post them tonight...it also shows the vacuum hose locations too.
Deffo worth a try. Worth having the injectors cleaned, I'd think. There's a Bosch injection manual on ratwell, if you have a look.
This is a diagram of the vacuum hoses which applied to our old motor, 1977 FI: Charcoal canistor to fan housing hose: Charcoal canistor to Air Filter h'sing: Decel valve to S boot: Crank breather to S boot: Decel valve to intake plenum / brake booster T connector: Close up of S boot:
@Chrisd The pdf wouldnt attach, file too large, if you havent got a copy off Ratwell as Snotty referenced, I could always email it to you if needs be
That is absolutely brilliant. Although I use Ratwell quite a lot, I don't have the manual other than his web based version. @MorkC68 , I've PM'd you with my email, if you could send me the PDF, that would be great. Lots of reading , but must finish of engine rebuild first
Worth a try getting it going. Nothing lost if it doesn’t work. The weak point seems to be the pot track on the airflow meter. Worth having a look to see how worn it is.
Ta...I have no idea what a 'pot track' is but would hazard a guess that it is the flap inside the airflow meter?
Once I create some time to get onto the FI, I plan to check each bit from my big 'pile' of bits and clean, learn, replace, learn a bit more and scratch my head repeatedly. I had found this site which looks strangely like Ratwells manual https://www.type4.org/manuals/ljet/index.html Any other resources I should check out would be good to know about. Cheers all.
Yes, inside the airflow meter. I've never actually seen one, but from what I understand the flap moves a potentiometer (a variable resistor, basically) as input to the (quite primitive by today's standards) controller. If the pot track wears, the FI may misbehave. Not really much you can do about it. Looks like it's all done using thick-film technology, which you're not going to fix in your garage ... Worth a look inside the AFM. Made by Bourns, in fact. Hurrah!
By the power of the tiniternet I bring you a pot track...I think Different model but looks similar to your picture @snotty https://www.k100-forum.com/t11055-bosch-air-flow-meter-restoration-summary I'm going to have to open that bit later aren't I ....
@snotty, I didn't fiddle, fettle or even fondle (well maybe a bit...) Pictures below of AFC and wiper track that look well used. Not sure how much this will affect operation.
Hmm. That track does look quite worn (not surprisingly, given that the pot's going back and forth all the time). I'd get the whole lot in and see if it misbehaves as a first step. If it does, you might have to find another controller in better shape. But...one thing at a time.
Seem to be a lot of broken links on ratwell. If anyone wants the Bosch FI Test Manual, PM me an email address.
I keep wondering why no-one has sourced and fitted a 1600 injection set up from a Beetle ?? Must be a good upgrade and plenty in the Brazzie scrapyards ... Sent from my SM-G960F using Tapatalk
