1.
Fuel distributor
2.
Breather valve
3.
Pressure gauge
4.
Fuel flow regulating valve
5.
Pressure regulation controller
6.
Connection to the fuel tank
3.4. CLEANING AND MAINTENANCE
a)
Use only non-corrosive cleaners to clean the surface.
b) After cleaning the device, all parts should be dried
completely before using it again.
c)
Store the unit in a dry, cool place, free from moisture
and direct exposure to sunlight.
1
6
2
3
4
5
WARNING! Hand-tighten adapters to avoid damaging
the O-rings. In exceptional cases, several adapters
must be connected together to get the right thread
combination.
E.
Reconnect the fuel pump, start the engine and check
for leaks.
F.
After connecting the tester, remove air from the
system.
WARNING! Do not bleed the system when the engine
or intake manifold are warm.
G. When the system pressure has stabilized, read the
value from the gauge. If the value is incorrect, the
problem may be in the cold phase controller.
H. If the pressure is normal, perform the remaining
pressure tests.
NOTE: Warm control pressure must be tested with
a warm engine. Primary pressure can be tested with
a cold or warm engine.
I.
I. If the warm control pressure values are not normal
check the setting of the fuel pressure regulator. If it
cannot be adjusted, it must be replaced.
II.
If the pressure of the engine running at idle speed is
low, measure the output voltage at the connectors of
the cold work phase regulator. It should be at least
11.5 V. If so, it means that the cold phase regulator
should be replaced.
J.
If the pressure is too low, check the fuel pump
output and whether the fuel supply lines are blocked
or there are leaks in the return lines. If none of the
above applies, the fuel system pressure needs to be
adjusted.
K.
If the fuel end pressure drops too quickly, check the
O-rings and fuel line connections for leaks.
L.
Deactivate the fuel pump and release pressure from
the fuel system.
M. Remove the device and reconnect the fuEL LINES.
N.
Start the engine and check for any fuel leaks.
O.
Remove residual fuel from the device (see 3.3.3 "I")
Measurement diagram for a typical CIS Bosch Jetronic
system.
d)
The device must be regularly inspected to check its
technical efficiency and spot any damage.
e)
Use a soft cloth for cleaning.
f)
Do not use sharp and/or metal objects for cleaning
(e.g. a wire brush or a metal spatula) because they
may damage the surface material of the appliance.
DISPOSING OF USED DEVICES
Do not dispose of this device in municipal waste systems.
Hand it over to an electric and electrical device recycling
and collection point. Check the symbol on the product,
instruction manual and packaging. The plastics used
to construct the device can be recycled in accordance
with their markings. By choosing to recycle you are
making a significant contribution to the protection of our
environment. Contact local authorities for information on
your local recycling facility.
•
Are any ignition cables broken, unplugged, or
punctured?
•
Is the ignition cap or distributor rotor disconnected or
ruptured?
•
Are the bodies of the individual electrical devices
loose or corroded?
•
Is any electrical component / plug disconnected?
C.
Battery and power supply system
•
Does the battery have sufficient voltage?
•
Is the alternator working properly?
•
Are any battery cables loose or tarnished / corroded?
D. Other
•
Are the vacuum hoses loose or disconnected?
•
Is refrigerant fluid or water leaking anywhere?
•
Are there any excessive oil leaks?
•
Is the sound of engine and its components correct?
•
Are the valves set correctly?
3.3.2 RELEASING PRESSURE FROM THE FUEL SYSTEM
•
Carry out the procedure away from heat or fire.
•
Use personal protective equipment - safety goggles,
gloves; type B fire extinguisher should be within reach.
•
With the ignition off, unscrew the fuel filler cap.
•
Disconnect the pump by pulling out the fuse or
disconnecting the plug or power cord from it.
Remember that some vehicles may have 2 fuel pumps
- turn them all off.
•
Turn the ignition on and start the engine, then wait for
it to turn off automatically.
•
Try to start the engine for 3-5 seconds. On vehicles
with an inertial pressure release switch, try to start the
engine for 15 seconds to release the pressure from
the system.
•
Turn the ignition off.
3.3.3 FUEL SYSTEM PRESSURE TEST
Each test should be carried out at idle run and on the
system side where the pressure is high.
A.
With the engine off, locate the pressure connector
on the fuel system (Schrader valve) and connect the
pressure gauge to it. If the vehicle does not have
such a valve in the system and the system must be
opened, the remaining pressure must first be released
to prevent fuel from splashing (see section 3.3.2).
Connect the tester using an appropriate adapter to
the input.
B. If you need to use a banjo screw adapter, only
the universal M12x1.25 adapter is included. If the
manufacturer has used a custom size, you may need
to use more than one washer depending on the
application.
C. After connecting the pressure gauge or a tee and
using the appropriate adapters, reconnect the fuel
pump and start the engine. Check for leaks first. If
nothing disturbing happens, watch the pressure
gauge. Initially, the fuel pressure should exceed the
operating value specified by the manufacturer but
after a while it should stabilize.
D. If there is an adjustable fuel pressure regulator, the
pressure should be set while the engine is running.
If there is a compensating fuel pressure regulator,
the pressure should drop by 8-9 psi (0.5-0.6 bar)
depending on the vacuum in the intake manifold.
E.
Locate the flexible hose on the return side and
squeeze it gently - never squeeze a metal hose. If the
manufacturer prohibits such action, this point should
be omitted.
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2
3
4
8
5
6
7
4
9
1.
Fuel pressure measuring point
2.
Vacuum hose to the intake manifold.
3.
Pressure regulator
4.
Flexible hose
5.
Fuel pump (in the tank)
6.
Fuel pump filter
7.
External fuel filter (usually in the engine compartment
or near the fuel tank)
8.
Fuel return line
9.
High pressure fuel line
3.3.4 CIS BOSCH JETRONIC FUEL SYSTEM PRESSURE TEST
Four types of pressure test can be done with this kit:
(a) cold control pressure - cold engine, valve open;
(b) warm control pressure - warm engine, valve open;
(c) primary pressure - cold or warm engine, closed valve
(closed valve eliminates pressure control);
(d) rest pressure - warm engine, valve open.
For the (a) procedure, the engine should be cold, i.e. not
started for at least a few hours or after an overnight stop.
A.
Release pressure from the fuel system (see 3.3.2).
B.
Make sure the fuel filter is not clogged.
C.
Remove dirt from the fuel distributor cover.
D. As per the connection diagram to the Jetronic /
CIS system, connect the tester between the fuel
distributor and the pressure controller. Connect the
hose without a flow control valve to the centre of the
fuel manifold. Connect the hose with valve to the hose
removed from the fuel distributor which is connected
directly to the pressure regulator.
F. If the fuel pressure is at the right level, some
manufacturers still recommend a flow test. For this,
open the fuel system, place a tank at the end and
watch. Then turn off the engine and observe the
pressure remaining in the system. Some manufacturers
specify a minimum time for maintaining pressure after
switching off the engine.
G.
Deactivate the fuel pump and release the remaining
pressure from the fuel system.
H.
Remove the tester and reconnect all cables. Then start
the engine and check for possible fuel leaks.
I.
Remove residual fuel from all hoses of the device and
the pressure gauge. For this, connect the smallest
banjo adapter to the quick coupler and hold the
gauge over the canister for the fuel to drain out.
Diagram for measuring a typical fuel system with multi-
point injection (MPI):
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Rev. 24.01.2022
Rev. 24.01.2022
