<VIC> Looking for a tune up of my mechanical injection (505Sti S1)
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  1. #1
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    Default <VIC> Looking for a tune up of my mechanical injection (505Sti S1)

    Hi,
    I've been spending a bit of time in vic recently for work, and my boss has finally decided that giving me hire cars for weeks on end isn't very economical so next time I'm over they are planning on shipping me and my car over on the Spirit of Tas.

    Well the upside of all this is I can finally get someone decent to properly tune the mechanical injection on my 505STi.

    So any recommendations of mechanics? Or if someone privately wants to have a go, I'm willing to hide a slab of tassie beer in the boot (or a few bottles of tassie wine) when I come over.

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    1984 505 STi

  2. #2
    Gus
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    Fellow Frogger! Gus's Avatar
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    Default ... if it ain't broke...

    The best advice I ever heard about the K-Jet (from a Pug mechanic who has been servicing them since they were new) is: If it ain't broke, don't fix it. He told me to just get it running OK, then leave it alone!

    You (or a well-meaning but underinformed mechanic) can easily get in lots of trouble mis-servicing the K-Jetronic (STI's mechanical injection system). If you don't find anyone to trust with it, don't trust anyone!

    If you are looking for a good mechanics, lots of 80s Volvos (as well as Porsches, Beemers and Mercs) had K-Jetronic so you might want to try a sympathetic Volvo injection specialist (more Volvo 240s than 505s out there!) Find one who knows K-Jetronic well.

    -- (More technical stuff starts here!!! Enter at own risk!) ---

    The problem is that the K-Jetronic system relies on a complicated series of checks and balances, and if you upset them you might find that the thing will never run properly again .

    If you're interested, there's a good summary here: http://www.volvoclub.org.uk/tech/fue...k_jetronic.htm (note that the electronics bits in part 3 are not part of the STI's design.)

    The good news is that there's rarely anything too drastic wrong with the system as a whole. It's probably one little thing that's upset the balance.

    So... what's wrong with it? What's it doing wrong? Bad idle, no power, flat spots, grumpy, uses lots of fuel, all of the above? ;-)

    Start with the basics like spark plugs and the air filter. If they're not at least recent, then get them replaced!

    If you've got some time and don't mind getting a little dirty, here are 3 basic things you can do to check out the injection system (at low risk):

    1) Fill a pump spray bottle (the kind that makes a mist) with plain water. Idle the engine, and spray it on all the black rubber hoses (vacuum hoses) and hose connections you can find attached to the inlet manifold. If the water droplets sputter, they're being sucked in through a small vacuum leak. Replace or reseat the old hose, and you'll get a smoother idle.

    2) Take the big black rubber dome off the top of the fuel distributor unit (you need to undo some big hose clamps.) Have a look at the metal cone with the round metal plate mounted in the bottom of it. When air comes up from the bottom, it pushes the plate up. This is what tells the injection system how much fuel to add! Without forcing it, make sure the plate can move up smoothly with even (light) resistance (it's spring loaded), without rubbing, and that when you drop it returns to the right spot. Don't lift the plate any further than it freely moves. You could also give it and the cone a bit of a clean, if you're game.

    3) There's a funny looking gizmo mounted on the thermostat housing (passenger side of the engine, at the front near the radiator hose) with a black vacuum hose hooked to either end, and a small electrical connector. It's called an extra air device, and it lets extra air in when the car's warming up.

    Unbolt it when the engine's cold and look in one of the vacuum hose sockets - you should be able to see through. Then hook it back up (don't need to bolt it down) and run the car till its warm (not just the car, but the gizmo too.) Now you should not be able to see through the vacuum hose holes.

    4) Dump a bottle of injector cleaner in your fuel tank (OK, you don't get have to get dirty for that one!) It's not a miracle cure, but it is better than nothing!

    Hope some of this helps. I kind of miss my 505 STI, but I don't miss it's fuel injection system! :eep:

  3. #3
    Fellow Frogger!
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    Default

    hey.. i was wondering it that applies to the '72 504 ti injection system or is it something different..... its got a flat spot, havent had time to get new filters yet but would any of what i have read, help in removing it???

    mike
    1972 504 Ti

  4. #4
    farmerdave
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    Quote Originally Posted by Armunn
    Hi,
    I've been spending a bit of time in vic recently for work, and my boss has finally decided that giving me hire cars for weeks on end isn't very economical so next time I'm over they are planning on shipping me and my car over on the Spirit of Tas.

    Well the upside of all this is I can finally get someone decent to properly tune the mechanical injection on my 505STi.

    So any recommendations of mechanics? Or if someone privately wants to have a go, I'm willing to hide a slab of tassie beer in the boot (or a few bottles of tassie wine) when I come over.
    Mercedes trained mechanics seem to have the best understanding of the system and its quirks, if you can find an independent M-B workshop that will work on the car that is your best bet.
    K-jet is a wonderfully simple yet complex system but it can be very humbling to work on, it needs patience and logical thought although the basic procedures are very simple.

    Farmerdave

  5. #5
    Member eatpeople04's Avatar
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    Default

    I have to say I never looked back when I upgraded from a S1 STi to a S2 GTi. Anyone who wants to work on the STi had better be prepared for the spaghetti they are confronted with when they open the bonnet!

    My STi always had a problem when cold. It would Idle fine, but as soon as you hit the throttle the motor would cough, and if the car wasn't moving, die. Thinking about it now, this was probably something wrong with the extra air bypass mentioned above, but trying to troubleshoot whilst staring at the mess under those bonnets is very daunting!
    Is your STi doing anything particularly naughty?

    On a related but slightly different note, simple problems can befall the L-jetronic system on the GTi as well! We recently replaced all of the important bits on the front of the motor (water pump, cam belt, seals, drive belts etc.) Unfortunately, somehow the color coded electrical connectors were replaced the wrong way around. The car would still run, but the idle always seemed to change (depending on the alignment of the stars etc ). We then changed them back, and the bugger wouldn't start!
    (See here for the full story
    505 Gti Cold Start )

    Stoopid complicated stuff!

    Good luck getting a tune up!

    Daniel
    eatpeople04

    Now showing in:
    "Betty" 1997 Black 306 GTi6
    "Shaggy" 2001 Green Subaru Outback

    The Mrs. Has
    "Wags" 2006 Ash Grey 307 XSE Hdi Touring

    And for floating...
    "Korka" 1978 Red/Blue Ramsay Lynx with 327ci Chevy

    Previously:
    "Cliff the 505th" 1985 White 505 GTi
    "Clive the 505" 1983 Poo Gold? 505 STi RIP

  6. #6
    Fellow Frogger! 604 tragic's Avatar
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    Default

    Quote Originally Posted by Armunn
    Hi,
    I've been spending a bit of time in vic recently for work, and my boss has finally decided that giving me hire cars for weeks on end isn't very economical so next time I'm over they are planning on shipping me and my car over on the Spirit of Tas.

    Well the upside of all this is I can finally get someone decent to properly tune the mechanical injection on my 505STi.

    So any recommendations of mechanics? Or if someone privately wants to have a go, I'm willing to hide a slab of tassie beer in the boot (or a few bottles of tassie wine) when I come over.
    Two quick recomendations for FI tuning in Melb.
    As mentioned before find a small place where the mechanic has experience on L Jets and wont treat your STI as an inconvenient piece of dog pooh.

    Dont use Ken Airs (melbournes FI guru) for your STI - wait till you have something exotic like a TR5 with Lucas FI, then you will get undivided attention.

    A small shop in Richmond called B & M Fuel Systems has been helpful wih my STI & a friends SLI . He's at 3 Albert St - Ph 9429 3510.

    But heed the advice given - unless there is a specific problem, stick to basic tune up not - exploritory surgery.
    So many projects - so little time.

  7. #7
    Budding Architect ???? pugrambo's Avatar
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    Default

    Quote Originally Posted by Mike L
    hey.. i was wondering it that applies to the '72 504 ti injection system or is it something different..... its got a flat spot, havent had time to get new filters yet but would any of what i have read, help in removing it???

    mike

    where is the flat spot

    i need more info to help you out

    hot, cold, WOT, part throttle, everything is needed
    3 x '78 604 SL

    1 x '98 306 GTi6

    1 x secret project

    1 x '98 406 STDT troop carrier and i don't care if it stinks, i don't sniff it's arse Death by wank tank

    1 x '99 406SV 5spd wagon, time to burn more fuel

    1 x 1994 605 SV3.0


    WTD long range fuel tank for 605

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