ABANDONED Porsche 924 Turbo is broken again! Bosch K-Jetronic Fuel Distributor Rebuild
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- čas přidán 27. 05. 2021
- Thank you so much for checking out our channel! Today we're back working on the Porsche 924 Turbo project. A couple weeks ago, I took the car for a drive and it was running a little rough at first, but thought it just needed the cobwebs blown out. A couple miles from the house it almost stranded me. It wouldn't run over 3200 rpm and had almost no power.
I tried checking the fuel pressure with my (Harbor Freight...) fuel pressure tester, but the adapter broke. But there was almost no pressure when I cracked the banjo bolt loose. With another pressure tester I got just above zero PSI at idle (should be ~80). There is plenty of pressure on the bottom side of the fuel distributor, so I suspect that something failed in the CIS fuel distributor.
Armed with a rebuild kit, we're setting out to restore the Bosch K-jetronic fuel system!
We're winding down towards the end of the project, and I can't say thank you enough for all the support you've given to our channel.
A free way to support us is to click the subscribe button and ring the bell to be notified when new videos go live!
Also you can pick up some killer Auto Anatomy merch by checking out our merch shop at auto-anatomy.creator-spring.c... Gonna get out a 924 Turbo shirt ASAP, so check back often!
Thank you so much for supporting us, and God bless!
Sean, Christie, and the Auto Anatomy team - Auta a dopravní prostředky
Unexpected setback but finally got the chance to open Pandora’s box! Now I’m confident the fuel distributor is good, one less thing to worry about.
What has been your favorite part of this revival? Comment below!
Great work, that diaphragm was really in an alarming state. Not that complicated rebuild, but lots of pitfalls if you dot the job quick and dirty, you really did a great job there.
Thank you so much!
Having worked for VWoA from 79 to 92, I fell in love with their (VW, AUDI and Porshe) vehicles, but learned how expensive parts can be.
My '82 was doing this exact thing. First thought was vacuum leaks but fixed a few minor things, no change. Then the consensus was ignition (I forget why, I need to back and see). Finally replaced the coil, it "fixed" it but then came back. I have a programmable ignition as a replacement distributor, ultimately decided that was failing and got a new one, but then made an oopsie and long story short, my head is at the machine shop getting new valves. I'm really thinking I may have to revisit the whole root cause thing after watching your video. The good news is that job actually looked like something I could do, I would have been afraid to try. So, thanks! This may come in handy!
Thanks for checking out the video Jeff. These cars are a bit finicky when something isn't right, but when they're right they're amazing. I wondered if the coil was the problem, but it just didn't feel like an ignition problem.
The diaphragm repair wasn't terribly difficult, but it is tedious and requires attention to detail. Take your time, watch a few videos, and don't be afraid to tackle something like it yourself!
Sean
Congrats! I just want to let you know that the torn diaphragm was also swollen. The reason for this is that today's fuel contains ethanol which was not specified when the Jetronic was developed. In Europe where I live fuel contains 5% for E5, 10% for E10 or even up to 85% for E85. I hope that the replacement kit was made out of FKM which is ethanol resistant. Otherwise the job has to be redone after some 10k miles.
I'm currently restoring an '81 931, and am in the process of rebuilding the fuel distributor. This video has been SO helpful and informative. Thanks for sharing!!
Awesome! Glad to be of help, and these are wonderful little cars
@@AutoAnatomy Can't wait to get it on the road where it belongs. The rebuild is almost complete. I just have one question. How did you get the plunger depth set back to .6 mm after the rebuild? I can tighten the nut down to about .8 mm, but after that the barrel starts to turn as well, which of course means the O-rings will me misaligned. Thanks in advance!
Great job getting this this resolved!
It only takes one small thing to create a problem, but you nailed it!
Thank you!
Your video caught my eye because just today, I spied a 931 having a complete engine rebuild in a shop where I was having work done on one of my old BMWs. Around 1990, when the internet was still a cow path, there were 4 of us with 1981 931s on a mail reflector called porschephiles. We were scattered around the globe but gave one another moral and direct support in keeping our old cars functioning. I was living in Canada, at the end of Lake Ontario. One guy was shifting his (932) with the wrong hand, in Australia. One was in San Francisco and another was in upstate New York. All of us have met in person, multpile times. Although none of us still has a 931, all but the guy in New York are still in regular contact, 30 years later. I learned far more about CIS than I ever wanted to lol. But, I do remember how they tried to frighten you to death about ever opening up the fuel distributor. I remember seeing statements such as, "BE CAREFUL WHEN YOU REMOVE THE PLUNGER! It is machined to extremely precise tolerances to perfectly mate with its cylinder so if you drop it on the workbench, it's all over. Just toss the whole distributor in the trash. " I still have fond memories of that car even though it tended to be naughty far more often than nice. ;-)
Very cool stories! I always heard about the CIS distributor being a "no-go" on disassembly, but it's really not that complicated and if you take your time it's pretty simple. And yes, mine was naughty more often than nice as well. But when it's nice, it's really nice!
Thanks for watching!
Sean
@@AutoAnatomy Completely concur lol. When that big turbo finally spooled up and your back was pasted to the seat back, the smile was ear to ear. A little hairy when the wastegate failed, but still "interesting" lol. Fortunately, in the 1981 version, they raided the parts bin and added 930 brakes all round, so once flying, you could still stop. I think the turbo may have been a bit bigger than the 1980 and earlier models as well ?? Digital ignition timing was a welcome improvement as well. I believe it may have been the first production car with digital timing control. Important trivia to know. It comes up all the time at cocktail parties :-)
@@kennethstanton5407 smaller turbo...smaller less mass spools up quicker
Did the same CIS distributor rebuild for my Audi 100 Turbo. Great work!
Thanks!!
Glad it's running so well now!
Thank you!
I was excited to watch this, but part dread knowing I’ll probably need to do this exact same fix when I finally get the engine put back together
It wasn't that bad, actually! Good luck on yours
Great job.Thanks for showing how its done
Very much enjoy all your content. I’m always learning something new. I don’t understand why the channel isn’t growing more. Keep up the good work. Salute from all the way up north in Quebec Canada.
Thank you so much, I appreciate that!
Excellent video! So glad you had the guts to open up the distributor 😎
Thank you!
Great in depth video. 👌
Very nice job on the whole project!
Thank you!!
Sean, wonderful and instructional video. No idea of your circumstances, but IMO you should give serious thought to keeping this car. They are only getting more rare, and are just starting to come into their own... plus, you know this one inside and out. Anyway, great work, as always.
I would really love to be able to keep the car, but we're moving 2000 miles east in about 6 weeks and already have three cars to move. If there was any way I could reasonably do it, I'd probably keep them all!
Sean
Excelentes tus videos, no me pierdo ninguno!
¡Muchas gracias!
Well done! :)
Thank you! You have some awesome graphics, we should talk. I'd love to connect about redoing the graphics on my videos.
Hey Sean! Fantastic job on that fuel distributor! The diaphragm looked really bad. Maybe the crappy ethanol that is in the fuel messed it up. I find the diaphragms in my 2 and 4bbl carbs turn hard as a rock! Keep up the good work!
George B. in Michigan
Thank you George! I really do think the new fuel was the major contributor to the diaphragm damage. The ethanol is murder on rubber components.
Thanks again!
Sean
Any remedy for the ethanol issue? This is a thing unfortunately.
Theres a rebuild kit for that new gasket larger plunger...again check the accumulators back by fuel pump...if you get it running and seems like running lean reach under and lift the plate that will reset...those accumulators if suspect failed theres a newer. Larger units avaliable..check factory workshop manuals and also as they call them .."campaigns"...or rest of us call them..recalls
Fantastic! Lovely car.
Thank you!
Thanks for sharing your experience - great result. Can you point me in the right direction for the ipad guide you used from Rasta Monsta please, as I have the same rebuild on the horizon for my neighbor. Thanks in advance.
The four springs on the plunger are now reversed.
I know, I did notice that as well. I went back and watched some other distributor rebuild videos and it appears that Bosch put them in both directions. If it causes any issues I'll reverse them.
Sharp eye, and thanks for watching!
Sean
Watching this and have learned a lot. What i note is that the thin plastic washer that was in place above the outlets with the springs and orings was not replaced in the reassembly. I heard a nice click when the plunger was re-set. Wondering if that plastic washer is really necessary or if the plunger seats better without it. Thoughts?
Great rebuild video. When you reassembled the fuel distributor, did you put any silicone grease on the diaphragm itself?
I honestly don't remember, sorry!
Nice!
Thank you!
Well done, Sean!
😀👋🇨🇦👍
Thank you very much!
Awesome 🙂
Thank you!
You have a link to the rebuild thread you followed? I am going to be tackling this soon. Also be nice to have links on everything you bought
If you email me at autoanatomy@icloud.com I can send you the instructions I have. I got the rebuild on eBay. www.ebay.com/itm/272895512883
Hey Sean, Great clip. I went exactly through the same process with my Turbo and am into CIS rebuild at the moment. Did you finally set the plunger at the 0,6 cm distance? Further I noticed that your steering is way lighter than mine. Does your car has/had a power steering setup or is it heavy as well and do I need some more muscles? ;-)
Thanks for sharing your experience - great result! Can you point me in the right direction for the ipad guide by Rasta Monster please. I have this same rebuild on the horizon for my neighbor. Thanks in advance - Matt
what's your email? I'll send it to you.
these cars are usually being rebuilt than driven
They definitely need to get driven, and they’re so fun to drive!
My neighbor had a 924 years ago, sitting for years, we changed the second gear syncro and when he started driving it there were some small screen type filters that keep getting plugged up. I can’t remember where they were in the system,I almost think they were in the fuel line somewhere.
I think I've changed everything on this car (filter wise), but who knows! Thanks for watching!
@@AutoAnatomy I wasn't sure if you got the grinding into second issue sorted but I'm guessing it's not doing that anymore since you're banging second and barking rubber. My neighbor brought the tranny over in a wheelbarrow and I took it apart and changed the second gear synchro, it was pretty easy so don't fret if you have to do it. I'm on my second 944 and have rebuilt the clutch slave on both, bleeding the current one was a pain but I ended up using a giant syringe at the connection near the firewall, pushed and pulled oil back and forth to the master cylinder and finally it worked. What kinda money do you think that car will bring?
The transmission is slow shifting, especially when cold. If you try to rush the upshift or downshift it will grind. A little blip of the throttle when downshifting makes a world of difference, and I can drive it very easily without any grinding.
The bleeding on these cars is also a challenge, and I found doing a pressure bleed from the bottom is the best way to ensure no air. Thanks again for watching!
Sean
What happened to the plastic ring that goes in before the springs on the plunger ? 😳
Hi
I’ve got a 1982 model 924 Turbo that isn’t starting. The battery is fine along with fuel and the ignition fires but as soon as I let go of the key it cuts out and won’t fire up.
Any ideas or help would be appreciated 😅
I have the same car. Is there anyway you have a link to the rebuild instructions?
I don't have the link anymore, and I think I just Googled on how to rebuild it. On one of the 924 forums there was a PDF that I downloaded.
Does your car smoke when you first star it?because mine does then it stops.
Mine does not smoke at startup, and typically that's indicative of valve stem seals that are leaking.
@@AutoAnatomy I was told that it could also be the turbo oil drain on this model was a factory mistake do you know if yours it’s been modified,do you know anything about this?
From memory, they modified the side of the cylinder head up near the oil filler (on the intake side of the head) to allow for better scavenging of the turbo oil drain. Mine has not been modified and seems to work fine.
Thumbs up if your Harbor Freight "tools" have let you down.
More than once...
do you have a link to the rebuild kit? my 924 runs like butt cheeks.
Here is the one I used, make sure it fits your car as the turbo and non-turbo could be different.
www.ebay.com/itm/272895512883?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=3rdO_J_FS5W&sssrc=2349624&ssuid=L-GDLJl9S76&var=&widget_ver=artemis&media=COPY
Verkaufe porsche turbo Baujahr 1979 vol Ausstattung voll verzinkte ab gemeldet 1992 5 gang elektrische Fensterheber und Spiegel beheitz