Technical Bulletin Model
924		 Group
20
Subject: Hot Starting Difficulties Part Identifier
2045		 Number
76-01

If hot engine fails to start quickly, proceed as follows:

 

  • Check fuel system pressure and control pressure. Follow standard CIS test procedures.

    System pressure: 4.5 - 5.2 bar (66 - 74 psi)
    Control pressure:

    cold -  1.3 - 1.7 bar
    (18 - 24 psi)
    warm -  3.4 - 3.8 bar
    (48 - 54 psi)

  • If fuel pressures are not to specification, check following parts for leaks:

    • injectors
    • cold start valve
    • warm-up regulator
    • fuel distributor
    		•

    Note:

    Some fuel "sweating" is permissable. Only replace parts that leak (wet or dripping).
    • If hot starting difficulty remains, install second accumulator (20 cc) and relocate fuel pump.

    Note:

    Factory air conditioned cars already have two accumulators installed.

    Parts required:

    Installation Kit, Part No. 477.298.111
    Kit 477 298 111
    1 -  20 cc accumulator
    2 -  accumulator clamp
    3 -  new fuel hoses
    4 -  fuel line plug
    5 -  fuel pump bracket
    6 -  pump rubber mount
    7 -  pump securing hardware
    8 -  pump bracket screws
    9 -  new pump mounting
    10 -  fuel line gaskets
    11 -  wire terminal sleeves
    12 -  wiring harnes terminals
    13 -  new fuel filter
    14 -  fuel line clamps
    15 -  fuel hose clamp
    16 -  extension electrical harness
    17 -  fuel pump clamp

    Modification Instructions:

    • Disconnect battery ground
    • Remove right rear wheel
    • Using template below as a guide, drill two holes (6.5 mm or ¼”) in rear fender well for mounting of new fuel bracket
    • Remove three hex nuts A holding fuel pump/accumulator bracket in place; discard existing heat shield B
    • Install pinch clamp A on suction fuel hose about 100 mm or 4 in. from fuel tank as shown; remove suction fuel hose from fuel pump at B
    Caution

    Hold container or rag under hose connection at fuel pump to catch fuel that runs out of hose

    • Remove steel line A from fuel pump and accumulator.
    • Cut line B and remove nut C for use later. Discard line.
    • Disconnect other steel line D at accumulator.
    • Pull off electrical connector E from fuel pump and cut wires as close to connector as possible.
    • Remove bracket assembly from car.
    • Remove center rubber mounting F from bracket for use later in relocating fuel pump.
    • Loosen clamp G around fuel pump and remove pump from bracket. Do not remove accumulator.
    • Clamp new accumulator A (No. 1 in kit) to bracket where fuel pump was removed using new clamp (No. 2 in kit); install new hoses (No. 3 in kit) as shown.
    • Install line plug (No. 4 in kit) at B on new accumulator using nut cut previously from discarded steel line.
    • Install accumulator bracket assembly in car with two of three hex nuts A previously removed.
    • Install fuel pump bracket A (No. 5 in kit) behind wheel well by inserting studs of two rubber mountings B (one No. 6 in kit and one previously removed) through bracket and newly drilled holes, using flat washers, lock washers, and hex nuts (No. 7 in kit) on wheel well side.
    • Drill two 3 mm. or 1/8 in. holes in body for sheet metal screws C; install screws (No. 8 in kit).
    • Attach fuel pump to new mounting kit A (No. 9 in kit) using clamp B (No. 17 in kit). Fuel pressure line connector C must point up.
    • Connect new fuel pressure line to fuel pump pressure line connector, using new gaskets (No. 10 in kit); install fuel pump assembly on bracket using two lock washers and hex nuts previously removed from accumulator center rubber mounting. Be sure pump does not kit bracket. Bend fuel pump mounting if necessary.
    • Install rubber sleeves A (No. 11 in kit) over cut fuel pump wires; crimp new terminals B (No. 12 in kit) on wires.
    • Cut fuel suction hose A from fuel tank to 190 mm. or 7 ½ in; cut 65 mm. or 2 ½ in. from long side of formed hose B.
    • Install hoses on new fuel filter (No. 13 in kit) using new clamps (No. 14 in kit) and connect formed hose to fuel pump as shown. Remove pinch clamp C from hose.
    • Install fuel pressure hose holder A (No. 15 in kit) on same bolt as fuel return line holder.
    • Run new fuel pump electrical harness B (No. 16 in kit) over crossmember as shown; connect plug C to connector on fuel pump and connect terminals together at D.
    • Slide rubber sleeves A (No. 11 in kit) over connectors.
    • Reconnect battery ground.
    • Start engine and check for fuel leaks.
    • Reinstall wheel.
    October 10, 1976
    Note

    To scale the template when printing, note that the distance from the centers of the two drilled holes should be 140 mm.