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Wingless Wonder
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Disassembling Bosch components

Many Bosch components are assembled in two halves. (Things like the CBV [Crankcase Breather Valve] and the FCOV [Fuel Cut Off Valve].)


My FCOV has developed a leak, so that vacuum will no longer operate it. The valves used by Lotus had two 25mm O.D. ports ( Bosch part number 0280 142 020). These are NLA (unless some of you Ebay searchers can find something I can't).

I have sourced a different NOS FCOV (part # ends on 001), the only trouble is, that the ports are smaller (18mm). Not so much of a problem with the metering unit hose, but a PITA on the side that is supposed to be firmly anchored into the grommet in the air filter housing.

If I could break the bond between the two halves I could swap out the OEM port-side onto the new piece. After some online searching, I found the following methods of un-bonding glued plastic:

1. Isopropanol alcohol. This works well on hot-glue, but it didn't work on the Bosch piece.

2. Freezing. This works with Crazy Glue, but an overnight stay in our -6F. freezer didn't phase the Bosch adhesive.

Other things I can try:

3. Heat. Using a heat gun or oven, I would heat to 175F. for 10 minutes and twist it apart. (works for auto headlamp assemblies)

4. Pine-Sol or vinegar

5. Acetone (nail polish remover). A last resort, this has the potential of melting the plastic. -eek-



Or, if I could find a REALLY thick grommet I could fit the smaller valve into my air filter housing...


Can anyone offer some advice? :scratchhead: I DO have a second non-functional FCOV to 'practice' on.:evil:
 

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Wingless Wonder
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5,524 Posts
^^^ That (# 38 in the diagram below) doesn't look anything like the Esprit part. :scratchhead:

 

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Integrator
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2,717 Posts
Discussion Starter #187 (Edited)
Esprit CIS K-Jetronic system used VW Transporter T3. 2.1 Lambda Sensor, Bosch PN 0258003022.
Original part has been obsolete for years, but some speculators ask $175 for the "original sensor" (doubtful).


It has been reported by members of this forum, that Bosch universal PN 15735 can be used with excellent results and at a much low cost ($36 on eBay).

Some British websites specify Walker Universal PN 250-23000 as a suitable replacement.
http://www.lambdasensor.com/main/bosch/price.pl?item=0258003022
or search eBay for
"Walker Products 250-23000 Oxygen Sensor 3 Wire Universal"
.
 

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Integrator
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2,717 Posts
Discussion Starter #189 (Edited)
I am replacing my previously added AEM-1 boost controller with Innovate SCG-1
http://www.innovatemotorsports.com/products/scg1.php

Very neat gadget, which also gives a data logging capabilities.

The Innovate Motorsports SCG-1 is a revolutionary approach to boost control that integrates an advanced standalone boost controller with Innovate’s industry leading DirectDigital™ wideband air fuel ratio technology. When we decided to build a boost controller, we knew we had to offer more capabilities than other products available today, while still maintaining the user friendly functionality demanded by our customers. Instead of repackaging the same boost control technology that has been used for decades, we choose to pair our advanced O² sensor control technology with our all-new, proprietary solenoid control that provides superior boost control accuracy, response and safety. We also added a user programmable shift light and housed the entire package in a compact gauge body for ease of installation and use. As with all of our air/fuel ratio products, the SCG-1 utilizes the only 100% digital wideband air/fuel ratio technology to provide real time feedback to the SCG-1. This air/fuel information is displayed on an integrated OLED display along with manifold pressure and wastegate duty status. The air/fuel ratio information is also used to provide a user definable boost cut that enhances the safety margin over most competitors offerings that only rely on over boost threshold. The SCG-1 has a full-programmable analog output ideal for applications using standalone ECU’s, piggy-back ECU’s or external data loggers. The SCG-1 also has a digital input/output for integration with our other Modular Tuning System (MTS) devices. This same digital output can be used to record air/fuel ratio, solenoid duty cycle, engine speed and manifold pressure with our free LogWorks PC software to help you dial in a perfect boost curve.


All-in-one, intelligent boost control and wideband air/fuel ratio gauge
Controller and display housed in 52mm (2 1/6”) diameter gauge body
Interchangeable faceplates & bezels: Black & silver bezel, black & white faceplates included
No PC required for configuration
OLED user configurable display
Boost, shift light, Air/Fuel ratio
AFR or Lambda, inHG, PSI, kPa, or BAR
Includes high resolution solenoid
4 BAR map sensor, pressure range -29 inHG to 43.5 PSI (-1 to 3 BAR)
User programmable boost cut safety using Air/Fuel and Pressure references
Programmable solenoid duty cycle with separate gain control function
Peak hold function
Patented DirectDigital™ wideband sensor control, the only 100% digital wideband air/fuel ratio technology!
Wideband O² Compatible with several fuel types (Leaded, Unleaded, Diesel, E85 & more)
Ability to calibrate O² sensor for maximum accuracy
Configurable linear 0-5v analog output for wideband O² for use with piggy back or stand alone ECU’s as well as external data loggers
Innovate MTS serial in/out (for use with other Innovate & 3rd party MTS enabled devices to add additional logging channels)
4 channels of log-able data with powerful LogWorks PC Software (MAP, RPM, A/F, WG duty)
.
 

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Integrator
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2,717 Posts
Discussion Starter #190 (Edited)
PL-1: Pocket Logger, Innovate MTS Datalogger

The PL-1 is the latest in Innovate Motorsports’ line-up of products to allow for easy data logging of your MTS (Modular Tuning System) compatible product. Whether you have an LC-1 & SSI-4, MTX gauges, or any other combination of Innovate Motorsports MTS devices, the PL-1 integrates seamlessly to record all the data from the connected devices.

Records up to 32-channels of Innovate MTS compatible devices
Sample rate of 12 times per second
Log directly to SD card (included) 2GB SD = 580 hours of recording!
Playback log data with powerful LogWorks software (available for download)
Positive lock connectors for all connections
Innovate MTS serial IN
Trigger recording on PL-1 and/or with "optional" remote push button (coming soon)
PL-1: Pocket Logger, Innovate MTS Datalogger
 

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Integrator
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2,717 Posts
Discussion Starter #191
If you add Innovate SSI-4 analog-to digital adapter, you can log any 0-5V sensor or other than Innovate, (PLX or other) stand along devices.

The SSI-4 device is a simple sensor interface that adds 4 inputs to an MTS Log Chain. The SSI-4 may also be used as a stand-alone device for logging data directly into a laptop with the included LogWorks software or it can be used in conjunction with any other MTS compliant device.
Channel 1 is a direct RPM input by default, and can also be configured for external 0-5V or frequency. Channels 2-4 are configured to digitize external 0-5V analog signals by default but they can setup to directly measure frequency (like driveshaft speed) or duty cycle (for injectors).

The SSI-4 is also a key component of Innovate Motorsports' Modular Tuning System (MTS). Using the SSI-4's serial ports you can daisy-chain other Innovate devices such as the XD-16, AuxBox (LMA-3), LC-1, DL-32, and TC-4. See: MTS Modular Tuning System
 

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Integrator
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2,717 Posts
Discussion Starter #192
Quick reference, condensed and to the point

Mitchell's Electronic Fuel Injection Troubleshooting Guide: Import Vehicles Paperback – January, 1990
by Mitchell International (Author)

Publisher: California Bill's Automotive (January 1990) Language: English ISBN-10: 1555610315 ISBN-13: 978-1555610319
 

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Integrator
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2,717 Posts
Discussion Starter #196 (Edited)
J&S Safeguard "Vampire" anti-knock sensor

When installing the J&S Safeguard individual cylinder anti-knock controller (dual channel Vampire, J&S Vampire )
on pre-1989 Esprits, it is necessary to add a boss for the knock sensor.

1989+ Esprits with Delco ECU had a primitive "retard all" anti-knock feature built in.
OE sensor location is between 3rd and4th cylinder, pic 1.

Modeling clay was used to make a pattern of the block ribs and corresponding grooves were milled in a block of 6061 aluminum. Hole was drilled and tapped for M8-1.25mm Helicoil.

Sensor and the bolt is supplied by J&S.

Attach the boss to the block ribs with Clickbond Hi-temperature structural epoxy adhesive, which is sometimes available at The Flight Shop (phone 435-723 3469), or Electrical Hub (425-745 1266).
CB394 is a two part structural paste adhesive which cures at room temperature and possesses
excellent strength to 350F/177C and higher. Its thixotropic nature and excellent high temperature
compressive strength also make it ideal for potting, filling, and liquid shim applications. CB394 adhesive
meets the specifications of MMM-A-132 Rev. A, Type I, Class 3.
 

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Integrator
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2,717 Posts
Discussion Starter #200 (Edited)
87/88 CIS Turbo- official power&torque?

WHAT'S RIGHT?

Dec 1988 Motor Trend and June 1988 Car and Driver
show 215 HP @6250 rpm and 192 lb-ft @5000 rpm

The book "Supercars: Lotus Esprit Turbo",p. 30, states 215 HP @ 6000 rpm, HP and 220 lb-ft @4250 rpm

"The Complete Story" book quotes on page 117, 215 BHP @ 6250 rpm and 220 lb-ft @ 4250 rpm,
but page 129 shows 215 BHP @ 6000 rpm and 220 lb-ft @4250 rpm

"Lotus since 70-s, volume 2", p. 71,
shows 215 BHP @ ? and 192 lb-ft @5000 rpm for Bosch injected cars with 8.0:1 CR.
 

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