Ford Escort Rs Turbo Technical and Fuel Injection Diagnosis Information
Ford Escort Rs Turbo Technical and Fuel Injection Diagnosis Information
Ford Escort Rs Turbo Technical and Fuel Injection Diagnosis Information
THE FUEL INJECTION SYSTEM USED IS THE BOSCH KE JETRONIC (VERSION KE2)
WITHOUT LAMBDA CONTROL.
START ENRICHMENT
WARM UP ENRICHMENT
ACCELERATION ENRICHMENT
OVERRUN CUT-OFF
PARTS LIST
AIRFLOW SENSOR
MIXTURE CONTROL UNIT
FUEL DISTRIBUTOR
FUEL PRESSURE REGULATOR
COLD START VALVE
INJECTORS
THERMO TIME SWITCH
AUXILIARY AIR VALVE
FUEL PUMP
FUEL FILTER
THROTTLE BODY
ENGINE COOLANT TEMPERATURE SENSOR
CONTROL UNIT
FUEL DELIVERY
1100 CM3 / MINUTE MINIMUM
SENSORS
TEMPERATURE SENSOR ( ENGINE COOLANT )
15-30 DEGREES C 1300-3600 OHMS
80 DEGREES C 250-390 OHMS
ADJUSTING CO
THE THROTTLE POSITION SWITCH SHOULD CLICK WHEN YOU START TO MOVE
THE THROTTLE, IF IT DOESN’T YOU WILL HAVE TO EITHER HAVE TO ADJUST IT ( BY
LOOSENING THE TWO SCREWS ) OR REPLACE IT ALSO CHECK THE RESISTANCE.
IF THE FUEL PRESSURE IS TOO HIGH THEN YOU NEED TO CHECK THE FOLLOWING.
CHECK THE FUEL RETURN LINE, THE BEST WAY IS TO EITHER DISCONNECT THE
RETURN AND USE YOUR OWN PIPE INTO A JUG AND THEN RE CHECK THE VALUE.
YOU CAN ALSO DISCONNECT THE RETURN LINE AND BLOW AN AIR LINE DOWN IT
(DON’T FORGET TO REMOVE THE FUEL CAP FIRST!)
IF IT IS TOO HIGH AND THE RETURN LINE IS NOT BLOCKED THEN THE PRESSURE
REGULATOR COULD BE FAULTY.
IF THE FUEL PRESSURE IS TOO LOW THEN YOU NEED TO DO A FUEL DELIVERY
TEST, IF THAT IS OK THEN IT COULD BE THE FUEL PRESSURE REGULATOR.
PUT THE AMP METER IN SERIES INTO ONE OF THE WIRES GOING TO THE
PRESSURE ACTUATOR, UNPLUG THE COOLANT TEMPERATURE SENSOR AND
CONNECT THE SENSOR SIMULATOR ACROSS THE MULTI PLUG AND CHANGE THE
RESISTANCE. THE PRESSURE SHOULD THEN CHANGE AS THE RESISTANCE IS
CHANGED. THIS DETERMINES THAT THE ELECTRONIC CONTROL UNIT AND THE
PRESSURE ACTUATOR ARE WORKING CORRECTLY.
FUEL PRESSURE ACTUATOR
THE PRESSURE ACTUATOR IS LOCATED ON THE SIDE OF THE FUEL DISTRIBUTOR,
IT IS CONTROLLED BY THE ECU WHICH LOOKS AT THE FOLLOWING INPUTS TO
DETERMINE HOW IT IS OPERATED : COOLANT TEMPERATURE SENSOR, AIR FLOW
SENSOR AND THE THROTTLE POSITION SWITCH.
YOU CAN TEST THE ACTUATOR BY CHECKING THE LOWER CHAMBER PRESSURE
AND ALSO CHECKING THE CURRENT ( SEE PIC ABOVE ON HOW TO CONNECT
AMP METER ).
BELOW YOU CAN SEE HOW THE PRESSURE REACTS WHEN THE CURRENT IS
CHANGED NOTE THE CURRENT VALUES MAY VARY SLIGHTLY.
ALSO CHECK THE RESISTANCE OF THE ACTUATOR, THIS SHOULD BE BETWEEN 16
AND 21 OHMS.
AFTER YOU HAVE COMPLETED THE PRESSURE TESTS, LEAVE THE GUAGE IN LINE
AND TAKE A NOTE OF THE READING. LEAVE THE CAR FOR 20 MINUTES AND IF
THE PRESSURE HAS DROPPED MORE THAN THE SPECIFIED VALUE YOU HAVE AN
INTERNAL FUEL LEAK. CHECK THE FUEL PIPES, FUEL PUMP NON RETURN VALVE
(located on output of pump), INJECTORS AND COLD START VALVE ARE NOT
LEAKING.
INJECTORS
LEAVE THE FUEL PIPES CONNECTED AND REMOVE INJECTORS FROM THE INLET
MANIFOLD. PLACE THEM IN A SUITABLE SEE THOUGH CONTAINER, BRIDGE THE
FUEL PUMP RELAY AND SLOWLY LIFT THE FUEL DISTRIBUTOR SENSOR PLATE AND
CHECK THE INJECTOR SPRAY PATTERN, IT SHOULD BE CONE SHAPED (SEE PIC
BELOW) AND NOT DRIP OR POUR PETROL OUT. IF THE CAR HAS DONE MORE THAN
60,000 MILES THEN THEY USUALLY NEED REPLACING AND CANNOT BE CLEANED.
CHECK THAT WHEN THE SENSOR PLATE IS AT REST POSITION THE INJECTORS DO
NOT DRIP.
SENSOR TESTS
AUXILIARY AIR VALVE
THIS SENSOR IS THE SAME AS USED IN THE OLDER XR3I K JETRONIC SYSTEM.
THE WAY IT WORKS IS BY AN ELECTRICAL HEATING ELEMENT WHICH IS
ACTIVATED WHEN THE FUEL PUMP RELAY TURNS ON DURING ENGINE CRANKING
AND RUNNING. AS THE ELEMENT HEATS UP IT CAUSES A PLATE TO SLOWLY
BLOCK OFF THE AIR PASSAGE SLOWING DOWN THE IDLE SPEED. IT TAKES
AROUND 3 MINUTES TO BLOCK THE PASSAGE OFF.
WHEN THE ENGINE IS COLD IF YOU CLAMP OFF THE PIPE FROM THE VALVE THE
ENGINE SPEED SHOULD DROP. WHEN THE ENGINE IS HOT THE ENGINE SPEED
SHOULD NOT BE AFFECTED.
IF IT IS DIFFERENT FROM THE ABOVE THEN CHECK THE WIRING, PIPES, INLET FOR
LEAKS, AND THE VALVE TO SEE IF IT WORKING CORRECTLY.
87 31 86 30 30 15 31b 31 87
25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
Earth
Throttle SwitchPressure
Actuator
BELOW IS A FAULT TABLE WHICH MAY BE
USEFUL TO HELP FIND FAULTY COMPONENTS
FAULT COMPONENT
Engine fails to Engine fails to Uneven idling Uneven idling Poor throttle Missfire
Start or cold start start or hot start during warm up engine warm take up
problem problem
Poor Engine High fuel Flat spot CO too CO too Idle speed Engine starts
performance runs on consumption acceleration high low too high & then dies
WIRING DIAGRAM
IGNITION ECU
25 20 15 14 13 12 7 6 2 1
EARTH
REV COUNTER
COIL
DISTRIBUTOR
IGNITION SWITCH
EARTH
BATTERY