Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical … Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical fuel injection systems

Chapter 4 Part B:Bosch K-Jetronic and KE-Jetronic mechanical fuel injection systems

Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . .5Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .2Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . .See Chapter 1Auxiliary air device - removal and refitting . . . . . . . . . . . . . . . . . . . .10Charge air temperature sensor - removal and refitting . . . . . . . . . .17Cold start valve - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .9Electro-magnetic pressure actuator - removal and refitting . . . . . .15Fuel accumulator - removal and refitting . . . . . . . . . . . . . . . . . . . . . .7Fuel distributor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .11Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1Fuel injection control module - removal and refitting . . . . . . . . . . . .16Fuel injectors and delivery pipes - removal and refitting . . . . . . . . . .8Fuel pressure regulator - removal and refitting . . . . . . . . . . . . . . . .13

Fuel pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .6Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . .1Idle speed and mixture adjustment . . . . . . . . . . . . . . . .See Chapter 1Idle speed compensator - removal and refitting . . . . . . . . . . . . . . .19Intercooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .22Thermo-time switch - removal and refitting . . . . . . . . . . . . . . . . . . .18Throttle cable - adjustment, removal and refitting . . . . . . . . . . . . . . .4Throttle housing - removal and refitting . . . . . . . . . . . . . . . . . . . . . .12Turbocharger - general description . . . . . . . . . . . . . . . . . . . . . . . . .20Turbocharger - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .23Warm-up regulator - removal and refitting . . . . . . . . . . . . . . . . . . . .14Waste gate solenoid control valve - removal and refitting . . . . . . . .21

GeneralSystem type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch mechanical continuous injection systemApplication:

XR3i and XR3i Cabriolet models up to 1990 . . . . . . . . . . . . . . . . . . . Bosch K-JetronicRS Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch KE-Jetronic

K-Jetronic system specificationFuel pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt electric roller cell typeFuel pump delivery quantity (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 litre (1.32 pints) in 30 secondsIdle speed (cooling fan on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpmIdle mixture CO content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5%Main system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 to 5.5 bar (68 to 80 lbf/in2)Control pressure (warm engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 to 3.8 bar (39 to 45 lbf/in2)Injector valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 to 4.0 bar (46.4 to 51.5 lbf/in2)

KE-Jetronic system specificationFuel pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt electric roller cell typeFuel pump delivery quantity (minimum):

1985 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 litres (1.9 pints) in 60 seconds1986 models onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 litres (4.4 pints) in 60 seconds

Idle speed (cooling fan on):1985 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 900 rpm1986 models onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 to 960 rpm

Idle mixture CO content:1985 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.75%1986 models onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.1%

Main system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 to 6.0 bar (82 to 87 lbf/in2)Injector valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 to 4.1 bar (43.5 to 59.5 lbf/in2)

4B•1

Easy, suitable fornovice with littleexperience

Fairly easy,suitable forbeginner withsome experience

Fairly difficult,suitable forcompetent DIYmechanic

Difficult, suitablefor experiencedDIY mechanic

Very difficult,suitable for expertDIY or professional

Degrees of difficulty

Specifications

Contents

4B

Kocho Mladenov

Note

Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical fuel injection systems

TurbochargerType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Garrett AiResearch T3Maximum boost pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 to 0.55 bar (6.5 to 7.9 lbf/in2)Solenoid control valve operating range . . . . . . . . . . . . . . . . . . . . . . . . . 2500 to 6000 rpm (approximately)

Fuel requirementFuel octane rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 RON (four-star)

Torque wrench settings Nm lbf ft

K-Jetronic systemAir cleaner retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 5 3 to 4Fuel distributor-to-sensor plate screws . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 38 24 to 28Sensor plate-to-air cleaner screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Warm-up regulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 2 to 4Cold start valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 2 to 4Auxiliary air device bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 2 to 4Inlet manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 12 to 15Throttle housing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 to 17 10 to 13Exhaust downpipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 40 25 to 29Banjo union bolts:

Fuel distributor inlet and return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 11 to 15Fuel distributor injector pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 8 4 to 6Fuel distributor cold start valve feed pipe . . . . . . . . . . . . . . . . . . . . . . 5 to 8 4 to 6Fuel distributor warm-up regulator feed and return pipes . . . . . . . . . 5 to 8 4 to 6Warm-up regulator inlet (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 to 15 8 to 11Warm-up regulator outlet (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 8 4 to 6Fuel pump, filter and accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 11 to 15

KE-Jetronic systemAir cleaner bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Fuel distributor-to-sensor plate screws . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 38 24 to 28Cold start valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Auxiliary air device bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Inlet manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 11 to 15Throttle housing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8Thermo-time switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Charge air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Air inlet duct to rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 to 18 10 to 13Cold start valve fuel supply pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 8 4 to 6Auxiliary air valve vacuum connection . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3Fuel pressure regulator unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 to 20 10 to 15Fuel distributor unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 to 15 8 to 11Fuel pump, filter and accumulator unions . . . . . . . . . . . . . . . . . . . . . . . 16 to 20 11 to 15Fuel injector pipe unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 12 7 to 9Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 to 17 10 to 13Turbocharger to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 26 15 to 19Exhaust downpipe to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 40 25 to 29

4B•2 Bosch K and KE fuel injection systems

General informationThe fuel system comprises a centrally

mounted fuel tank, electrically-operated fuelpump and Bosch K-Jetronic or KE-Jetroniccontinuous injection system according tomodel. The system is used in conjunction witha turbocharger on RS Turbo models.

A more detailed description of the varioussystem components is given in the followingparagraphs.

Bosch K-Jetronic system

The Bosch K-Jetronic fuel-injection systemis of the continuous injection type andsupplies a precisely controlled quantity ofatomised fuel to each cylinder under alloperating conditions.

This system, when compared withconventional carburettor arrangements,achieves a more accurate control of theair/fuel mixture resulting in reduced emissionlevels and improved performance.

The main components of the fuel injectionsystem are as follows (see illustration).a) Fuel tankb) Fuel pump

c) Fuel accumulator d) Fuel filtere) Fuel distributor/mixture control assemblyf) Throttle valve (plate) g) Injector valves h) Air box (plenum chamber) I) Warm-up regulatorj) Auxiliary air devicek) Cold start valvel) Thermo-time switchm)Safety modulen) Fuel shut-off valveo) Speed sensor moduleThe fuel pump is of electrically-operated,

roller cell type.

1 General information andprecautions

The fuel accumulator has two functions, (i)to dampen the pulsation of the fuel flow,generated by the pump and (ii) to maintainfuel pressure after the engine has beenswitched off. This prevents a vapour lockdeveloping with consequent hot startingproblems.

The fuel filter incorporates two paper filterelements to ensure that the fuel reaching theinjection system components is completelyfree from dirt.

The fuel distributor/mixture controlassembly. The fuel distributor controls thequantity of fuel being delivered to the engine,ensuring that each cylinder receives the sameamount. The mixture control assemblyincorporates an air sensor plate and controlplunger. The air sensor plate is located in themain airstream between the air cleaner and

the throttle butterfly. During idling, the airflowlifts the sensor plate which in turn raises acontrol plunger which allows fuel to flow pastthe plunger and out of the metering slits to theinjector valves. Increases in engine speedcause increased airflow which raises thecontrol plunger and so admits more fuel.

The throttle valve assembly is mounted inthe main air inlet between the mixture controlassembly and the air box.

The injector valves are located in the inletmanifold.

The air box is mounted on the top of theengine and functions as an auxiliary inletmanifold directing air from the sensor plate toeach individual cylinder.

The warm-up regulator is located on theinlet manifold and incorporates two coilsprings, a bi-metal strip and a control

pressure valve. The regulator controls the fuelsupplied to the control circuit which providespressure variations to the fuel distributorcontrol plunger. When the coil springs arepushing against the control pressure valvethere is a high control pressure and this givesa weak mixture. The coil spring pressureapplication is controlled by the bi-metal stripwhich in turn is activated in accordance withengine temperature and an electrical heat coil.

The auxiliary air device is located on theinlet manifold. It consists of a pivoted plate,bi-metal strip and heater coil. The purpose ofthis device is to supply an increased volumeof fuel/air mixture during cold idling.

The start valve system consists of anelectrical injector and a thermo-time switch.Its purpose is to spray fuel into the air box toassist cold starting, the thermo-time switchregulating the amount of fuel injected.

Bosch K and KE fuel injection systems 4B•3

4B

1.5 K-Jetronic system maincomponent locations

A Warm-up regulator

B Speed sensing module

C Fuel accumulator (early model location)

D Fuel pump

E Throttle housing

F Cold start valve

G Fuel distributor

H Fuel filter

The safety module is located under thefacia panel on the driver’s side and iscoloured purple (see illustration). Its purposeis to shut off the power supply to the fuelpump should the engine stall or the vehicle beinvolved in an accident. The module sensesignition pulses, and cuts the fuel supply if theignition pulses stop.

The fuel shut-off valve system is aneconomy device whereby air is drawn fromwithin the air cleaner unit through the shut-offvalve and directed into the ducting chamberabove the air sensor plate causing adepression. This then causes the sensor plateto drop which, in turn, shuts off the fuelsupply. The valve is operated by signals froma coolant temperature sensor and a throttleposition sensor. The shut-off valve will onlyoperate under the following circumstances:a) When the engine coolant temperature is

at or above 35°C (95°F)b) When the throttle is closed and with the

engine speed decelerating from speedsabove 1600 rpm

The engine speed is sensed by a speedsensing module which is coloured black andlocated beneath the facia panel on the driver’sside.

Bosch KE-Jetronic systemThe Bosch KE-Jetronic fuel-injection

system is fitted to Escort RS Turbo modelsand is a further development of the K-Jetronicsystem.

Apart from minor alterations the basicprinciples of the hydraulics and mechanicsused on the K-Jetronic system are unchangedon the KE-Jetronic system. The maindifference between the two types is that on theKE-Jetronic system all mixture corrections arecontrolled electronically by an electromagneticpressure actuator incorporated in the fueldistributor. The pressure actuator is directlycontrolled by a variable electric currentdelivered by the fuel-injection control module.

This module receiver inputs from the variousengine sensors concerning enginetemperature, engine load, throttle shift, throttleposition and starter actuation. This informationmodifies a program stored in the modulememory so that the electromagnetic pressureactuator, on receiving the signal from themodule, can alter the mixture to suit all engineoperating conditions. This renders the controlpressure circuit and warm-up regulator of theK-Jetronic system unnecessary, and alsoundertakes the functions of the fuel shut-offvalve, safety module and speed sensingmodule (see illustration).

PrecautionsDue to the complexity of the fuel-injection

system, and the need for special tools andtest equipment, any work should be limited tothe operations described in this Chapter.Other adjustments and system checks arebeyond the scope of most readers and shouldbe left to a Ford dealer.

Before disconnecting any fuel lines, unionsor components thoroughly clean thecomponent or connection and the adjacentarea.

Place any removed components on a cleansurface and cover them with plastic sheet orpaper. Do not use fluffy rags for cleaning.

The system operates under pressure at alltimes and care must be taken whendisconnecting fuel lines. Relieve the systempressure as described in the relevant Sectionbefore disconnecting any fuel lines under

pressure. Refer to the warning note at the endof this Section, and always work with thebattery negative lead disconnected and in awell ventilated area.

When working on the KE-Jetronic systemthe following additional precautions must beobserved:a) Never start the engine when the battery is

not firmly connected.b) Never disconnect the battery when the

engine is running.c) If the battery is to be rapid charged from

an external source it should be completelydisconnected from the vehicle electricalsystem.

d) The KE-Jetronic control unit must beremoved from the car if temperatures arelikely to exceed 80°C (176°F) as would beexperienced, for example, in a paint sprayoven or if any electric welding is beingcarried out on the car.

e) The ignition must be switched off whenremoving the control unit.


1.16 K-Jetronic system speed sensingmodule and fuel pump safety module

locations

1.19 KE-Jetronic fuel-injection system layout and components

1 Injector2 Cold start valve3 Throttle plate4 Sensor plate5 Fuel distributor6 Electro-magnetic pressure actuator7 Thermo-time switch8 Temperature sensor

9 Throttle position switch10 Auxiliary air device11 Pressure regulator12 Control module13 Fuel filter14 Fuel accumulator15 Fuel pump16 Fuel tank

Warning: Many of the proceduresin this Chapter entail the removalof fuel pipes and connectionswhich may result in some fuel

spillage. Before carrying out any operationon the fuel system refer to the precautionsgiven in Safety First! at the beginning ofthis manual and follow them implicitly.Petrol is a highly dangerous and volatileliquid and the precautions necessary whenhandling it cannot be overstressed

K-Jetronic system

Removal1 Remove the air cleaner element asdescribed in Chapter 1.2 Detach the fuel filter from the side of thecleaner casing (leave the fuel lines attached tothe filter) and the air inlet hose from the frontend of the case.3 Unscrew and remove the casing retainingnuts from the inner wing panel and lift out thecasing.

Refitting4 Refitting is the reversal of the removalprocedure. Refit the air cleaner element asdescribed in Chapter 1.

KE-Jetronic system

Removal5 Undo the two bolts securing the air cleanerassembly to the air sensor plate unit andremove the air cleaner assembly (seeillustration).

Refitting6 Refit the unit to the air sensor plate andsecure with the two bolts.

The procedures are the same as describedin Part A of this Chapter for carburettorengines, but in addition disconnect the fueltank-to-fuel pump hose from the rear face ofthe tank.

AdjustmentThe procedure is the same as described in

Part A of this Chapter for carburettor engines,except that the cable adjuster is situated in abracket alongside the throttle housing.

Removal and refittingThe procedure is the same as described in

Part A of this Chapter for carburettor engines,except that it is not necessary to remove theair cleaner, and the location of the mountingbracket is alongside the throttle housing.

The procedure is the same as described inPart A of this Chapter for carburettor models.

Note: Refer to the precautions at the end ofSection 1 before proceeding.

Removal1 The fuel pump is bolted to the underside ofthe car just to the rear of the fuel tank. Foraccess raise and support the car securely atthe rear. 2 Disconnect the battery earth lead.3 On the K-Jetronic system relieve thesystem pressure by slowly loosening the fuelfeed pipe union at the warm-up regulator (seeillustration). Absorb the fuel leakage in acloth.4 On the KE-Jetronic system relieve thesystem pressure by slowly loosening the coldstart valve union on the top of the fueldistributor (see illustration). Absorb fuelleakage in a cloth.5 Clamp the fuel inlet hose midway betweenthe tank and the pump using a brake hoseclamp, self-locking grips or similar. If the fuellevel in the tank is low you may prefer to drainthe fuel from the tank into a suitable containeronce the inlet hose is disconnected.6 Disconnect the fuel inlet and outlet pipesfrom the pump, catching fuel spillage in asuitable container (see illustration). Oncedisconnected do not allow dirt to enter the

pipes, temporarily plug or seal them ifnecessary.7 Note the electrical connections to the pumpand disconnect them.8 Loosen the pump bracket retaining bolt andthen withdraw the pump unit with rubberprotector sleeve.

Refitting9 Refitting of the fuel pump is a reversal ofthe removal procedure. Renew the feed pipefrom the tank if it is damaged or defective.10 Check that the rubber protector sleeve iscorrectly positioned round the pump beforetightening the clamp nut.11 On completion, tighten the warm-upregulator or cold start valve fuel unions,reconnect the battery earth lead, start theengine and check for any fuel leaks.


Pre-1986 models

Removal1 The fuel accumulator is mounted adjacentto the fuel pump, above the rear left-handsuspension arm.2 Disconnect the battery negative lead.

7 Fuel accumulator - removaland refitting

6 Fuel pump - removal andrefitting

5 Accelerator pedal - removaland refitting

4 Throttle cable - adjustment,removal and refitting

3 Fuel tank - removal and refitting

2 Air cleaner - removal andrefitting


4B

2.5 KE-Jetronic air cleaner retaining bolts(arrowed)

6.3 Warm-up regulator fuel feed pipe (A),outlet pipe (B) and wiring multi-plug (C)

6.4 KE-Jetronic system cold start valvepipe union (arrowed) on fuel distributor

6.6 Fuel pump outlet pipe (A), electricalconnections (B) and pump bracket

retaining bolt (C)

3 Raise the rear of the car and support it onaxle-stands (see “Jacking and VehicleSupport”).4 Relieve the system pressure by slowlyloosening the fuel feed pipe at the warm-upregulator. Absorb fuel leakage in a cloth.5 Disconnect the fuel pipes from the fuelaccumulator and catch the small quantity offuel which will be released (see illustration).6 Remove the clamp screw and remove theaccumulator.

Refitting7 Refitting is a reversal of removal. Check forleaks on completion (with the enginerestarted).

1986 models onwards

Removal8 On later models with K-Jetronic and KE-Jetronic systems the fuel accumulator islocated in the engine compartment behind thefuel distributor.9 Disconnect the battery negative lead.10 For access remove the air cleaner asdescribed in Section 2.11 Relieve the system pressure by slowlyloosening the cold start valve union on the topof the fuel distributor (see illustration 6.4).Absorb fuel leakage in a cloth.12 Disconnect the fuel pipes from the

accumulator and catch the small quantity offuel which will be released (see illustration).13 Remove the clamp screw and remove theaccumulator.

Refitting14 Refitting is a reversal of removal. Checkfor leaks on completion (with the enginerestarted).

Note: Refer to the precautions at the end ofSection 1 before proceeding. It is important tonote that each injection supply pipeconnection in the distributor head has a screwadjacent to it. These four screws are not foradjustment and must not be removed or havetheir settings altered. New O-ring seals mustbe used on refitting.

Removal1 Disconnect the battery earth lead.2 Detach the four supply pipes from theinjectors, and use a rag to collect any spilledfuel.3 Unscrew and remove the respectiveinjector retaining bracket bolts, then withdrawthe injectors and their O-ring seals (seeillustration).

4 The injector fuel delivery pipes can beremoved by unscrewing and removing thefour banjo bolts at the distributor head. Notethe respective pipe connections as they aredetached and remove the pipes completewith the plastic hoses and the injectorharness. Do not separate the pipes or hosesfrom the injector harness.5 Before reassembling the fuel delivery pipes,or the injectors, clean all pipe connectionsthoroughly and use new O-ring seals on theinjectors. Use new seal washers on the banjoconnections fitting two washers (one eachside) per union. Do not overtighten the banjobolts, or the washers may fracture.

Refitting6 Refitting of the injectors and the fuel deliverypipes is otherwise a reversal of the removalprocedure. On completion check that the pipesand hoses are not distorted and when theengine is restarted check for any signs of leaks.


K-Jetronic system

Removal1 Disconnect the battery earth lead. 2 Detach the electrical wiring multi-plug fromthe valve (see illustration).3 Slowly unscrew and remove the fuel supplypipe banjo bolt. Take care on removal, as thesystem will be under pressure. Soak up fuelspillage with a cloth.4 Unscrew and remove the two socket-headmounting bolts using an Allen key or Torx typekey or socket bit on later models, and removethe valve.

Refitting5 Refitting is a reversal of the removalprocedure. Do not overtighten the banjo boltor the washers may fracture (use a new oneeach side of the union).6 On completion restart the engine and checkfor signs of fuel leakage.

9 Cold start valve - removal andrefitting

8 Fuel injectors and injectordelivery pipes - removal andrefitting


7.5 Fuel pipe connections (arrowed) at theunderbody mounted fuel accumulator

7.12 Fuel inlet pipe (A) and outlet pipe (B)at the engine compartment mounted fuel

accumulator

8.3 Injector fuel pipe union (A) andretaining bracket bolt (B)

9.2 Disconnecting the cold start valvewiring multi-plug

9.8 KE-Jetronic system cold start valvelocation

A Fuel pipe union B Retaining bolts

KE-Jetronic system

Removal7 Disconnect the battery earth lead.8 Disconnect the wiring multi-plug from thevalve which is located underneath the throttlehousing (see illustration).9 Slowly unscrew and remove the fuel supplypipe banjo union. Take care on removal, asthe system will be under pressure. Soak upfuel spillage with a cloth.10 Unscrew and remove the two Torx typemounting bolts using a Torx key or socket bit.Remove the valve from under the throttlehousing.

Refitting11 Refitting is a reversal of removal. Do notovertighten the banjo bolt or the washers mayfracture (use a new one each side of theunion).12 On completion restart the engine andcheck for leaks.

K-Jetronic system

Removal1 Disconnect the battery earth lead.2 Disconnect the wiring multi-plug and thetwo air hoses from the device which is locatedbeneath the cold start valve (see illustration).3 Undo the two Torx type retaining boltsusing a Torx key or socket bit and lift the unitaway (see illustration).

Refitting4 Refitting is a reversal of removal.

KE-Jetronic system

Removal5 Apply the handbrake, jack up the front ofthe car and support it on axle stands (see“Jacking and Vehicle Support”).

6 Disconnect the battery negative lead.7 Disconnect the auxiliary air device wiringmulti-plug and the two air hoses.8 Undo the two Torx type retaining boltsusing a Torx key or socket bit and remove theunit from under the inlet manifold (seeillustration).


Note: Refer to the precautions at the end ofSection 1 before proceeding. It is important tonote that each injection supply pipe connectionin the distributor head has a screw adjacent toit. These four screws are not for adjustment andmust not be removed or have their settingsaltered. A new O-ring and new banjo unionsealing washers will be required on refitting.

K-Jetronic system

Removal1 Disconnect the battery negative lead.2 Relieve the system pressure by slowlyloosening the fuel feed pipe union at the

warm-up regulator (see illustration 6.3).Absorb the fuel leakage in a cloth.3 Disconnect the four injector feed pipes, thefuel inlet and return pipes, and the warm-upregulator feed and return pipe banjo unions atthe fuel distributor (see illustration). Note thesealing washers on each side of the banjounions which must be renewed on reconnectionof the pipes. Take care not to allow dirt to enterthe pipes or their connection ports.4 Unscrew the three retaining screws fromthe fuel distributor top face and remove theunit from the car (see illustration). Recoverthe sealing O-ring.

Refitting5 Refitting is a reversal of removal, but ensureperfectly clean mating faces and use a newsealing O-ring and new washers for the banjounions. Check for any signs of leaks oncompletion and adjust the idle speed andmixture settings as described in Chapter 1.6 The main system fuel pressure should bechecked and if necessary adjusted by a Forddealer to ensure satisfactory running of thesystem.

KE-Jetronic system

Removal7 Disconnect the battery negative lead.8 Relieve the system pressure by slowlyloosening the cold start valve union on the topof the fuel distributor (see illustration 6.4).Absorb fuel leakage in a cloth.

11 Fuel distributor - removal andrefitting

10 Auxiliary air device - removaland refitting


4B

10.2 K-Jetronic system auxiliary air deviceconnections

A Throttle housing hoseB Cold start valve hoseC Wiring multi-plug

10.3 K-Jetronic system auxiliary air deviceretaining bolt locations

10.8 KE-Jetronic system auxiliary airdevice retaining bolts

11.3 K-Jetronic fuel distributor pipeconnections

A To injectorsB To cold start valveC Fuel returnD From warm-up

regulator

E Fuel inletF To warm-up

regulator11.4 K-Jetronic system fuel distributor

retaining screws (arrowed)

9 Disconnect the four injector feed pipes, thecold start valve pipe and union adapter, thefuel inlet pipe and pressure regulator returnpipe from the fuel distributor. Note the sealingwashers on each side of the banjo unionswhich must be renewed on reconnection ofthe pipes. Take care not to allow dirt to enterthe pipes or their connection parts.10 Disconnect the wiring multi-plug from thepressure actuator on the side of the fueldistributor.11 Undo the retaining screws and removethe fuel distributor (see illustration). Recoverthe sealing O-ring.

Refitting

12 Refitting is a reversal of removal, butensure perfectly clean mating faces and use anew sealing O-ring and new washers for thebanjo unions. Check for any signs of leaks oncompletion and adjust the idle speed andmixture settings as described in Chapter 1.

Note: During manufacture the throttle plate isadjusted so that it is fractionally open, to avoidthe possibility of it jamming shut, and it mustnot be repositioned. Idle speed adjustment isprovided for by means of a screw which,according to its setting, restricts the airflowthrough the air bypass channel in the throttlehousing.

K-Jetronic system

Removal1 Disconnect the battery negative lead.2 Slacken the retaining screw and detach theinlet air hose from the throttle housing.3 Disconnect the accelerator cable at thehousing linkage with reference to Section 4.4 Disconnect the distributor vacuum hoseand auxiliary air hose from the underside ofthe throttle housing.5 Undo the four nuts and carefully withdrawthe throttle housing from the manifold studs.

Refitting6 Refitting is a reversal of removal, but ensurethat the mating faces are perfectly clean.Renew the gaskets, one on each side of theinsulator block, if necessary.7 On completion adjust the idle speed asdescribed in Chapter 1.

KE-Jetronic system

Removal8 Disconnect the battery negative terminal.9 Disconnect the charge air temperaturesensor and throttle position sensor wiringmulti-plugs (see illustration).10 Slacken the hose clip and detach the airinlet hose from the inlet duct.11 Undo the two bolts securing the inlet ductto the rocker cover slacken the throttlehousing connecting hose clip and remove theinlet duct (see illustration).12 Extract the retaining clip and disconnectthe throttle cable end from the linkage ball-stud.13 Undo the two bolts and remove thethrottle cable bracket from the throttlehousing.14 Disconnect the auxiliary air hose, thenundo the four nuts and remove the throttlehousing.

15 Do not remove the throttle position sensorfrom the throttle housing unless absolutelynecessary. If it must be removed, mark itsposition for refitting and then have itaccurately adjusted by a Ford dealer oncompletion. This will also be necessary if thesensor or throttle housing are renewed.

Refitting16 Refitting is the reversal of removal, butuse a new gasket and ensure clean matingfaces. After refitting adjust the idle speed asdescribed in Chapter 1.


Removal1 The fuel pressure regulator is only used onKE-Jetronic systems and is located behindthe fuel distributor (see illustration).2 Disconnect the battery negative lead. 3 Relieve the system pressure by slowlyloosening the cold start valve union on the topof the fuel distributor (see illustration 6.4).Absorb fuel leakage in a cloth. 4 Place absorbent cloth beneath theregulator and undo the two fuel feed unionsand the fuel return union. Note the pipelocations to ensure correct refitting.

13 Fuel pressure regulator -removal and refitting

12 Throttle housing - removaland refitting


11.11 KE-Jetronic fuel distributor retainingscrews (arrowed)

12.9 Component attachments at the KE-Jetronic throttle housing

A Charge air temperature sensor multi-plugB Throttle position sensor wiring multi-plugC Throttle cable bracketD Connecting hose retaining clip

12.11 Air inlet duct retaining bolts(arrowed)

13.1 KE-Jetronic fuel pressure regulatorlocation (arrowed) behind fuel distributor

13.6 KE-Jetronic fuel pressure regulatorpipe connections

A Fuel feed B Fuel return

5 Remove the securing tie and withdraw theregulator from its bracket.

Refitting6 Refitting is a reversal of removal. Ensurethat all unions are correctly reconnected andsecure, and on completion check for fuel leakswith the engine running (see illustration).

Note: Refer to the precautions at the end ofSection 1 before proceeding. New banjounion sealing washers must be used onrefitting.

Removal1 The warm-up regulator is only used on K-Jetronic systems and is situated on the inletmanifold just to the rear of the rocker cover.2 Disconnect the battery negative lead.3 Relieve the system pressure by slowlyloosening the fuel feed pipe union at thewarm-up regulator (see illustration 6.3).Absorb the fuel leakage in a cloth.4 After relieving the system pressuredisconnect the fuel feed union completely,followed by the outlet union. Recover thesealing washers used on each side of theunions.5 Disconnect the regulator wiring multi-plug.6 Undo the two Torx type screws using asuitable Torx key or socket bit and remove theregulator from its location (see illustration).

Refitting7 Refitting is a reversal of removal, but usenew sealing washers on each side of the banjounions and apply a thread-locking compoundto the Torx retaining bolts. On completioncheck for leaks with the engine running.

Note: Refer to the precautions at the end ofSection 1 before proceeding. New O-ringsmust be used on refitting.

Removal1 The electro-magnetic pressure actuator isonly used on KE-Jetronic systems and islocated on the side of the fuel distributor.2 Disconnect the battery negative lead.3 Remove the air cleaner as described inSection 2.4 Relieve the system pressure by slowlyloosening the cold start valve union on the topof the fuel distributor (see illustration 6.4).Absorb fuel leakage in a cloth.5 Disconnect the wiring multi-plug, then undothe two screws securing the actuator to thefuel distributor (see illustration). Remove theunit and the sealing O-rings.

Refitting6 Refitting is the reverse sequence toremoval, but ensure both mating faces are

clean. New O-rings must be used and caretaken not to displace them when fitting. Oncompletion check for fuel leaks with theengine running.

Removal1 The fuel-injection control module is onlyused on KE-Jetronic systems and is located inthe engine compartment behind the heaterplenum chamber and fan motor.2 Disconnect the battery negative lead.3 Remove the plenum chamber top coverrubber seal (see illustration).4 Release the five retaining clips and lift offthe plenum chamber top cover (seeillustrations).5 Undo the two nuts securing the heater fanmotor assembly to the bulkhead. Lift the unitoff the studs and place it on the engine, butavoid straining the wiring (see illustrations).6 Disconnect the module wiring multi-plug,then undo the three screws and remove theunit from its location (see illustration).

Refitting7 Refitting is the reversal of removal. Takecare not to trap the motor wiring when refittingthe fan motor assembly and ensure that it isengaged in the slot provided in the housing(see illustration).

16 Fuel-injection control module- removal and refitting

15 Electro-magnetic pressureactuator - removal and refitting14 Warm-up regulator - removal

and refitting


4B

14.6 K-Jetronic system warm-up regulatorretaining screws

15.5 Pressure actuator wiring multi-plug(arrowed)

16.3 Remove the plenum chamber rubberseal

16.4a Release the retaining clips . . . 16.4b . . . and lift off the plenum chambertop cover

16.5a Heater fan motor retaining nut

Removal1 The charge air temperature sensor is onlyused on KE-Jetronic systems and is located inthe air inlet duct (see illustration). 2 Disconnect the battery negative lead. 3 Disconnect the wiring multi-plug andunscrew the sensor from its location.

Refitting4 Refitting is the reversal of removal.

Removal1 Disconnect the battery negative lead.2 Drain the cooling system as described inChapter 1. 3 Raise the front of the car and support it onaxle stands (see “Jacking and VehicleSupport”).4 Disconnect the wiring multi-plug from thethermo-time switch located on the inletmanifold intermediate flange and accessiblefrom under the car (see illustration).5 Unscrew the unit and remove it from itslocation.

Refitting6 Refitting is a reversal of removal. Refill thecooling system as described in Chapter 1.

Removal1 The idle speed compensator is only fitted toK-Jetronic systems from 1986 onwards and islocated in the centre of the enginecompartment bulkhead (see illustration).

2 Disconnect the battery negative lead.3 Disconnect the electrical lead, undo the twoscrews and withdraw the unit. Detach the airhoses from each end and remove thecompensator.

Refitting4 Refitting is a reversal of removal. The airhoses can be connected to either end and thearrows on the unit can be ignored.

Escort RS Turbo models are equipped withan exhaust driven turbocharger, which is adevice designed to increase the engine’spower output without increasing exhaustemissions or adversely affecting fueleconomy. It does so by utilising the heatenergy present in the exhaust gases as theyexit the engine.

Basically the turbocharger consists of twofans mounted on a common shaft. One fan isdriven by the hot exhaust gases as they rushthrough the exhaust manifold and expand.The other draws in fresh air and compresses itbefore it enters the inlet manifold. Bycompressing the air, a larger charge can be letinto each cylinder and greater power output isachieved.

20 Turbocharger - generaldescription

19 Idle speed compensator -removal and refitting

18 Thermo-time switch -removal and refitting

17 Charge air temperaturesensor - removal and refitting


16.5b Removing the heater fan motorassembly . . .

16.6 . . . for access to the fuel-injectioncontrol module

16.7 Fan motor wiring engaged in housingslot (arrowed)

17.1 Charge air temperature sensorlocation (arrowed)

18.4 Thermo-time switch (A) and temperature sensor (B) on theKE-Jetronic system (viewed from under the car)

19.1 K-Jetronic system idle speed compensator location

The temperature of the inlet air is reduced,thus increasing its density, by passing itthrough an intercooler, mounted alongside theradiator, prior to it entering the manifold.

The boost pressure generated by theturbocharger is controlled by a waste gatewhich when open allows a high proportion ofthe exhaust gases to bypass the turbochargerand directly enter the exhaust system (seeillustration). The turbocharger therefore losesspeed and boost pressure is reduced.

The waste gate is opened and closed bythe waste gate actuator through an actuatorrod. The waste gate actuator is in turncontrolled by the solenoid control valve whichreceives signals in the form of a pulsedvoltage from the ignition system. ElectronicSpark Control module (see Chapter 5, Part B).The Electronic Spark Control module receivesdata from various engine sensors, particularlythe charge air temperature sensor in the inletair duct, which modify the module program tosuit all operating conditions. he module thensignals the solenoid control valve to open orclose the waste gate via the waste gateactuator.

Lubrication oil for the turbocharger is takenfrom the engine lubricating circuit via a specialbranch line. The turbocharger shaft rotates inplain bearings through which a relatively largeamount of oil is allowed to pass. Thereforewhen rotating, the shaft floats on a thick filmof lubricating oil.

The turbocharger is a close tolerance,

expensive component and servicing or repairsshould be left to a dealer service departmentor specialist with turbocharger repairexperience. Apart from the information in thefollowing Sections, any other work on theturbocharger or its related components isbeyond the scope of the average reader.

Removal1 The solenoid control valve is mounted on abracket located underneath the ignitiondistributor (see illustration).2 Disconnect the battery negative lead. 3 Disconnect the solenoid wiring multi-plug. 4 Identify and mark the hose locations at thesolenoid connections, then remove the hoses. 5 Undo the retaining screws and remove theunit from its location.


21 Waste gate solenoid controlvalve - removal and refitting


4B

21.1 Waste gate solenoid control valvelocation (arrowed)

20.4 Turbocharger and waste gatecomponents

1 Turbocharger exhaust manifold and waste gate housing

2 Bypass duct3 Waste gate4 Waste gate actuator5 Actuator rod6 Waste gate lever

1985 models

Removal1 Disconnect the battery negative lead. 2 Remove the air cleaner as described inSection 2. 3 Remove the intercooler upper and lower airhoses (see illustration).4 Undo the upper retaining bolt, tilt theintercooler towards the engine at the top andlift up to disengage the lower retaining pins.Remove the unit from the engine compartment.


1986 models onwards

Removal6 Proceed as described in paragraphs 1 to 3.7 Undo the two radiator and intercooler lowerretaining bolts (see illustration).8 Move the radiator and intercooler assemblytowards the engine and undo the four boltssecuring the intercooler to the radiator.9 Undo the retaining bolt and move the hornnearest to the intercooler to one side.10 Withdraw the intercooler from the enginecompartment.


Note: New gaskets and new tabwashers mustbe used on refitting.

Removal1 Disconnect the battery negative lead.2 Disconnect the turbocharger inlet andoutlet air hoses and the hoses from the wastegate actuator and solenoid control valve attheir turbocharger connections. Tape over allthe disconnected unions and outlets toprevent dirt ingress.3 Support the exhaust system anddisconnect it from the turbocharger exhaustmanifold .4 Disconnect the oil feed union on the top ofthe turbocharger and the oil return line fromunderneath the unit (see illustration). Tapeover all disconnected pipes and unions.5 Bend up the tabwashers, then unscrew thenuts securing the turbocharger to the exhaustmanifold. Remove the unit and store it in aclean plastic bag while removed from the car.

Refitting6 Before refitting the turbocharger ensurethat all mating faces are clean and obtain newgaskets and a set of new tabwashers. It isalso advisable to renew the engine oil andfilter, particularly if a new turbocharger isbeing fitted or if there was any sign ofprevious oil contamination.

7 Refitting is a reversal of removal, butbearing in mind the following points:a) Tighten all retaining nuts to the specified

torque and secure with the tabwashers.b) Before connecting the oil feed union,

prime the turbocharger bearings byinjecting clean engine oil into the unionorifice.

c) Crank the engine over on the starter withthe ignition LT lead at the coildisconnected until the oil pressurewarning light goes out.

23 Turbocharger- removal andrefitting

22 Intercooler - removal andrefitting


22.7 Intercooler mountings and attachments - 1986 models onwards

23.4 Turbocharger oil feed union (A),turbocharger exhaust manifold (B) and

retaining nuts (C)

A Retaining bolts B Upper air hose

22.3 Intercooler upper air hoseattachment (arrowed)

Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical … Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical fuel injection systems

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