VW Passat repair


+ 1. Ekspluatatsiiya of the car
+ 2. Maintenance
+ 3. Engines
+ 4. Cooling system
- 5. Power supply system
   - 5.1. Power supply systems of petrol engines
      5.1.2. General information
      5.1.3. PIERBURG 2EZ carburetor
      5.1.4. Air filter
      5.1.5. Fuel pump
      5.1.6. Fuel filter
      5.1.7. Fuel accumulator
      5.1.8. Fuel tank
      5.1.9. Fuel level sensor
      5.1.10. Accelerator cable
      5.1.11. Systems of injection of fuel
      5.1.12. Inlet collector
      5.1.13. System of self-diagnostics and codes of malfunctions
      5.1.14. Check of a control system by the Digifant engine
      5.1.15. Check of a control system by the CIS-E-Motronic engine
      5.1.16. System of production of the fulfilled gases
   + 5.2. Power supply system of the diesel engine
+ 6. Ignition system
+ 7. Coupling
+ 8. Transmission
+ 9. Drive of forward wheels
+ 10. Suspension brackets
+ 11. Steering
+ 12. Brake system
+ 13. Wheels and tires
+ 14. Systems of heating, ventilation and conditioning
+ 15. Electric equipment
+ 16. Body
+ 17. Electric circuits


Repair B3-B4/Passat B3-B4 Volkswagen Passat>> Power supply system>> Power supply systems of petrol engines>> Systems of injection of fuel
The system of injection of fuel represents the difficult device with many elements. For its diagnostics and repair the special equipment, use of difficult multistage techniques and considerable practical experience is necessary. Therefore it is best of all to charge diagnostics and repair to specialized service stations and car repairs to Volkswagens having for this purpose the special equipment.

System of the central injection  of Mono-Jetronic fuel

Fig. 5.23. System of injection of Mono-Jetronic: 1–fuel pump; 2–fuel tank; 3–fuel filter; 4–nozzle; 5–air flowmeter; 6–control unit; 7–proof-reader of idling; 8–butterfly valve potentiometer; 9–relay; 10-the ignition switch, 11 – the accumulator; 12-butterfly valve; 13-ignition distributor; 14-sensor of temperature of the engine; 15-lambda sensor; 16-pressure regulator


The system of injection of Mono-Jetronic fuel provides electronic faltering injection of gasoline in an inlet collector. Thus the Mono-Jetronic system unlike systems of injection of Digifant and K-Jetronic has one is central the located nozzle 4 (fig. 5.23) for all cylinders. Fuel distribution in separate cylinders occurs, as in engines with the carburetor, – through an inlet collector. Air is soaked up by the engine via the air filter and gets to the injection device. In the case of an injector there is a butterfly valve operated by a flexible cable 12. The corner of opening of a butterfly valve is fixed by a potentiometer of the 8th butterfly valve, and transmits a signal to the control unit 6, depending on instant value of turns of the engine and defines amount of soaked-up air.
The control unit regulates by measured amount of air and data on frequency of turns of the engine from ignition system the moment and number of injection. The nozzle is more long open, the it is more amount of injected fuel.
Additional sensors are responsible for correctly measured amount of fuel in different modes of movement.
The potentiometer of the 8th butterfly valve reports to the control unit 6 about the provision of a butterfly valve idling.
The control unit slightly opens or covers through a servomotor, a butterfly valve and thus supports stable turns of idling.
The sensor of temperature 14 on a connector of cooling liquid takes engine temperature.
The air temperature sensor measures air temperature in the reception channel.
The lambda sensor 15 measures the content of oxygen in a stream of exhaust gases. The control unit, on its signal, supports the content of harmful emissions in exhaust gases at the lowest level.
At cars with the catalyst the composition of exhaust gases is supported at the level providing the best reburning in the catalyst.

Fig. 5.24. An arrangement of elements of system of injection of Mono-Jetronic in a motor compartment: 1–injector; 2–temperature regulator; 3–ECU control unit; 4–fuel nozzle; 5–regulator of pressure of fuel; 6–the socket of a heater of air arriving in the engine; 7–control bulb; 8–vacuum adjustment of a corner of an advancing of ignition; 9–butterfly valve potentiometer; 10-I will corrode a lambda sensor; 11-water reflector of a potentiometer of a butterfly valve; 12-sensor of temperature of system of injection (blue); 13-a heater thermoswitch in an inlet collector (red), 14 – a potentiometer of provision of a butterfly valve; 15-air temperature sensor; 16-the electromagnetic valve of the filter with absorbent carbon (gray); 17-electromagnetic valve; 18-additional resistor of an injector; 19-electric socket of a potentiometer of provision of a butterfly valve; 20-throttle shock-absorber


The arrangement of elements is shown on fig. 5.24 .

System of the central injection  of Mono-Motronic fuel
The system of injection of Mono-Motronic fuel unlike Mono-Jetronic is executed in one block. Thanks to combination of system of ignition with injection system, ignition works under various operating conditions of the engine better. The majority of carried-out works and instructions for Mono-Jetronic system touch as well Mono-Motronic.
Electronics of a monitor registers malfunction in injection system. This malfunction after the first emergence, registers in memory. At the same time on an additional guard the control bulb lights up, signaling that malfunction is written down. If malfunction arises only once, for example at unreliable contact, it all the same registers in memory of a monitor.

System of the distributed injection  of Digifanf fuel

Fig. 5.25. System of injection of fuel: 1–fuel tank; 2–fuel pump; 3–fuel filter; 4–fuel distributor; 5–pressure regulator; 6–control unit; 7–nozzle; 8–nozzle of start of the cold engine; 9–screw of adjustment of turns of idling; 10-potentiometer of provision of a butterfly valve; 11-butterfly valve; 12-air flowmeter; 13-temperature sensor; 14-thermotime sensor; 15-ignition distributor; 16-regulator of turns of idling; 17-accumulator; 18-ignition lock; 19-relay


The system of injection of Digifant fuel is developed by VW and is established on engines with an alphabetic reference of RV, PF, PG and 2Е. The block 19 (fig. 5.25) exercises administration of ignition and injection at the same time. The injecting part generally corresponds to BOSCH firm L-Jetronic system. The system of injection of Digifant fuel injects fuel into an inlet collector in front of each inlet valve. Unlike Mono-Jetronic the Digifant system has a separate nozzle for each cylinder.
Fuel gets from a fuel tank 1 electric fuel pump 2 and via the fuel filter 3 moves through the fuel highway to nozzles 6, 10.
The regulator of pressure of the 4th fuel highway watches continuous maintenance of pressure in fuel system.
The quencher of fluctuations in a regulator of pressure 4 reduces pressure fluctuations in the pipeline of return of fuel.
Air is soaked up by the engine via the air filter, an inlet collector and its volume measured by a flowmeter of the 15th stream of air.
In the case of a flowmeter of air there is a zaslonka which when passing an air stream deviates. The corner of a deviation of a zaslonka serves as a measure of a stream of air. From a potentiometer on a zaslonka axis in the control unit the signals corresponding to the provision of a zaslonka arrive.
The control unit 19 regulates time and amount of injected fuel according to measured amount of air and frequency of turns of the engine. The nozzle is more long open, the more fuel is injected. Additional sensors allow to dose out precisely fuel in different operational modes.
The distributor of fuel 5 stabilizes idling turns, especially during engine warming up or if the engine is loaded by the included electric consumers.
The potentiometer of the 18th provision of a butterfly valve is located directly on a shaft of a butterfly valve 12. It signals the control unit about the provision of a butterfly valve at turns of idling and full capacity. It concerns management of the switch of supply of fuel as while contacts a regulator of 13 turns of idling are closed, at the turns of the engine exceeding 1500 mines-1 (compulsory idling), the control unit should stop supply of fuel in the engine.
The lambda sensor, established in cars with the adjustable catalyst, measures the content of oxygen in exhaust gases and sends the corresponding electric signals to the control unit. The control unit changes quality of an air and fuel mix so that exhaust gases in the best way дожигались in the catalyst. If out of operation there is participating in regulation process a sensor, the control unit is switched to the emergency program, interfering with that to engine breakage, but, allowing to continue movement. Thus ignition changes on more later and the capacity and acceleration performance of the engine falls.

Fig. 5.26. An arrangement of elements of system of injection of Digifant in a motor compartment: 1–butterfly valve case; 2–switchboard of ignition of TSZ-H; 3–idling switch; 4–control unit; 5–switch of an open butterfly valve; 6–valve of stabilization of turns of idling; 7–I will corrode a lambda sensor; 8–inlet collector; 9–valve of adjustment of pressure; 10-ignition coil; 11-the sensor of temperature of cooling liquid (black); 12-the ignition distributor, 13 – the sensor of temperature of system of injection (blue); 14-nozzles; 15-detonation sensor; 16-fuel distributor; 17-the adjustment screw WITH; 18-air filter; 19-measuring instrument of a stream of air; 20-pressure regulator; 21-screw of adjustment of turns of idling; 22-air inlet


The provision of elements of a power supply system is shown on fig. 5.26 .

System of the distributed injection of K-Jetronic fuel

Fig. 5.27. System of injection of K-Jetronic: 1–fuel tank; 2–fuel filter; 3–fuel accumulator; 4–fuel pump; 5–storage battery; 6–ignition switch; 7–switch of the fuel pump; 8–ignition distributor; 9–thermoswitch; 10-the valve of start-up of the cold engine, 11 – a spark plug; 12-nozzle; 13-inlet pipe; 14-air valve of start-up of the cold engine; 15-butterfly valve case; 16-butterfly valve; 17-measuring instrument of a consumption of air; 18-measuring instrument plate; 19-cap; 20-fuel distributor; 21-valve of warming up of the engine; 22-piston of the distributor of fuel; 23-pressure regulator; 24-lever of a plate of a measuring instrument; 25-persistent lever of the piston of the distributor of fuel; 26-screw of adjustment of quality (structure) of a mix; 27-screw of adjustment of quantity of a mix


Fig. 5.28. An arrangement of elements of system of injection of K-Jetronic in a motor compartment: 1–pressure sensor; 2–screw of adjustment of turns of idling; 3–sensor of provision of a butterfly valve; 4–switchboard of ignition of TSZ-H; 5–control unit; 6–butterfly valve case; 7–ignition distributor; 8–ignition coil; 9–valve of stabilization of turns of idling; 10-control unit turns of idling and shutdown of supply of fuel; 11-sensor of temperature and thermotime sensor; 12-valve of cold start; 13-heating valve; 14-сапун case; 15-nozzle; 16-a zaslonka of heating of air arriving in the engine; 17-fuel distributor; 18-the screw of adjustment of the contents WITH; 19-air filter; 20-valve of shutdown of supply of fuel


The system of injection of K-Jetronic fuel — is system of mechanical consecutive injection of fuel in an inlet collector in front of inlet valves. Fuel gets from a fuel tank 1 (fig. 5.27) , submitting fuel pump located in it and the main fuel pump 4, and moves via the fuel accumulator 3 in the fuel filter 2, to the fuel 20 distributor. The distributor of fuel distributes and submits to cylinders fuel through nozzles 12 according to amount of the measured air. Additional sensors allow to dose out precisely fuel at various temperatures and service conditions (fig. 5.28) .
The fuel accumulator holds fuel under pressure a long time, even after engine switching off that interferes with formation of bubbles and improves start of the hot engine.
The switch of the fuel pump 7 (see fig. 5.27 ) submits a current to the fuel pump 4 and the valve of 21 warmings up of the engine. The switch of the fuel pump interrupts current giving to the pump, at switching off of ignition and lack of impulses of ignition (the engine is switched off, ignition is switched off). Besides, the switch interrupts supply of fuel at excess by the engine of the maximum turns.
At start of the cold engine the valve 10 of start-up of the cold engine injects additional amount of fuel into an inlet collector, for simplification of start.
The thermoswitch 9 regulates duration of injection of the valve 10 of start-up of the cold engine.
The regulator of pressure 23 supports pressure in system about 470-540 kPas.
The regulator of warming up enriches a mix during warming up.
The electric control unit operates valves of shutdown of supply of fuel and stabilization of turns of idling.

System of the distributed injection of KE-Motronic fuel
The system of injection of KE-Motronic fuel — is the combined system of ignition and injection, with the general control unit. Nozzles are mechanically arranged how and in K-Jetronic system (see fig. 5.27 ), but in addition have electronic control. Thanks to electronics there is a management of number of injection by means of additional sensors which more completely and quicker collect and process information. Besides, the lambda regulation is facilitated at catalyst operation. When using KE-Motronic system need for the warming up regulator, the disconnecting valve and system of adjustment of pressure disappears.
The electronic control unit regulates a fuel dose in various operational modes of the engine through an electrohydraulic regulator of pressure which is located on the distributor of amount of fuel. It means that the monitor watches mix enrichment at cold start and engine warming up, mix enrichment at acceleration and full capacity. Besides, it blocks fuel access at movement by inertia.
The membrane regulator of pressure, on the distributor of amount of fuel, supports pressure in system from 610 to 660 kPas.
The filter of absorbent carbon interferes with that harmful pairs of fuel got from a fuel tank into the atmosphere, evaporating fuel collects in capacity with absorbent carbon. At pair movement under control of two magnetic valves again move in the engine for combustion.
The memory in the control unit distinguishes the appeared malfunction and writes down it. At failure of the important sensor, the control unit is switched to the reserve program (using average codes) that the engine did not stop.

Fig. 5.30. An arrangement of elements of system of injection of KE-Motronic in a motor compartment: 1–I will corrode a lambda sensor; 2–butterfly valve case; 3–control unit; 4–a pipe of measurement of the contents WITH; 5–valve of stabilization of turns of idling; 6–output block; 7–ignition coil; 8–the distributor with the Hall sensor; 9–relay of the fuel pump; 10-connection of the sensor, corner of an advancing of ignition; 11-socket of the sensor of a detonation; 12-temperature sensor; 13-valve of cold start; 14-sensor of a detonation 1; 15-injector; 16-sensor of a detonation 2; 17-a zaslonka of heating of air arriving in the engine; 18-pressure regulator; 19-fuel distributor; 20-coal filter; 21-air filter; 22-potentiometer; 23-pressure regulator; 24-air flowmeter; 25-valve of the coal filter; 26-spark plug; 27-sensor of provision of a butterfly valve


The arrangement of elements of system of injection of KE-Motronic in a motor compartment is shown on fig. 5.30 .

Control system of the Simos engine
The device and principle of action of a control system of the Simos engine are similar to Digifant system.

Fig. 5.29. Arrangement of elements of system Simos engine: 1–electromagnetic valve of the canister of charcoal; 2–measuring instrument of a stream of air; 3–socket of the sensor of oxygen; 4–throttle case; 5–ECU block; 6–injector; 7–regulator of pressure of fuel; 8–ignition coil; 9–sensor of a drive of a speedometer; 10-socket of the sensor of a detonation; 11-socket of a plait of wires; 12-sensor of frequency of rotation of a cranked shaft of the engine; 13-socket of the sensor of frequency of rotation of a cranked shaft of the engine; 14-ignition distributor; 15-the sensor of temperature of cooling liquid; 16-detonation sensor; 17-connection with weight; 18-the sensor of temperature of air arriving in the engine; 19-charcoal filter


The arrangement of elements of system of injection of Simos in a motor compartment is shown on fig. 5.29 .
Precautionary measures at work with the injection device
At removal and installation of elements of systems of injection it is necessary to observe the following rules:
– do not start the engine at unreliably connected storage battery. Sockets of system of ignition and injection disconnect or connect only at the switched-off ignition. It concerns also measuring devices;
– start by means of the starting arrangement is admissible only during no more than 1 mines, at tension no more than 16,5 In;
– do not disconnect the storage battery from an onboard network at the working engine, it can lead to control unit failure;
– before inspecting electronic system of injection, it is necessary to be convinced of serviceability of system of ignition, it means that ignition and candles should correspond to technical requirements;
– at work with system of injection be careful to prevent dust and dirt hit in various components of system. It is not recommended to use the compressed air or fleecy fabrics for system cleaning.

       PREVENTION
At work with mechanical parts of system of injection it is necessary to observe strict purity. Before dismantling it is necessary to wash out details gasoline. The system is under pressure. Therefore before replacement of details to reduce pressure, gradually weakening fastening on the valve of cold start.

Check and adjustment of turns of idling (XX) and quality of a mix
For check and adjustment of turns of idling and quality of a mix the tachometer and the analyzer of exhaust gases be required.
Preparation for adjustment of turns by XX and quality of a mix carry out as follows:
– check and adjustment carry out on the heated-up engine every moment of ignition and serviceable system of production of the fulfilled gases;
– start the engine and leave to idle, while the temperature of oil will not reach 80°С. Thus watch, that the temperature of cooling liquid did not exceed normal as during check and adjustment the fan should be switched off;
– muffle the engine, disconnect everything consumers of energy (headlights, a radio tape recorder, the conditioner, etc.);
– disconnect and muffle a stopper a hose of ventilation of a case;
– connect a control tachometer and a gas analyzer;
– if топливопроводы were disconnected from nozzles or are replaced new before check and adjustment of frequency of rotation of idling, increase frequency to 3000 mines-1, then leave the engine to idle during 2 mines prior to the beginning of check and adjustment;

       PREVENTION
The reason of increase in the contents WITH not in adjustment, and in saturation by pairs of oil from an engine case as a result of an oil razzhizheniye at heavy traffic on short distances. At long uniform movement on the equal district the amount of fuel in oil decreases, and the contents WITH is normalized. It also is normalized after continuous (about 30 mines) movements or after oil replacement

– the throttle zslonka should be in the family way idling.
Adjustment of turns by XX and quality of a mix of system of injection of Digifant fuel carry out in the following order:
– at the switched-off ignition connect a tachometer and a gas analyzer of exhaust gases in compliance to instructions of the manufacturer;

Fig. 5.31. Ventilation of a case of the engine: 1–a ventilation hose, 2 – the socket of the sensor of temperature


– disconnect a hose of ventilation of a case 1 (fig. 5.31) from the valve of adjustment of pressure 9 (see fig. 5.26 ) and densely close a hose;
– start the engine and let's to it work in an idling mode within one minute, then disconnect the blue socket from the sensor of the 20th temperature;
– by means of a cable of management of an accelerator open and close three times a butterfly valve. When opening butterfly valve turns of the engine should exceed 3000 mines-1;

Fig. 5.32. Adjustment of turns of idling and quality of a mix: 1–the screw of adjustment of XX, 2 – the screw of adjustment of quality of a mix


– transfer the engine to an idling mode, and check idling turns, and quality of a mix (fig. 5.32) . For adjustment remove a cap and the corresponding tool, turn the screw of adjustment of turns of idling 1 and the screw of adjustment of quality of a mix 2 (WITH);
– connect the socket of the sensor of temperature, then sharply three times open a butterfly valve (exceeding 3000 mines-1), transfer the engine to a mode of idling and repeatedly check turns of idling and quality of a mix (WITH);
– at connection of a hose of ventilation of a case the contents WITH can increase;
– on the PF engine check a lambda sensor: disconnect a hose of a regulator of pressure from the throttle case, the contents WITH should increase for an instant, then will go down to normal value;
– if frequency of idling and the contents WITH are satisfactory, establish into place hoses and disconnect a tachometer and a gas analyzer;
– if adjustment does not give a positive effect, check the idling switch (cars with a mechanical transmission) or a potentiometer of provision of a butterfly valve (cars with an automatic transmission) on the special equipment.
Adjustment of turns by XX and quality of a mix of system of injection of Mono-Jetronic fuel carry out in the following order:
– connect a tachometer and a gas analyzer of exhaust gases according to instructions of the manufacturer;
– start the engine in a mode of turns of idling;
– check, turns of idling and the contents WITH;
– if turns of idling and the contents WITH differ from demanded, check, that vacuum hoses had no cracks and damages and were reliably fixed;
– check the valve of system of the coal filter. If it is serviceable, check injection system at service station as the specialized diagnostic equipment connected to the socket of system of memory of damages for this purpose is required. Adjustment of turns of idling or the contents WITH is not made.
Adjustment of turns by XX and quality of a mix of system of injection of K-Jetronic fuel carry out in the following order:

Fig. 5.33. Hoses of ventilation of a case disconnected from the case: 1, 2 – hoses, 3 – the case. The connector 4 should be in a hose 2


– disconnect hoses of ventilation 1, 2 (fig. 5.33) of a case from сапуна sideways the block of cylinders, then disconnect a hose of ventilation of a case of small diameter together with the calibrated connector 4 from a hose of big diameter;
– include the ignition, the regulating valve of stabilization of idling should publish noise and vibrate;
– connect a tachometer and a gas analyzer of exhaust gases according to instructions of the manufacturer;

Fig. 5.34. A socket detachment at check of turns of idling and the contents WITH on system of injection of K-Jetronic


Fig. 5.35. Adjustment of turns of idling and quality of a mix: 1–the screw of adjustment of XX, 2 – the screw of adjustment of quality of a mix


– disconnect the socket 1 (fig. 5.34) , then check frequency of idling and the contents WITH. For adjustment turn the screw 1 (fig. 5.35) of adjustment of turns of idling and the screw of 2 adjustments of quality of a mix;
– at connection of a hose of ventilation of a case the contents WITH can increase;
– switch off the engine, disconnect the analyzer of exhaust gases and a tachometer.

       PREVENTION
The reason of increase in the contents WITH not in adjustment, and in saturation by pairs of oil from an engine case as a result of an oil razzhizheniye at heavy traffic on short distances. At long uniform movement on the equal district the amount of fuel in oil decreases, and the contents WITH is normalized. It is normalized and after continuous movement about 30 mines or after oil replacement.

Adjustment of turns by XX and quality of a mix of system of injection of KE-Motronic fuel carry out in the following order:
– check a corner of an advancing of ignition;
– switch off ignition and connect a tachometer to the engine;
– connect a gas analyzer of exhaust gases according to instructions of the manufacturer;
– start the engine in an idling mode;
– check, that turns of idling corresponded to the demanded;
– on cars with the conditioner, turns of idling should increase by 70 mines-1 at the switched-on conditioner;

Fig. 5.36. A hose detachment from the coal filter on system of injection of KE-Motronic: 1–coal filter


– check the contents WITH. For adjustment, remove a hose from the coal filter 1 (fig. 5.36) , and disconnect hoses of ventilation of a case from a case (see fig. 5.33 );
– switch off ignition, disconnect the socket from a regulator of pressure 23 (see fig. 5.30 ) and connect the universal measuring device;
– include ignition, thus in a chain of management there should be a positive current, otherwise check electric wires;
– start the engine in an idling mode;
– rotate the screw of adjustment of the contents WITH until the current in цепине will be established from 0 to 5 мA;
– before verification of the contents WITH by short time increase engine turns.

Check and adjustment of a measuring instrument of a consumption of air (K-Jetronic and KE-Motronic system)
Check and adjustment of a measuring instrument of a consumption of air (K-Jetronic and KE-Motronic system) carry out in the following order:
start the engine and warm up it to working temperature;
– remove an air pipe from a measuring instrument of a consumption of the air located in one block with the air filter;
– disconnect from the coil of ignition 8 (see fig. 5.28 ) a high-voltage wire, connect it to "weight" and include a starter for ten seconds;

Fig. 5.37. Measuring instrument of a consumption of air: a= (0–0,5) mm


– lift a plate of 1 measuring instrument of a stream of air (fig. 5.37) and be convinced that it moves with identical resistance on all length of a working course;
– if by fast pressing of a plate of a measuring instrument of a stream of air down there is a resistance, it is necessary to replace the block of a measuring instrument of a stream of air;
for system of injection of K-Jetronic fuel:

Fig. 5.38. System of injection of K-Jetronic fuel: adjustment of provision of a plate of a measuring instrument of a consumption of air


– check, that the top part of a sensitive plate was established flush with the top part of a diffuzor or is lower on 0,5 mm, and = than 0-0,5 mm (see fig. 5.38 );
– in case of need, the provision of a plate can be adjusted, bending a bracket of 2 fastenings under a plate (see fig. 5.37 );
for system of injection of KE-Motronic fuel:
– check a starting position of a plate of a measuring instrument of a consumption of air. The top part of a plate should be lower on 1,9–3,0 mm, and = than 1,9-3,0 mm (see fig. 5.38 ) the upper edge of a diffuzor;
– if adjustment is necessary, uncover the air filter and take filtering element from the filter case;

Fig. 5.39. System of injection of KE-Motronic fuel: 1–screw of adjustment of provision of a plate of a measuring instrument of a consumption of air


– adjust the provision of a plate, turning a regulator (fig. 5.39) ;

Fig. 5.40. System of injection of KE-Motronlc fuel: place of check of a free wheeling of a plate of a measuring instrument of a consumption of air


– check size of a free wheeling of a plate of a measuring instrument of a consumption of air. Include a starter on 10 with, then lift a plate of a measuring instrument of a consumption of air a little so that a little to feel resistance. The minimum free wheeling should be 0,5 mm, and maximum – 3,0 mm to diffuzor edge (fig. 5.40) ;

Fig. 5.41. System of injection of KE-Motronic fuel: adjustment of a free wheeling of the distributor of fuel; and = 0,6 mm


Fig. 5.42. Adjustment of the lock screw of a plunzher of management: 1–a nut of stuffed consolidation, and = 06 mm (distance from the lock screw to a nut shoulder)


– adjustment is necessary for making at the fuel distributor, turning the lock screw of a plunzher of management. The distance from the lock screw to a shoulder of a nut 1 should be 0,6 mm ( fig. 5.41 and fig. 5.42 ). A quarter of a turn of the screw corresponds 1,3 mm of moving of a plate. For increase in a free wheeling screw the lock screw, and for reduction turn out it;
– repeatedly check idling turns;

Fig. 5.43. Check of the main installation of the adjusting lever of a measuring instrument of a stream of air


– if the measuring instrument of a stream of air or the distributor of fuel were replaced, it is necessary to execute the main installation of the adjusting lever of a measuring instrument of a stream of air. For this purpose, using a depth gage, measure distance between a surface of contact of the distributor of fuel and a tip of the lever of adjustment (see fig. 5.43 ) which should make 18,7–18,9 mm. For adjustment, turn the screw of adjustment of the contents WITH, but keep in mind that the subsequent adjustment of the screw of the contents WITH will change initial installation

Nozzles
Check of nozzles of system of injection of Digifant fuel carry out in the following order:
– for check of nozzles 14 (see fig. 5.26 ) it is necessary to use a sampler with a light-emitting diode;

Fig. 5.44. Connection to the socket of a food of nozzles of a light-emitting diode sampler on system of injection of Digifant fuel


– disconnect the socket of giving of tension to nozzles, connect to the socket a sampler with a light-emitting diode and include a starter (fig. 5.44) ;
– at work of a starter and normal tension, the light-emitting diode will flicker. If it burns constantly, replace electric wires from the accumulator to a transmission and the tire of grounding of a control system of Digifant;
– if the light-emitting diode does not burn, check a condition of electric wires of the control unit and a nozzle. Measure resistance of wires of a food of a nozzle, having connected the socket to the measuring device. If resistance of 3,7-5,0 Ohm, means, nozzles in a normal state. If resistance more than 5,0 Ohm, check separately each nozzle and the socket. Resistance of each nozzle makes 15–20 Ohm, and in the socket – no more than 0,5 Ohm;
– quality of dispersion of nozzles can be checked only at service station with use of the special equipment
Removal and installation of nozzles of system of injection of Digifant fuel carry out in the following order:
– disconnect a wire from the negative plug of the storage battery;

Fig. 5.45. Fuel highway and nozzles of system of injection of Digifant fuel: 1–hose of fastening of a regulator of pressure of fuel; 2–bolt; 3–regulator of pressure of fuel; 4–feeding топливопровод, 5 – returnable топливопровод; 6, 7 – an arm; 8–insert; 9–a sealing ring, 10 – a bolt; 11-bracket; 12-case of a plait of wires; 13-fuel highway; 14-nozzle; 15-fuel hose; 16-valve of adjustment of pressure; 17-socket; 18-the sensor of temperature of cooling liquid; 19-sensor of temperature of system of injection of fuel; 20-socket; 21-hose


– disconnect electroconducting 12 (fig. 5.45) from the fuel highway 13;
– remove pressure in fuel system. Unscrew a regulator of pressure of fuel 3 from the fuel highway. Disconnect feeding 4 and returnable 5 топливопроводы from a regulator 3 and the fuel highway;
– unscrew bolts of the 10th fastening of the fuel highway to a head of the block of cylinders and remove the fuel highway together with nozzles;
– disconnect sockets from nozzles 14;
– weaken a bracket of the 11th fastening of each nozzle and take nozzles from the fuel highway;
– installation carry out to sequences of return to removal.
Check of nozzles of system of injection of K-Jetronic and KE-Motronic fuel carry out in the following order:
– nozzles can be checked only at service station with use of the special equipment.
Removal and installation of nozzles of system of injection of K-Jetronic and KE-Motronic fuel carry out in the following order:

Fig. 5.46. Elements of system of injection of K-Jetronic fuel: 1, 5, 9 – electric connecting blocks; 2–sealing ring; 3–топливопровод from the fuel pump; 4–a tube fuel plum in a fuel tank; 6–thermoswitch of the valve of start-up of the cold engine; 7–branch pipe of system of cooling; 8–valve of warming up of the engine; 10-pressure regulator; 11-adjusting washer; 12-fuel distributor; 13-measuring instrument of a consumption of air; 14-piston of the distributor of fuel; 15-sealing ring; 16-cap; 17-screw of adjustment of quality (structure) of a mix; 18-nozzle; 19-inlet pipe; 20-laying; 21-valve of start-up of the cold engine


– switch off ignition and pit pressure in fuel system, for this purpose weaken an inhaling of fastening of a bolt топливопровода to the valve 21 (see fig. 5.46 ) start-up of the cold engine;
– collect rags the flowed-out fuel and tighten a bolt;
– unscrew a connecting nut, weaken a hose of system of injection of fuel on a nozzle 18 and take a nozzle from a stage on a head of the block of cylinders;
– unscrew a nut and disconnect a nozzle from топпивопровода;
– for a nozzle otvorachivaniye from a head of the block of cylinders it is necessary to use the special VW 3135 tool;
– installation carry out to sequences, return to removal, but at nozzle installation previously moisten a sealing ring 2 in gasoline.

Elements of system of injection of Digifant fuel
Check of the valve of stabilization of turns of idling carry out in the following order:

Fig. 5.47. System of injection of Digifant fuel: 1–valves of stabilization of turns of idling


– the valve of stabilization of turns of idling is established behind the butterfly valve case (fig. 5.47) . If at ignition inclusion, the valve vibrates and publishes noise, means, it is serviceable;
– disconnect the electric socket from the valve and by a tester measure resistance which should make 3,5–4,5 Ohm;
– if the valve is serviceable, means, there is a damage in electric conducting to the valve or in the control unit.
Check a lambda sensor carry out in the following order:
– connect a gas analyzer to a measuring tube;
– start the engine in a mode of idling and let's to it work during 2 mines, then check the contents WITH;
– disconnect a hose from a regulator of pressure 20 (see fig. 5.26 ) on the case of a butterfly valve and densely close it. Thus the contents WITH should increase quickly, and then return to the measured level;

Fig. 5.48. System of injection of Digifant fuel: socket of wires of heating lambda sensor


Fig. 5.49. System of injection of Digifant fuel: serial connection of a wire a lambda sensor (black) with a positive and negative pole of the accumulator


– if value of the contents WITH does not go down, disconnect a lambda sensor and the socket of wires of heating of the sensor (fig. 5.48) . Connect a wire between the block a lambda sensor and in turn with negative and positive accumulator conclusions (fig. 5.49) . The contents WITH should increase and decrease serially. If the contents WITH does not correspond to norm, the block of board or electric conducting are damaged and they are necessary for checking on HUNDRED;
– disconnect a gas analyzer and connect hoses and sockets.
Check of braking by the engine and enrichments at completely open butterfly valve carry out in the following order:
– braking by the engine and enrichment at completely open butterfly valve are connected via the control unit;

Fig. 5.50. System of injection of Digifant fuel: 1–butterfly valve opening; 2–screw-driver


– start the engine at idling turns, then open a butterfly valve 1 (fig. 5.50) and enclose a screw-driver 2 so that to increase engine turns to 2000 mines-1. Turns of the engine should change, as the system of braking works with the engine;
– if the system of braking does not work with the engine, disconnect the electric socket from the temperature sensor (dark blue), then connect socket contacts by a wire piece. If turns of the engine change, the sensor of temperature is faulty, and it is necessary to replace it;
– if engine turns still do not change, repeatedly connect the socket of the sensor of temperature and check electric conducting of the sensor of temperature or the butterfly valve switch. If they in working condition, means, the control unit is damaged.

Elements of system of injection of Mono-Jetronic fuel
Check of the switch of a single course / regulating valve carry out in the following order:

Fig. 5.51. System of injection of Mono-Jetronic fuel: 1–lever of a drive of a butterfly valve; 2–rod; 3–shock-absorber; 4–regulator lock-nut; 5–butterfly valve switch; 6–electric socket; 7–management valve


– include ignition, open and close a butterfly valve. The regulating valve 7 should work (fig. 5.51) twice. Otherwise, disconnect the electric socket, and connect to the socket a light-emitting diode sampler. At the closed butterfly valve the light-emitting diode sampler will light up, at the opened — will go out;
– start the engine in a mode of turns of idling, then disconnect the socket and repeatedly connect it. Turns of the engine should increase, and then decrease. Otherwise replace regulating valve;
– switch off ignition, disconnect the electric socket from the device of provision of a butterfly valve;
– using additional wires, connect accumulator poles to clips of the device of provision of a butterfly valve, thus the rod 2 should move on 2,5 cm, then disconnect wires;

Fig. 5.52. Adjustment of the switch of idling and the valve on system of injection of Mono-Jetronic fuel: 1–a nut of adjustment of the switch of idling and the regulating valve, 2 – a block of the electric socket, and = 0,5 ±0,1 mm


– press a rod to the limiter and shchupy check a gap (fig. 5.52) . If necessary adjust a gap a nut 4 (see fig. 5.51 ).
– connect a tester to the bottom contacts of the electric socket 2 (see fig. 5.52 ). At installation щупа the switch should be opened, and after extraction щупа the switch should be closed (0 Ohm).
Check of the resistor carry out in the following order:

Fig. 5.53. Resistance measurement on system of injection of Mono-Jetronic fuel: 1–the resistor, 2 – the tip of the electric socket


– disconnect the electric socket 2 resistor 1 (fig. 5.53);
– connect a tester to socket contacts, the tester should show existence of resistance of 3-4 Ohm.
Check of the shock-absorber of a butterfly valve (cars with a mechanical transmission) carry out in the following order:
– check, that at the closed butterfly valve the lever 1 (see fig. 5.51 ) moved a rod 2 in the shock-absorber 3 on 4 mm;
– otherwise, weaken a nut of a regulator 4 and establish the shock-absorber so that the lever only concerned a rod;
– from this situation turn the shock-absorber on 4 1/4 turns to the lever.
Check of a regulator of pressure carry out in the following order:
– in connection with use of the special equipment, check is necessary for carrying out on HUNDRED.
Check of the coal filter carry out in the following order:

Fig. 5.54. Coal filter: 1–electric socket (black); 2–electric socket (gray); 3–electromagnetic valve I; 4–electromagnetic valve II; 5–arm; 6–hose; 7–coal filter. Arrows A, B and C specify the direction of streams of ventilation, And and In — at the switched-off ignition And — the electromagnetic valve I is switched off, the temperature of cooling liquid is lower than 60 °C And, In and With — the electromagnetic valve I is switched on, the temperature of cooling liquid is higher 60 ° With


– check a condition and reliability of fastening of hoses and electric sockets (fig. 5.54) ;
– connect a tester to the black electric socket 1 and include ignition;
– the tester should show tension 12 In;
– repeat the same operation with the gray electric socket 2;
– for check of the electromagnetic valve 3 include ignition and check that the valve is closed;
– at ignition switching off the valve should open;
– system effectiveness of the coal filter depends on the correct functioning of the Mopo-Jetronic control unit, a lambda sensor and other elements. Due to the use of the special equipment, check is necessary for carrying out at service station.

Elements of system of injection of K-Jetronic fuel
Check of the valve of cold start and the thermotemporary switch carry out in the following order:
– disconnect from the coil 10 (see fig. 5.26 ) ignitions a high-voltage wire and it connect to "weight";

Fig. 5.55. System of injection of K-Jetronic fuel: 1–light-emitting diode sampler; 2–electric tip of the valve of cold start


– disconnect the electric tip from the valve of cold start and connect to contacts a light-emitting diode sampler (fig. 5.55) ;

Fig. 5.56. System of injection of K-Jetronic fuel: 1–thermotime switch; 2–electric socket.


– disconnect the electric tip from the thermotemporary switch and connect to weight contacts of a green-white wire (fig. 5.56) . Do not connect to "weight" contact of a red-black wire;
– include a starter, thus a light-emitting diode sampler should light up;
– connect the electric socket to the switch, leaving a green-white wire connected to "weight";

Fig. 5.57. System of injection of K-Jetronic fuel: 1–nozzle of the valve of cold start; 2–glass jar


– remove the valve of cold start and insert it into a glass jar. Include a starter, the valve should leave an equal stream in the form of a cone (fig. 5.57) ;
– wipe the valve and dry it during 1 mines;
– at the established valve of cold start, but the disconnected contact of a wire, connect a light-emitting diode sampler to two contacts of the socket;
– include a starter on 10 with, the light-emitting diode sampler depending on temperature of the thermotemporary switch will be lit on 1–8 with;

Fig. 5.58. The chart of duration of turning on of the valve of cold start depending on temperature of cooling liquid


– dependence of duration of inclusion of a light-emitting diode on a sampler from temperature of cooling liquid is presented on the chart (fig. 5.58) .
Check of enrichment of fuel in a mode of acceleration of the cold engine carry out in the following order:
– fuel enrichment in a mode of acceleration of the cold engine works only when the switch of a mode of starting supply of fuel, the sensor of pressure of a diaphragm and the switch of a butterfly valve are closed;
– remove from the coil 10 (see fig. 5.26 ) ignitions and connect to weight a high-voltage wire;
– disconnect the electric tip from the valve of cold start and connect a light-emitting diode sampler to contacts in the socket. Start the engine in an idling mode, thus the light-emitting diode sampler should not burn;
– quickly open a butterfly valve, thus a light-emitting diode sampler should light up quickly (on 0,4 c).
Check of the sensor of pressure of a diaphragm carry out in the following order:
– disconnect the electric tip from the pressure sensor;
– start the engine in an idling mode;
connect a tester to two contacts on the switch, thus resistance should be equal to infinity, i.e. contacts are opened;
quickly open a butterfly valve, thus resistance should decrease quickly.
Check of the switch of a butterfly valve carry out in the following order:

Fig. 5.62. A butterfly valve and the butterfly valve switch on cars with a mechanical transmission: 1–switch; 2–electric tip


disconnect the electric tip 2 (see fig. 5.62 ) from the switch of 1 butterfly valve;
– connect a tester to two contacts;
– at the closed butterfly valve, resistance should equal infinity;

Fig. 5.59. System of injection of K-Jetronic fuel. Gap check between the limiter of idling and the butterfly valve lever: 1–adjusting screws


– slowly open a butterfly valve, before click of contacts of the switch. During this moment resistance should equal infinity, and the gap between the limiter of idling and the lever of a butterfly valve should make 0,1 mm (fig. 5.59) ;

Fig. 5.63. A butterfly valve and the butterfly valve switch on cars with an automatic transmission: 1–electric socket of a potentiometer; 2–potentiometer; 3–electric socket of the switch


– in case of need adjust the switch (see fig. 5.63 ).
Check of a heater carry out in the following order:
– disconnect from the coil of ignition and connect to weight a high-voltage wire;

Fig. 5.60. System of injection of K-Jetronic fuel. Check of giving of feeding tension and resistance of a heater


– disconnect the electric tip 2 (fig. 5.60) from a heater and connect a light-emitting diode sampler to contacts in the socket;
– include a starter, thus a light-emitting diode sampler should light up;
– check resistance of an element of a heater 1 which should make 20–26 Ohm.
Check of the main installation of a butterfly valve carry out in the following order:
– the adjusting screw is established at plant and does not demand adjustment. If the screw turned away, it is necessary to execute the following adjustment:

Fig. 5.61. System of injection of K-Jetronic fuel. Main installation of a butterfly valve: 1–nut


– weaken a nut 1 (fig. 5.61) , unscrew the adjusting screw so that the gap between the screw and the limiter then turn the screw clockwise, to a limiter contact was formed;
– it is possible to define the moment of contact, using a leaf of the thin paper inserted between them. From this moment turn the screw further on a half of turn;
– put the liquid interfering an otvorachivaniye, on a carving of a nut and tighten a nut;
– after adjustment, check idling turns.

Elements of system of injection of KE-Motronic fuel
Check a lambda sensor carry out in the following order:
– connect the universal measuring device to a regulator 23 (see fig. 5.30 ) pressure difference;
– warm up the engine to working temperature, and let's to it work in an idling mode within two minutes;

Fig. 5.64. System of injection of KE-Motronic fuel. Arrangement of the electric socket lambda sensor: 1–hose сапуна; 2–connector lambda sensor


– note a current in a management chain, then press a hose 1 (fig. 5.64) . The current in a chain of management should decrease. Otherwise, disconnect wires a lambda sensor 2 and close a control unit wire on weight for twenty seconds. If the current in a chain of management changes, means, is faulty a lambda sensor.
Check of system of braking by the engine carry out in the following order:
– connect the universal measuring device to a regulator 23 (see fig. 5.30 ) pressure difference;
– include ignition, thus a current in chains should be positive and make 90–110 мA. Otherwise change polarity of connection of connecting wires;
– start the engine and increase turns to 3000 mines-1;
– quickly close a butterfly valve, thus a current in a chain of management should change quickly on the negative.
Check of the valve of cold start carry out in the following order:
– disconnect wires of a food of the coil 7 (see fig. 5.30 ) ignitions;
– disconnect the electric socket from the temperature sensor;
– connect consistently to the socket the resistor resistance of 15 kiloohms;
– remove the valve of cold start 13 and insert it into a glass jar;
– include a starter, the valve should leave an equal stream in the form of a cone;
– wipe the valve and dry it within a minute.
Check of the switch of a butterfly valve carry out in the following order:
– disconnect the electric tip 2 (see fig. 5.62 ), connect a tester to the butterfly valve switch. Check, that resistance between two contacts was equal 0 Ohm at the closed butterfly valve, and infinity – at an open butterfly valve;
– check the moment of switching of the switch of turns of idling, slowly opening and then closing a butterfly valve. Operation should occur at a gap between the lever of a butterfly valve and a control lever, equal 0,15–0,5 mm. If the gap differs from demanded, insert щуп in the thickness of 0,10 mm between levers, weaken switch 1 screws (see fig. 5.59 ), then move the switch so that the moment of operation was a little above. Tighten screws, and check adjustment.
Check of the main installation of a butterfly valve is carried out as it should be, analogicheny to K-Jetronic system.
Check of the coal filter carry out in the following order:
– check a condition and reliability of fastening of hoses and electric sockets;

Fig. 5.65. Coal filter: 1–electromagnetic valve I (gray); 2–rubber support; 3–electromagnetic valve II (black); 4–electric socket (black); 5–butterfly valve case; 6–arm; 7–electric socket (gray); 8–to a fuel tank; 9–bolt; 10-coal filter


– check, that at the included ignition the valve of frequency 3 (the traction relay II) (fig. 5.65) was open. Also check, that at the switched-off ignition the gate-type valve 1 (the traction relay I) was open;
– at temperature of cooling liquid below 60 °C remove a hose the leader to the filter from the valve of frequency 1 (the traction relay 1), then start the engine in an idling mode;
– on connection of the valve there should not be an absorption (or very insignificant) and the valve should not work. At operation of the valve the pulsation will be appreciable;
– start the engine and warm up so that the temperature of cooling liquid exceeded 60 °C, and repeatedly check operation of the valve. The valve should pulse about 2 mines, and in a place of its connection the strong razryazheniye then the valve should cease to pulse on 90 with, without a podsasyvaniye on connection should be felt;
– otherwise check electric conducting to traction relays. If electric conducting is serviceable, probably, the KE-Motronic control unit is faulty.

Removal and installation of elements  of system of injection of Digifant fuel

       PREVENTION
All works on removal and installation of elements of system of injection are necessary for carrying out at the removed wire from a negative conclusion of the storage battery.

Removal and installation of a measuring instrument of a consumption of air carry out in the following order:

Fig. 5.66. Elements of system of injection of Digifant fuel: 1–a filtering element; 2–cover of the air filter; 3–temperature regulator; 4, 14, 24, 26, 28, 32, 33, 36 – a bolt; 5–laying; 6–measuring instrument of a stream of air; 7–electric socket; 8–the screw of adjustment of the contents WITH; 9–cap; 10-sealing ring; 11-collar; 12-branch pipe; 13-screw of adjustment of turns of idling; 15-hose; 16-connector; 17-butterfly valve case; 18-laying; 19-hose; 20-idling switch; 21-switch of an open butterfly valve; 22-a potentiometer of provision of a butterfly valve, 23 – an arm; 25-inlet collector; 27-a hose to the vacuum amplifier of brakes; 29-a plate of fastening inlet to a final collector; 30-cap; 31-a pipe WITH; 34-arm; 35-holder; 37-laying; 38-valve of stabilization of turns of idling; 39, 41, 42, 43 – a hose; 40-tee; 44-ring; 45-rubber laying; 46-case of the air filter; 47-zabornik of air


– weaken a collar 11 (fig. 5.66) and disconnect a branch pipe of the 12th air inlet from a measuring instrument of a stream of air 6;
– disconnect the tip from the electric socket 7 from a measuring instrument of a stream of air;
– weaken brackets of fastening and raise a cover 2 air filters;
– disconnect hoses 43 regulators of pressure and uncover the air filter;
– unscrew four bolts of 4 fastenings, remove a measuring instrument of a consumption of air from a cover of the air filter and consolidation 5.
Installation is carried out to sequences, return to removal.
Removal and installation of the case of a butterfly valve carry out in the following order:
– weaken a collar and disconnect a branch pipe of the 12th air inlet from the butterfly valve case 17;
– disconnect a hose of ventilation of a case, a hose of a regulator of pressure and, at existence, hoses to the coal filter on connections of the case of a butterfly valve;
– disconnect switches of a butterfly valve 21;
– disconnect an accelerator cable from a butterfly valve;
– unscrew bolts of the 14th fastening;
– remove the block of a butterfly valve 17 from an inlet collector and laying 18 with the valve.
Installation is carried out to sequences, return to removal.

Removal and installation of elements of system of injection of Mono-Jetronic fuel

    
  PREVENTION
All works on removal and installation of elements of system of injection are necessary for carrying out at the removed wire from a negative conclusion of the storage battery.

Removal and installation of a regulator of temperature of air arriving in the engine carry out in the following order:

Fig. 5.67. Elements of system of injection of Mono-Jetronic fuel: 1–additional resistor; 2–vacuum шлан; 3–bolt; 4–a regulator of temperature of air arriving in the engine; 5–valve cover; 6–sealing ring; 7–injector; 8–electric socket; 9–the control unit, 10 – a fastening plate; 11-ventilating tube; 12-management valve; 13-a vacuum hose, 14 – a tube of return of fuel (dark blue); 15-tube of supply of fuel (black); 16-cover of an air inlet of an injector; 17-air inlet union; 18-tip; 19-electric socket of the additional resistor


– weaken a collar, disconnect an air inlet branch pipe from a cover of an air inlet of an injector 7 (fig. 5.67) ;
– disconnect vacuum hoses 3, 13 from a cover of an air inlet of an injector;
– unscrew three bolts of 3 covers of an air inlet of the 16th injector and disconnect it from an injector 7;
– unscrew screws and disconnect a regulator of 4 temperatures of air arriving in the engine from a cover of an air inlet of an injector.
Installation carry out to sequences, return to removal.
Removal and installation of an injector is carried out in the following order:
– weaken a collar, disconnect an air inlet branch pipe from the union 17 of a cover of the 16th air inlet of an injector;
– disconnect electric sockets from an injector;
– unscrew nuts, disconnect submitting (black) 15 and returnable (dark blue) 14 fuel tubes from an injector;
– unscrew two screws of fastening, remove the valve of management of the 12th provision of a butterfly valve from an injector. 13 and the electric tip 18 it is possible to leave vacuum tubes on the valve;

Fig. 5.68. Injector of system of injection of Mono-Jetronic fuel: 1–screw; 2–holder of a nozzle; 3–cover; 4–sealing ring; 5–nozzle; 6–rack-bopt; 7–the top case of an injector, 8 – laying; 9–screw; 10-clamp; 11-cover; 12-spring; 13-diaphragm; 14-pressure regulator; 15-screw; 16-transitional plug; 17-sealing ring; 18-electric socket


– unscrew bolts of 3 fastenings and remove an injector (fig. 5.68) .
Installation carry out to sequences, return to removal.
Removal and installation of the additional resistor carry out in the following order:
– disconnect the electric socket 19 (see fig. 5.67 );
– unscrew nuts and remove the resistor 1 together with an arm.
Installation carry out to sequences, return to removal.
Removal and installation of an element of heating of an inlet collector carry out in the following order:
– the element of heating of an inlet collector is established on a reverse side of an inlet collector, and for access to it it is better to remove a collector;
– disconnect the electric socket, unscrew screws of fastening and remove a heating element from a collector and laying.
Installation carry out to sequences, return to removal.
Removal and installation a lambda sensor carry out in the following order:
– disconnect the electric socket 10 (see fig. 5.24 ) the sensor, then turn on and disconnect a lambda sensor from a final collector;
– grease a carving a lambda sensor with high-temperature VW G5 lubricant, but thus watch, that greasing did not get to grooves or an opening of the case of the sensor.
Installation carry out to sequences, return to removal;
Removal and installation of a thermoswitch and temperature sensors carry out in the following order:
– the thermoswitch and temperature sensors are placed in a connecting branch pipe of system of cooling on the forward party of a head of the block of cylinders.

Removal and installation of elements  of system of injection of K-Jetronic fuel

       PREVENTION
All works on removal and installation of elements of system of injection are necessary for carrying out at the removed wire from a negative conclusion of the storage battery.

Removal and installation of the distributor of fuel carry out in the following order:
– works should be carried out in well aired room;
– disconnect a wire from the negative plug of the storage battery;

Fig. 5.69. Elements of system of injection of K-Jefronic fuel: 1–bolt; 2–screw; 3–fuel distributor; 4–sealing ring; 5–fuel hoses; 6, 27 – a hollow bolt; 7–cap; 8–sealing ring; 9–pressure regulator; 10-electric socket (dark blue); 11-switch of starting supply of fuel; 12-electric socket (brown); 13-temperature sensor; 14-electric socket (gray); 15-heater; 16-vacuum union; 17-valve of cold start-up; 18-laying; 19-plug; 20-sealing ring; 21-nozzle; 22-nut of the fuel highway; 23-measuring instrument of a consumption of air; 24-plunzher; 25-the screw of adjustment of the contents WITH; 26-spring; 28-adjusting washer


– pit pressure in fuel system for what weaken a collar of an inlet fuel hose 5 (fig. 5.69) in a motor compartment;
– uncover, note an arrangement топливопроводов on the distributor 3 and clear them of dirt;
– disconnect топливопроводы;
– unscrew screws of 2 fastenings and remove the distributor of 3 fuels from the top part of a measuring instrument 23 streams of air.
Installation carry out to sequences, return to removal.
Removal and installation of a measuring instrument of a consumption of air carry out in the following order:
– the measuring instrument of a stream of air can be removed together with the fuel distributor.
– pit pressure in fuel system for what weaken fuel connection of an inlet fuel hose in a motor compartment;
– uncover, note an arrangement топливопроводов on the distributor 3 and clear them of dirt;
– disconnect топливопроводы;
– unscrew screws of 2 fastenings and remove the fuel distributor from the top part of a measuring instrument of the 15th stream of air;
– disconnect the electric socket from the sensor of pressure of a diaphragm;
– disconnect a vacuum hose, unscrew screws of fastening and remove the switch;
– disconnect an air pipe from a measuring instrument of the 15th consumption of air;
– unscrew fastening screws, disconnect a measuring instrument of a consumption of air from the air filter.
Installation carry out to sequences, return to removal.
Removal and installation of the valve of braking by the engine carry out in the following order:
– press a bracket of fixing and disconnect the electric socket from the valve 12 (see fig. 5.69 .);
– disconnect a vacuum hose from the valve on a tee of the line of the sensor of pressure of a diaphragm;
– disconnect the air filter and hoses of connection of an air inlet with the gate-type valve;

Fig. 5.71. Vacuum highways on system of injection of K-Jetronic fuel: 1–control unit; 2–temperature regulator; 3–valve of braking by the engine; 4–pressure sensor; 5–zaslonka adjustment; 6–to the conditioner; 7–to the indicator; 8–to the vacuum amplifier of brakes; 9–to the ABS indicator; 10-ABS limiter


– remove the valve 3 (see fig. 5.71 ) braking by the engine.
Installation carry out to sequences, return to removal.
Removal and installation of the valve of cold start carry out in the following order:
– pit pressure in fuel system for what weaken a collar fuel connection of an inlet hose in a motor compartment;

Fig. 5.70. Elements of supply of air in the engine on system of injection of K-Jetronic fuel: 1–measuring instrument of a consumption of air; 2–the screw of adjustment of the contents WITH; 3–cap; 4–branch pipe of supply of air; 5–vacuum connecting coupling; 6–bolt; 7–sensor of pressure of a diaphragm; 8–connecting coupling; 9–temperature regulator; 10-butterfly valve switch; 11-screw of adjustment of turns of idling; 12-uplotnitepny ring; 13-a bolt, 14 – laying; 15-butterfly valve case; 16-top inlet collector; 17-a hose to a heater; 18-valve of stabilization of turns of idling; 19-valve of cold start-up; 20-bolts; 21-union; 22-hose of ventilation of a case; 23-bottom inlet collector; 24-union; 25-valve of braking by the engine; 26-hose of supply of warmed-up air; 27-adjustment of a folding zaslonka; 28-case of the air filter; 29-air filter; 30-cover of the air filter


– unscrew a hollow bolt 20 (fig. 5.70) and disconnect топливопровод from the valve 19 of cold start;
– remove washers from two parties of the coupling топливопровода;
– unscrew bolts and remove a collector 23;
– disconnect a hose from the valve.
Installation carry out to sequences, return to removal.

Removal and installation of elements of system of injection of KE-Motronic fuel

       PREVENTION
All works on removal and installation of elements of system of injection are necessary for carrying out at the removed wire from a negative conclusion of the storage battery.


Fig. 5.73. Types lambda sensors: 1–the sensor without heating with flutes is established in Mono-Jetronic system with the catalyst; 2–the sensor with heating with openings is established in Mono-Jetronic system without the catalyst; 3–the sensor with several grooves is established on all systems except Mono-Jetronic


Applied in systems of injection of fuel oxygen sensors are shown on fig. 5.73 .
Removal and installation of a regulator of pressure carry out in the following order:

Fig. 5.72. Elements of system of injection of KE-Motronic fuel: 1–electric sockets lambda sensor; 2–electric socket; 3–electric socket; 4–control unit; 5–lambda sensor; 6–plug; 7–sealing ring; 8–nozzle; 9–connecting coupling; 10-electric socket; 11-bolt; 12-pressure regulator; 13-sealing ring; 14-coal filter; 15-temperature sensor; 16, 24 – bolts; 17-valve of cold start-up; 18-inlet collector; 19-returnable pipeline; 20-connecting coupling; 21-plunzher; 22-measuring instrument of a stream of air; 23-diafragmenny regulator of pressure; 25-lock screw of a plunzher; 26-sealing ring; 27-hollow bolt; 28-the feeding pipeline; 29-cap; 30-the fuel distributor, And, In, With, D and Е — hoses


– the regulator of pressure 12 (fig. 5.72) is established sideways the fuel 9 distributor;
– unscrew screws 11 of fastening and remove a pressure regulator.
Installation carry out to sequences, return to removal.
Removal and installation of a diafragmenny regulator of pressure carry out in the following order:
– pit pressure in fuel system for what weaken fuel connection of an inlet hose in a motor compartment;
– unscrew nuts and disconnect топливопроводы from a diafragmenny regulator of 23 pressure;
– weaken fastening of the holder and remove a diafragmenny regulator of pressure.
Installation carry out to sequences of return to removal.
Removal and installation of the coal filter carry out in the following order:
– weaken collars and disconnect hoses from the coal filter 14;
– unscrew bolts and remove the coal filter.
Installation carry out to sequences, return to removal;
Removal and installation of the distributor of fuel carry out in the following order:
– pit pressure in fuel system for what weaken fuel connection of an inlet hose in a motor compartment;
– uncover the fuel 30 distributor, note an arrangement топливопроводов and clear them of dirt;
– disconnect топливопроводы;
– unscrew bolts of the 25th fastening and remove the fuel distributor from the top part of a measuring instrument of a consumption of air;
– put a label to designate position of the screw (see fig. 5.41 );
– measure size of a vystupaniye of the lock screw from a nut (see fig. 5.42 ) and unscrew the lock screw;
– wash out a plunzher in gasoline or alcohol;
– check a condition of a sealing ring of the lock screw and if necessary replace it, thus a sealing ring establish in smaller diameter to a plunzher.
Installation carry out to sequences, return to removal.