Bentley - Mulsanne - Workshop Manual - 1987 - 1987

B v ROLLS Workshop Manual Engine -Management Systems ROYCE U- Rolls-Royce B Bentley motor cars Rolls-Royce Silver Spirit Rolls-Royce Silver Spur Rolls- Royce Corniche Rolls-Royce Comiche II Bentley Eight Bentley Mulsanne Bentley Mulsanne S Bentley Turbo R Bentley Continental 1987,1988, and 1989 model year cars TSD 4737 September I989 Introduction This manuai is written specifically for skilled service personnel and it is therefore assumed that the warkshop safety and repair procedures generally accepted by the motor trade are appreciated, understood, and carried wt Information relating to any subsequent modification will be circulated by the issue of amended or addition+ pages. Each chapter incorporates an issue record shoet Reference must be made to these sheets when determining either the current issue date for a particular page, or the number of pages contained within a chapter/section. Throughout the rnanuat reference is made to the right-hand and left-hand side of the car, this is determined when sitting in the driver's scat. In order to identify the two banks of engine cylinders, it should be noted that 'K bank of cylinders is on the right-hand side and '8' bank on the left-hand side when viewed from the driveis seat S e ~ c personnel e at Rolls-Rgree Motor Cars Limited are always prepared to aanswr queries or give advice on individual servicing problems. When making an enquiry it is essential that the full vehicle identification number (VINJ is quoted. important When obtaining information for a particular model always refer to the appropriate Chapter and/or Section contents page. 9/89 TSD 4737 Contents Uupter A General information Chapter B Fuel injection -ern Chapter C Fuel system Chapter D Turbochargingsystem Chapter E Ignition.system (For details of the ignition system fitted to l989 r n d l year turbcharged cars. refer to Chapter B. Seaion 54, K-Moronic) Chapter F Exhaust emission control system Chaptw G Fuel evaporative emission control system Chapter U Crankcase emission con! rol system Chapter J Air intake system Chapter K Throttle linkage Chapter L Special toque tightening figures Chapter M Workshop took Chapter N -Runningchanges Chapter A General information Contents Sections Bentley Rolls-Royce Contents and issue record sheet Eight Muisanne/ Turbo R Mulranne S Continental Spur Comiche / Comiche II A1 Al A9 A1 At Silver Spirit Sihrer AI Al. 1987188109 model years General information 10188 " TSD 4737 Issue record sheet The dates quoted below refer to the issue date of individual pages within this chapter. Sections Page No. 1 &l 1 ~2 I 1 2 10188 3 4 10188 5 6 10188 l0188 10188 10188 lOl88 10188 1 I I T I I 1 1 1 I I I Section A2 General information Heahh risk Engine oils Prolongedand repeated contact with mineral oil will result in the removal of natural fatsfrom the skin. leading t o dryness. irritation, and dermatitis. In addition. used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Health protectionprecautions 1. Avoid prolonged and repeated contsct with oils, particularly used engine oils. 2. Wear protective clothing, including impervious gloves where practicabte. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes, particularly underpants. with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6. First aid treatment should be obtained immediately far open cuts and wounds. 7. Use barrier creams. applying before each work period. to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is rernwed (skincleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been remwed. 9. Do not use fuel, kerosine, diesel fuel, gas oil, thinners, or solvents for washing skin. 10. Ifskin disorders develop. obtain medical advice 11. Where practicable, dsgrease components prior t o handling. 12. Where them is a risk of eye comaet. eye protection should be worn, for example, chemical goggles or face shields; in addition an eye-wash facility should be provided. See atso UK Health and Safety Executive Cautionary Notice SHW 397 'Effects ofMineral Oil on the Skin'. Operating the air conditioning system in 8 confined space incmases the danger of these Bases entering the car. ideally. engines should be tun inthe open where the exhaust gases can discharge into the atmosphere However. when running engines within an enclosed working area. the exhaust gases must always be removed safely. Refer t o further text withirrthis manual regarding the use of exhaust gas extraction hoses and equipment. Fuel Fuel may contain up to 5% of benzene as an anti-knock additive Benzene is extremely injurious t o health {being carcinogenic) therefom all cantact should be kspt tb an absolute minimum, particularly inhalation. Fuel has a sufficiently high vapour pressurnto allow a hazardous build-up of vapour in poorly ventilated areas. Therefore. any work should be carried out in a well ventilated area. Fuel vapour is an irritant t o the eyes and lungs, and if high concentrations are inhaled it may cause nausea, headache, and depression. Fuel liquid is an irritant t o the eyes and skin and may cause dermatitis following prolonged or repeated contact. When it becomes necessary t o carry out work involvingthe risk of contact with fuel, particularly for prolonged periods, it is advisable t o wear protective clothing including safety goggles, gloves, and aprons. If there is contact with fuel the following emergency treatment is advised. Ingestion Iswallowing) Do not induce vomiting. Give thepntient milk to drink (if none is availabte water can be given). The main hazard after swallowing fuel is that some of the liquid may get into the lungs. Send the patient to hospital immediately. Eyes Wash with a good supply of clean water for at least 10 minutes. Environmental protection precautions tt is illegal to pour used oil onto the ground, down sewers or drains. or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is fitted. In cases of doubt check with the Local Authority. Dispose of used oil through authorized waste disposal contractors t o licensed waste disposal sites, or to the waste oil reclamation trade ff in doubt, contact the Local Authority for adviceor disposal facilities. Inhalation {breathing in vapour) Move the patient into the fresh air. Keep the patient warm and at rest. If there is loss of consciousness give artificial respiration. Send the patient to hospital. Exhaust gases The exhaust gases contain carbon monoxide (CO), which is odourless and invisible but very poisonous. High vohage Isvets Dangerously high vohsge levels are present in an electronic ignition system. These levels are not only Skin contact Immediately drench the affected parts of the skin with water. Remove contaminated clothing and then wash all contaminated skin with soap and water. TSD 4737 A2-1 present in individual components, but also in the wiring looms, plug& sacketr and test connections. Both primaty and secondary circuits are subject to these high wltages. Therefore. whenever the system is switched &? do not touch any cornponents/circuits contained within the ignition system Always wear thick rubber glows and use insulated tools when working on the system with the ignition switched on. Workshop precsutions Electrical Always ensure that the battery master switch is turned to the OFF position or the battery is disconnected, before disconnecting or connecting any eteetrical components. In addition, note the following. Never disconnect the battery or switch off the battery master switch when the engine is running. Always ensure correct polarity when making cable connections. Ir is recommendedthat when carrying out tests on the car wiring. a good quality mufti-meter is used. Never use generator type meters. Do not use a test lamp on circuitry that contains electronic components, such as the ignition system. Before using test equipment always read the manufacturer's instructions. Do not pierce any electricai leads or tooms with test probes. etc. Do not remove the high tension lead situated between the ignition coil and distributor when the engine is running. . Ensure that no arcing takes place:herween -.. electrical connections Do not supply more than 16 volts direct current t o the ignition system. Fire Fuel is highly flammable, therefore great care must be exercised whenever 1he fuel system is opened IiAL pipes or unions disturbed) or the fuel is removed from the system. Always ensure that 'no smoking' signs and CO, (carbon dioxide) fire extinguishers are placed in the vicinity of the vehicle. Always ensure that the battery is disconnected before opening any fuel lines. If the fuel is to be removed from the tank, ensure that it is siphoned into a suitable covered container. 'Fuel Pressure The fuel system contains fuel that may be under high pressure. Therefore, to reduce the risk of possible injury and fire, always ensure rhat the system is depressurized by one of the foIlowing methods before commencing any work t h a t necessitates opening the system. 1. Allow the pressuret o fall naturally by switching off the engine and allowing the vehicle to stand for a minimum of four hours before opening the system. 2. Clean the inlet connection to the fuel fitter. Wrap an absorbent cloth around the joint and carefully stacken the pipe nut to release any pressurized fuel from the system. Tighten the pipe nut. Always dispose of the cloth carefully, in accordance with the prevailing Health and Safety regulations. Cleanliness It is extremely important t o ensure maximum cleanliness whenever work is carried out on the system. The main points are. 1. Inorder t o prevent the ingress of dirt, always clean the area around a connection before dismantling a joint. 2. Having disconnected a joint (either fuel or air1 always blank off any open connections as soon as possible - 3. Any components that require cleaning should be washed in white spirit and dried, using compressed air. 4. If it is necessary t o use a cloth when working on the system, ensure that it is lint-free. Generd Before working on the ear. always ensure that the parking brake is firmly applied. the gear range selector level is in the park position, and f w e A6 is removed from fuse panel F2 on the main fuseboard. A number of the nuts. bolts, and setscrews used in the fuel injection system are dimensioned t o the metric system, it is important therefore, that when new parts become necessary the correct replacements are obtained and fitted. Terminology It should be noted that not all of the components listed are.fiaed to any.one particular model or model year of car. This section merely explains the abbreviation and operation of the specialist components used inthe systems. Air flow sansor plate Balances the air flow entering the induction system with fuel pressure acting an the control pjston. Air flow sensor potentiorneter Monitors the quantity of ait flowing into the engine The information is conveyed ro the ECU as a measure of engine load and is one of the elements used in the calculation of ignition timing and fuelling requirements. Air pressure transducer {APT) The air pressure transducer monitors induction manifold pressura It passes this information to the relevant ECU so that the necessary electrical corrections can be made t o the retevant control system. On cars fined with one APT the unit provides instantaneous boast pressure information for the fuel injection end ignition control systems. It also suppties the information to the boost control system. On cars fitted with TWO APTs one assembly is connected to the fuel injection system and the second unit is connected to the boost control system. Air pump clutchedpufley The air injection system is de-activated whenever the coolant tcrmprature is a b o y 3 3'C (91°F 1 w engine speed exceeds 3000 + l00 wlmin. This is achieved by dis-engaging the air pump clutch. Air swkchingvmlw The air switching value comprises a vacuum operated valve with m integml control solenoid. At coolant temperatures belaw 33OC 19t°F) the solenoid b energized The resulting vacuum then applied to the diaphragm chamber opens the valve and allaws injected air to PISS to the exhaust manifold. At coolant temperatures above 33OC {91QFl the solenoid is de-enefgued, the vacuum signal is inhibited and the injected air is re-routed t o the engine air intake system. Auxairy air valve Allows ealibreted increases in idle circuit air flow and hence engine speed, with closed throttle plates. 1his provides the correct mixture strength during cold starting and warm-up periods. air intake Closum of the dump valve allows induction manifold presswe l boost1to build-up during increasing engine load, tovalues predetermined by the boost conmh system. The dump valve also acts as a relief valve /f the boost presswe exceeds a preset level. Eleetro-hydraulicactuator (EHAI Mounted on the fuet distributor. the electro-hydraulic. actuator replaces the warm-up regulator used on KJetronicsystema A positive increase in cunem (mA) supply to the EHA results in a corresponding increase in fuel flow and hence fuel mixture strength. On 1989 model year cars-fittedwith the KE3-Settonicfuel injection system, it is also possible t o have a negative increase in thesupply t o the €HA which will 'Iran off* the mixture Engine~ n n i n sensor g Inhibits thesupply of power to the fuel pump unless the engine is running. The only exception being one by-pass to the circuit. which allows the fuel pump t o operate when the engine is being 'cranked' by the starter motor. Check valves A check valve is fitted into the air injeetion pipe to each exhaust manifold. The valves prevent the back flow of exhaust gas. Cold start injector Sprays finely atomized fuel during engine cranking (cold engine) into the induction manifold. The amount and duration of cold start injector operation a* dependent upon the coolant ternpenturn Control piston Cylindrical plunger type of'&= that moves vertically in the fuel distributor. A precision machined edge on the piston opens the metering slits in the fuel distributor. Coolant temperature sensor The coolant temperature sensor is located in the thermostat housing. The internal resistance of the sensor changes with the engine coolant temperature. To achieve the correct starting and warm-up characteristics at low operating temperatures, the ECU uses the signal it receives from the coolant temperature sensor to compute the correction factors for the ignition timing and the fuel injection system electro-hydraulic actuator. .Crankshaft refarence sensor Initiation of A1 ignition and subsequent engine firing order occurs when The from damper mounted reference pin passes the crankshaft reference sensor. Differential pressure vaives One for each cylinder. maintains the correct pressure of fuel at the metering slits. Dump valve Allows compressed air to recirculate back through the Engine s p e d sensor The signal generated by the rotation of the four segment timing wheel is sensed by the engine speed sensor. The information is then conveyedt o the KMotronic ECU for calculstion of the engine speed. Exhaust gas recirculation valw EGR) The operation of this valve is vacuum controlled. A proponion of exhaust gas is recirculated from the exhaust svstem, through the EGR value, into the induction manifotd where it mixes with intake air. Exhaust gas wastegate Regulates the flow of exhaust gas to the turbocharger turbine when either boost pressure or engine detonation reach predetermined Iwels. The boost contr01system actuates wastegate control. Four segmant timing wheel The four segment timing wheel has four equal length segments and gaps. Angular felationship of segment t o gap is 54 and 36 respectively, ant3 produces a 60:40 ratio signal for engine speed cakulation. Fuel aceumutatar When the engine is stopped. the small volume of fuel held in the accumulator (under pressure from the accumulator spring) maintains pressure in the primary fuel circuit to ensure good starting response during the .engine 'cranking' operation {i.e.fuel is immediately . .. availabbl. . . . .. .. , , Fuel cooler The fuel cooler is located in the left-hand side of the.. engine compartment. It uses air conditioning system refrigerant to cool the fuel prior t o its return to the tank. Fud distributor Apportions the fuel equally ta h e injectorsadjacent to each e n ~ i n e cylinder. Fuel pressure rngulator Maintains a eansrant primary circuit fuel pressura When the engine is stopped. the fuel pressure regulator allows the system pressure to drop rapidly t o a value preset by the fuel accumularor (ia.just below the injeftor valve operating pressure). It also seals the return tine from the lower chambers of the differential pressure value. Haatad ox ygsn sensor Measures the oxygen content (which is directly related to the aidfuel ratio) in the exhaust gas and by means of an electrical signal transmits the information t o the electronic control unit. Idle speed actuator The idle speed actuator contains a stepping motor, the armature of which is connected to a rotating slide. This adjusts the crosssectional area of the by-pass passags The dury cycle from the K-Motronic ECU produces a torque at the rotating armature which acts against a return spring. The by-pass opening is continuatly adjusted to maintainthe correct engine idle speed under all potential engine Load conditions. Injector One injector is used for each engine cylinder and sprays finely atomized fuel under all running conditions into the induction system. lntercooier A charge air intercooler is fitted below the air cleaner assembly. It is situated in the ambient air stream behind the air dam and beneath the front bumper. The intercooler reduces compressed air temperature, this enables recovery of charge air density and maintains optimum engine power output. KEZ-Jetronic electronic control un8 (ECU) Processes input from a chain of engine mounted sensors and provides the necessary electronic fuel corrections in terms of DC mA t o the electro-hydraulic actuator. This includes start, post s t a n warm-up, acceleration enrichment, and positive induction manifold pressure compensation. K-Motroriic digital ECU The K-Motronic ECU is mounted in the ECU compartment in the rear right-handcomet of the engine compartment. The K-Matronic system brings together the benefits of digital fuel injection (KE3-Jeaanicl and ignition control (£258F)systems into a single electronic control unit (ECU).Other features of the system include cold srart and warm-up enrichment, idle speed regulation. and automatic correction of any long term mixture strength deviations. On cars fitted with catalytic conveners the K-Motronic system also provides an 'on-bard' setf .diagnostic facility. The engine is equipped with sweral sensors that continuously monitor operating parameterssuch as engine speed, coolant temperature, and load. The sensors are connected to the digital ECU which is programmed with eharecteristicdata for the following functions, mixture strength control, ignition timing, idle speed control, end purging of the eveporative emission control canister. Knock sensors Sense crankcase vibration and then produce an output signal which is processed by the boost electronic contr~ll unit. If knock is present the ECU signals the boost conrrol valve t o divert the compressor pressure signal more towards the wastegate than atrnosphera 'On board' self diagnostic ability A facia mounted warning panel illuminates to alen the driver to a number of possible engine related faulta The lamp displays the message 'Check Engine' and is illuminated when the engine is running and a failure is identified. When the 'Check Engine' lamp is illuminated a fault message (in the form of a four digit code! is stored within the K-Motronie ECU and can be subsequently used to inform workshop personnel of the faulty components or system. Pnrssure control vslw Operating from an electrical signal received from the electronic control unit. the valve varies the fuel pressure in the lower chambers of the differential pressure valves. Pressure damper Darnpens the pressurepulses caused by the operation of the pressure control valve. Purge control valve This valve is connected into the purge line of the fuel evaporative emission control system. It regulates the putge flow rate depending upon engine load and mode of operation. The valve receives a dury cycle signal from the engine management system ECU. Thermal time switch Situated in the thermostat housing. Depending upon the temperature of the coolant, it controls the operatian of the cold stsn injector. Throttle position switch ITPSI Identifies the engine operating mode (i.eidle. part load, or furl ioaul. Pan load occurs when the switch contacts are broken between idle and full Load. Turbocharger Increases the power and torque of the engine by utilizing energy from rhe exhaust gas. Vehicle specification Specification l UK and all countries not Listed Norway and Sweden Naturally Aspirated Naturally Aspirated Turbocharged Turboc harged p - Engine L410 1 L 410 If L 410 IT1 - - I - 87188f89 - 87/88 - 89 - - Fuel system 87/88 89 Recircularory with in-tank and main pumps With fuei cooler 87/88 89 - 87188184 K-Motronic engine management system) - 87188:89 87/88 89 - --. Fuel injection system Bosch K-Jetronic Bosch KEZ-Jetronic Bosch KE3-Jetronic (electronically controiled by 1 - 87/08/89 + - 87:88 B9 Turbocharging system Boost pressure control system regulaz~ngexhaust gas by-passing turbocharger vha a wasregate - 87/88;89 Ignition control system Constant energy type. Lucas 35 OM 8 distributor conventional vacuum and centrifugai advance 87/88/09 - l - 87'88 89 -- 87'88 89 87 88 89 8 7 88'89 87'88i89 i - T Digital nm-adjustable E2 58F. Twin 2 X 4 cylinder distributor , Digital non-adjustableEZ 58F lelec tronically controlled by K-Motronic engine management systemi. Twin 2 X 4 cylinder distributor. - Exhaust emission control system Air injection system - - 89 EGR system - - B9 Catalytic converter system with closed-Ioop - - "89 "89 - 88;89 - W Fuel cvaporative emission control system Standard purge control system Programmed purge control system 1 1 Crankcesr emission control system Recirculatory closed breather type 89 - - 87188189 87;88:89 87/88/09 fhronle intake Rod and feuer system 1 87188 - With charge air intercoaler -- - I t japan has excessive exhaust temperature warning$+ 1 - 89 1 87:88:89 87188!89 - 87/88:89 I Other than Australia With mods for boos1 system 87:88 87,88:89 89 87/88\89 'Middle East has revised ignition timing "Remote CO tapping I 89 I: l Air intake system Filter rnounted on right-hand inner wing valance - 89 89 -- 87:88:89 87180t89 I I - Austria and Switzerland Maddle East and Taiwan Australia, Canada. Japan. and USA Aspirated Naturally Asp~rated Naturally Aspirated Narurally furbocharged - 87 88/09 - 87 89 - Turbocharged - 87 08/89 - -- - - -- - 87 89 B7 88 89 v 87 and 89 'Ld - 87 88/89 - 87:88 89 87 88 89 h - 87,88189 - - 07/88/89 '87 88:89 1 89 87188 89 a7 - 87 88 - B9 - 89 - 1 Chapter E TSD P700 l 89 87/88/89 87 88 89 Workshop Manual Turbocharged 87/88i89 87188 89 I B9 . Chapter B TSD 4737 - Chapter C TSD 4737 Chapter D TSD 4737 89 A Chapter E TSO 4737 Chapter E TSD 4737 Chapter 6 TSD 4737 89 p - 80 85 e9 - 08 89 -- "88 89 BR E 9 - "89 - - 89 - - - - 89 - v '871 88/89 ' "87188189 - $87108' 89 t 89 tt87188 87!88/09 p 87 '88189 - 89 r l ~ 87 and B9 87/88;89 87188189 87:88!89 8'7 88!89 87 87;88189 87/88 87188189 89 Chaplet F TSD 4737 I 8'f 88189 - - - 89 - 1 Chapter G TSD 4737 89 &apter H TSO 4737 89 Chapter J - - TSO 4737 I 87'88:89 87 and 89 87/88/89 87/88/89 87/88/89 89 Chapter K TSO 4737 Chapter B Fuel injection system I . 8 . . Sections Contents RolleRoyce Silver Spur Silver Spirit Comiche / Comkhe I t Bentley Eight MuIsanne/ Turbo R Cmtinental Mulsanne S Contents and issue record sheet 1987/8&89 model years Naturally aspirated cars Fuel injection system K-Jetronk - 198 7/88 modd years Turbocharged cars Fuel injection system KE2-Jetronic - 1 989 model year Turbncharged cars Fuel injection and Ignition control systems K-Motronic 5/88 - TSD 4737 . : B1-l Issue record sheet The dates quoted bsbw refer to the issue date of individual pages within this chapter. Sections I B1 I P# (a3 Paae No. I I 1 1 \ I B4 IF-a m l I TSD 4737 B1-3 Section B2 Fuel injection system K-Jetronic at the engine idle speed setting, during manufaciure. of the vehicle. This is achieved by turning a screw which alters the position of the air flow sensor plate lever relativeto the control piston. Turning the adjustment screw either raises or lowers the controi piston for a given engine idle speed position of the air flow sensor plate, thereby richening or weakening the idle mixture. The adjustrrient scmw is subsequently sealed and no further mixture adjustment should be necessary. Naturally aspirated engines are fitted with the Bosch K-Jetronic continuous fuel injection system. f he K-Jetroniesystem is a mechanically and hydraulically controlled fuel injeciion system that requires no form of drive. The basic principle of operation is that the accelerator pedal controls the movement of the throttle plates which regulate the amount of air drawn into the engine. An air flow sensor fitted upstream of the throttle plates, monitorsthe quantity of intake air entering the system. Dependent upon the volume of air metered, a fuel distributor apportions a quantity of fuel to the injector adjacent to each cylinder. The air flow sensor and the fuel distributor are combined into one assembly known as the mixture control unit (see fig. 82-21. The precisely metered quantity of fuel is continuously sprayed from the injectors in a finely atomized form into the induction manifold behind the engine inlet valves. Theairffuel mixture is then drawn into the engine cylinders whenever an inlet valve opens. Cars fitted with a catalytic converter also have a 'closed loop' (lambda control) system. This system accurately controls the airlfuel ratio about the stoichiometric value which is necessaryto achieve efficient operation of the three-way catalytic converter. Differential pressure valves (upper chambers) 4,6 bar (67.0 Ibflin2) Differentialpressure valves (lower chambers) 4,7 bar (68.1 Ibf/ina) nominal Control circuit (variable dependent upon engine temperature) 0.5 barto 3,6 bar (7.25 tbflin2to 52.2 lbflinz) Fuel injector pressure 3,6bar (52.2 Ibflina) Air Row sensing The sir flaw sensor consists of an air cone in which moves an air flow sensor plate mounted on a pivoted lever (seefig. 82-31. When the engine is operating the sensor plate is deflected into the air cone, the deflection being dependent uponthevolume of air passing through the cone. The air will deflect the sensor plate until a state of balance exists between the force on the air sensor plate and the counter force provided by fuel at a constant pressure acting on the end of the control piston. The weight of the sir sensor plate and connecting lever are balanced by a counterweighton the fuel distributor side of the lever. Movement of the control piston and its horizontal control edge Isee fig. 82-3)either increases or decreasesthe open area of the eight metering slits {onefor each engine cylinder) in the fuel distributor. Differential pressure valves (one for each cylinder) located within the fuel distributor, maintain a constant pressure drop across the metering slits. Since the airflow sensor plate and the control piston are operated by the same lever, therate of fuel discharge is proportionalto the deflection of the air sensor plate which is governed by the calibrated cone within the funnel. The mixture strength of each engine is adjusted Primay fuel circuit (see fig. 82-4)' The primary circuit fuel pressure is regulated by a plunger type valve to nominally 5,2 bar to 5,8 bar 175.4 lbflinPto 84.1 ibf/inz). In the fuel distributor the fuel initially enters a passage which joins with the lower chambers of the differential pressure valves via a small fixed orifice Isee fig. 82-7). When the engine is operating the fuel flows through the metering slits (machinedinto the barrel of the fuel distributor)to the upper side of the diaphragm in the differential pressurevalves. Then through injector lines to the injector valves. The injector valves have an opening pressure of approximately3,6 bar (52.2 Ibf/inz)and are designed to spray finely atomized fuel under all operating conditions, From the primary fuel circuit a fuel line feeds the cold start injector. When the engine is stopped, the primary system pressure regulator allows the system pressure to drop rapidly to a pressure governed by the fuel accumulator which is just below the injector opening pressure and maintains it at this level by sealing the return line to the fuel tank. This sealis effected by a rubber '0' ring fitted to the valve which is compressed against the fuel distributor housing (see fig. 52-5). Fuel circuit The fuel supply system comprises the primary circuit, control circuit, and the lambda control circuit (if fitted). The fuel is at different pressures in various patts of the circuit as follow. Primary circuit 5,2 bar to 5 8 bar (75.4 Ibflin2to 84.1 Ibf/in2) - TSD 4737 Fig. 82-1 Enginecompartment d m i l s 1 Idle speed control solenoid 2 Fuel pressure damper 3 -Fuel pressurecontrol valve 4 Auxiliary air valve 5 Fuel distributor 6 7 8 9 10 Secondary throttle spindle Air meter Primary throttle spindle Acceleration enrichment switch Warm-up regulator Simultaneously a push valve, integral with the system pressure regulator closes and prevents leakage through the control circuit. This retention of fuel pressure in the system is important because during 'hot soak' conditions it prevents fuel vaporization'and subsequent poor starting. In addition, the sudden pressure drop at the fuel injectors (causingthem to close) prevents 'dieseling' (i.e. the tendency of an engine to continue 'running-on' after the ignition has been switched off). Cantrot fuel circuit (see fig. 82-41 f he control circuit provides the control pressure that acts upon the upper end of the control piston and provides the balancingforce for the air load acting on the air sensor plate. In addition, it also provides a means of enriching the mixture for cold starting. The control circuit is supplied with fuel from the primary circuit through a restrictor in the fuel distributor (see fig. B2-7).The fuel then passes either into the chamber above the control pistan via a damping restrictor or via an external connection to the warm-up regulator, where nominal control pressure of 3,6 bar (52.2 IbfJin2)[3,5 bar (50.7 Ibf/in2) on cars f i e d with a lambda control system1 is maintained at normal engine operating temperature (at sea level). The pressure regulator in the warm-up regulator is tensioned by a bi-metal spring when the engine is cold. This in turn reduces the load on the regulating valve and correspondingly lowers the control pressure. With a tower control circuit pressure, the air flow sensor plate is allowed to travel further downwards in the air cone for a given rate of sir consumption which in turn; moves the control piston further up'in the barrel of the fuel distributor. This increasesthe opening of the fuel metering slits and thereby enriches the mixture. The bi-metal of the warm-up regulator is heated electrically whenever the engine is running. This causes the effect of the bi-metal to be reduced with a corresponding reduction in the amount of mixture enrichment. The warm-up regulator is mounted so that it can assume the temperature of the engine. Therefore, when the engine is started in the semi-warm condition, unnecessary enrichment of the airlfuel rni~ture is avoided. Fuel from the warm-up regulator flows through the push valve assembly which assists in maintaining the pressure by closing the primary circuit when the engine is switched off. Excess fuel flows around the push valve and into the fuel tank return line which is not under pressure (see fig. 02-41. Fuel distribution (see fig. B2-4) To-ensurethatthe fuel is uniformly distributed to the cylinders a control piston and barrel assembly is used (see fig. 82-1 1l. This assembly operates by controlling the open cross sectional area of the metering slits machined in the-barrel. Fig. 02-2 Mixture acmtml unit 1 Air intake 2 Fuel supply to distributor 3 Fuel distributor 4 Fuet feed to injector 5 Fuel feed to warm-up regulator 6 System pressure regulator 7 Fuel return from warm-up regulator 8 Fuel return to tank 9 fuel feed to cold start injector 10 Fuel feed to pressurecontrol valve 11 Air meter Fig. 62-3 Airflow sensor and fuel distributor (mixturecontrol unit) Fuel feed pipe to injector Fuel distributor assembly Control piston Fuel distributor barrel Differential pressure valve Position of sir sensor plate at idle speed Air meter Air flow sensor plate Pivot Counterbalance weight Fuel inlet TSD 4737 B2-3 Fig. B2-4 Fuel injection system Key to fig. B24 Fuel injection system 1 Thermostat housing 2 Thermal time switch 3 Air cone 4 Air meter 5 Air sensor ptate 6 Differential pressure valve 7 Comrol piston 8 fuel distributor 9 Anti-suction valve 10 System pressure regulator 11 Warm-up regulator 72 Fuel damper 13 Pressure control valve 14 Electronic control unit (ECU) 15 Oxygen sensor 16 Exhaust system 17 Fuel pre-pump 18 Fuel pump 19 Fuel pressure damper 20 Fuel filter 21 Fuel cooler 22 Fuel aeeurnulator 23 fuel tank 24 Throttle body 25 Idle speed adjusting screw 26 Cold start injeetor 27 Injector 28 Auxiliary air valve 29 idle speed control solenoid A Upper chamber pressure B Lower chamber pressure C Control pressure D Primary circuit pressure E Injection pressure F Unpressurizedreturnline G Pre-pump t o main pump supply pressure Fig. B2-5 System pressurermgulator 1 Fuel return to tank 2 System pressure line 3 Fuel return from warm-up regulator 4 Push valve 5 Regulator valve sealing face Note Items 12,13,14and 15 arefittedto cars with a lambda control system Iclosed loop mixture control). 1he barrel has one slot shaped opening (the rectangular metering slit) for each cylinder. Each metering slit has a differential pressure valve to hold the drop in pressure at the metering slits constant at the various flow rates. As a result, effects of variations in the primary system pressure and differences in the opening pressure of the injector valves are eliminated. With a constant drop in pressure at the metering slits, the amount of fuel flowing t o the injector valves depends solely upon the open cross sectional area of the slits. Differential pressurevalves (seefigs. B2-4 and 02-71 There is a differential pressure valve for each engine cylinder. The valve is a diaphragm type consisting of an upper and lower chamber with the diaphragm separating the two halves (see fig. 82-7).The basic principle of operation is that the fuel pressure in the upper chamber is at approximately 0.1 bar (1.5 Ibf/inz) less than the pressure in the lower chamber. The Fig. B24 Relationship between primary circuit pnnrsum and control pressure 1 Damping restrictor 2 fuel feed to warm-up regulator 3 Differential pressure valve 4 Control circuit pressure 5 Control circuit restrictor 6 Primary circuit pressure 7 Control piston pressure differential is produced by the helicalspring built into the upper cham bet. Under these conditions equilibrium of forces exists at the diaphragm. If additionat fuel flows through the metering slit into the upper chamber, the pressure rises temporarily. This increase in pressure will force the diaphragm downwards until a differential pressure of 0.1 bar (1.5 Ibf/in2)again prevails at the metering slit. At higher rates of fuel flow, the diaphragm opens a larger annular cross section, so that the pressure differential remains constant. If the rate of fuel flow decreases, the diaphragm reduces the amount of fuel flowing into the injector line. The total travel of the diaphragm is only a few hundredths of a millimetre. Note f he fuel pressure in the lower system and therefore, the pressure differential between the two halves of the chamber is affected slightly by the operation of the lambda control system. 'Closed loop' mixture control system (Lambda control system) Cars fitted with a catalytic converter also have a 'closed loop' lambda control system. The lambda control system is an addition to the K-Jetronic fuel injection system and isfitted to give accurate control of the airlfuel ratio about the Fig. 82-7 A B Diiwential pmssure valve High flow rate Low flow rate stoichiometric value which is necessary to achieve efficient operation of the threeway catalytic converter. The control principle is based on the fact that by means of the oxygen sensor the exhaust is continuously monitored and the amount of fuel fed to the engine is continuously corrected. With an ideal (stoichiometriclair/fuel mixture the 'air factor is identified by the value * A= 1. At this mixture ratio the output signal from the oxygen sensor develops a voltage jump which is processed by the electronic control unit. This voltage changes sharply for small deviations from the stoichiometric mixture (the airlfuel ratio for full combustion of the fuel). The electronic unit therefore, controls the injection system for 'closed loop' fuel metering by modulating the signal to the pressure control valve. This in turn, affectsthe pressure in the lower chambers of the differential pressurevalves. By responding to the unconsurnedoxygen content of the exhaust gas, the sensor registers the extent of the complete combustion and regulates the airffuel mixture to the ideal or stoichiometric ratio. X Fig. B24 injector 1 Nozzle 2 Insulating sleeve 3 Fuel supply connection 4 Filter Actual intake air = Theoretical requirement Description af the components Injector (seefig. B2-81 An injector is fitted into the inductionsystem just behind each inlet valve. The injector opens automatically when the fuel pressure in the injection lines reaches 3,6 bar (52.2 Ibf/in2).It has no metering functions, its purpose being to continually spray finely atomized fuel under all running conditions. The injector is supported in a spetially shaped moulded rubber sleeve, it is pressed (not screwed) into position. The hexagonal section is provided to hold the injector while the fuel line is attached. A retention plate is fitted over the injector and secured to the cyIinder head by two small setscrews, each plate retains two injectors. Cold start injector (seefig. 82-91 In order to facilitate engine starting particularly from low ambient temperatures, a cold start injector is fitted into the induction manifold and sprays additional finely atomized fuel during engine cranking. A thermal time switch mounted in the thermostat housing controls the operation of the cold start injector. This injector ceases to operate when the ignition key is released from the START position. In the cold start injector a helical spring presses the movable armature and seal against the valve seat, closing the fuel inlet. When the armature is energized {and therefore drawn upwards) the fuel port is opened and the pressurized fuel flows along the side of the armature to the swirl nozzle. Idle speed adjustment screw [see fig. 82-10) this adjustment screw is situated at the forward end of the throttle body and allows limited adjustment of the engine idle speed. During manufacture of the vehicle the engine idle speed is set using the throttle butterfly valve adjusting screws. These screws are situated on the side of the throttle body and sealed after the initial adjustment. Afterwards, adjustment to the engine idle speed is by means of the idle air bleed screw situated at the forward end of the throttle body. This screw is the only means of limited adjustment to the engine idle Fig. B26 Cold start injector 1 Electricsl connection 2 Fuel inlet 3 Magnetic coil 4 Sealing ring 5 Swirl n o u l e 6 Armature speed. ldle speed control soknoid {see fig. 82-10) Movingthe transmission selector from the neutral position causes the engine idle speed t o decrease, due to the additional load of the transmission. To compensate for this idle speed decrease a solenoid valve is opened (energized) when the transmission selector i s moved from the neutral position into any forward gear. This allows more intake air to by-pass the throttles and effectively increase the idle speed to the optimum setting. Air flow sensor plate (see fig. 82-3) f he sensor plate is housed in the air venturi of the air meter. Its function is described on page 82-1 under the heading of Air flow sensing. DiFferential pressurevalues {see fig. B2-7) The differential pressure valves (one for each engine cylinder) are housed in the fuel distributor. Their function is describedon page 82-5 under the heading Differential pressure valves. Fig. 82-10 Idle spe- Gun 1 ldle speed adjustment screw 2 Idle speed control solenoid TSD 4737 Fwl distributor (see fig. 82-31 The fuel distributor forms part of the mixture control unit. Its funaion is described earlier in this section. -Control piston (seefigs. B2-3 and B2-111 This is a cylindrical plunger type of valve that moves vertically in the fuel distributor. It is operated by a lever connededto the air flow sensor plate. A precision machined edge on the control piston opens the fuel meteringslits in the fuel distributor barrel and therefore. controls the amount of fuel injected into the engine cylinders. System pressure rsgubtor (see fig. 82-5) When the engine is operating this regulator maintains a constant primarycircuit fuel pressure. When the engine is stopped, the regutator valve allows the fuel pressure in the primarycireuit to fall rapidly to just below the injector opening pressure. In rrddition, the push valve (the smaH valve on the outer end of the regulator) closes and prevents leakagefrom the control circuit. Fuel pressure damper {see fig. B2-12) Fitted to cars with a lambda control system. This assembly is designed to 'damp' the pressure pulses caused by the operation of the pressure control valve. Fuel pressure control valve (see fig. B2-f 21 Fig. 82-1t Fuel distributor barrel and control piston 1 Fuel distributor barrel 2 Fuel metering slits 3 Piston control edge 4 Fuel inlet poes 5 Control piston fig. 82-12 Fuel pressurecontrol valve and damper 1 Air intake elbow 2 Fuel feed from disfrihutor 3 Pressuredamper 4 Crankcase breather housing 5 Pressure control valve 6 Cold start injector Fitted to cars with a lambda control system. This valve is operated by an electrical signal received from the electronic control unit. The pressure control valve receivessquare-wave pulses of constant frequency t70 cycles per second) but of variable width (i.e. the proportion of time that the valve remains open during any one cycle is variable, controlling the flow rate through the valve). This action varies the fuel pressure in the tower chambers of the differential pressure valves. Electronic mntml unit (ECU) (see fig. 82-13] Fitted to cars with a lambda control system. The electronic control unit, converts the electrical signal from the oxygen sensor into a hydraulic of the fuel mixture. This is achieved by the correc~ion signal it transmits to the pressure control valve. The oxygen sensor reacts to a change from a weakto a rich mixture with a vottage jump which is processed by the electronic control unit. As a result of this change to a richer mixture, the control unit changes the open-closed ratio of the pressure control valve smoothly towards a weaker mixture, until the oxygen sensor reacts to the resulting weaker mixture. This develops a voltage jump in the opposite direction, causing the openclosed ratio of the pressure control valve to be changed in the richer mixture direction. To avoid driving continuously with a weak mixture if the oxygen sensor malfunctions. the control operation is periodically monitored within specified fixed time spans and. in the event of a defect, the controt operation is switched to the 'internal-signal mode'. When in this operating mode the pressure conrrof valve receives a constant pulse signal to control the on-off ratio. In addition a warning lamp situated on the facia will be illuminatedto indicate thar attention is necessary. In addition to the basic fundion of the electronic control unit to evaluate the signal from the oxygen sensor, it also performs the following additional - functions. Until theoxygen sensor attains its operating temperature, a control function cannot take place. Therefore, during this warm-up periodthe electronic control unit isswitched to the 'internal-signal mode' ('open loop control'). When it is necessary for the engine to operate under full load conditions it is also desirable to switch from the 'external-signal mode' or 'closed loop control'. This is achieved by a throttle position switch, situated on the side of the throttle housing activating a micro-switch and thereby, switching the electronic control unit into the 'internal-signal mode'. Simultaneously. the electroniccontrol unit modifies the signal to the pressure control valve to provide the additional enrichment required for satisfactory engine operation at full throttle. Oxygen sensor (see fig. B2-14) Fitted to cars with a lambda control system. The oxygen sensor measures the oxygen content in the exhaust gas and by means of an electrical signal transmits the informationto the electronic control unit. The assembly consists of a sintered zirconium dioxide ceramic, impregnatedwith certain metal oxides. The surfaces of the tube are coated with a thin layer of platinum. In addition, a porous ceramic layer is applied to the outer side which is exposed to the exhaust gas. The surface of the hollow inner side of the ceramic tube is in contact with the ambient air. When in position, the ceramic sensor tube is subjected to the exhaust gas on the outside, whilst ambient air is allowed to pass inside the sensing tube. If the oxygen concentration inside the-sensordiffers from the outside. a voltage is generated between the two boundary surfaces due to the characteristics of the material used. This voltage is a measure of the difference in the oxygen concentration inside and outside the sensor. The ceramic sensor tube exhibits a steep change in signal output (approximately1000 mV) when stoichiometric conditions are approached (see fig. 32-151. The oxygen sensor will only exhibit this steep change in signal output when a certain predetermined operating temperature is attained. Therefore, to reduce the axygen sensor's dependency upon exhaust gas to maintain it at operating .temperature, the sensor is heatedefectrically,using a ceramic heating rod fitted inside the zirconium dioxide tube. When staRing the engine, paniculariy from cold, satisfactow 'closed loop control' is not possible. During these conditions the electronic control unit supplies a fixed on-off ratio signal ('internal-signal mode') until the oxygen sensor attains its operating temperature. otherwise driveability would be impaired at this time without the regulating effea of fig. B2-I 3 Electronic control unit 1 Knee roll sensor (Auto ACU) 2 Electronic control unit 3 Test lead {blacldslarel Fig. 62-14 Oxygen sensor l Two spring contactsfor heater 2 Ceramic insulator 3 Heater 4 Ceramic sensor body 5 Protective tube 6 Air side 7 Exhaust gas side 8 Supporting ceramic 9 Protectivesleeve 10 Contact for sensor control valve operation. If the oxygen sensor fails to function, this fixed on-off ratio signal is transmitted to the control valve in addition to illuminating a warning lamp on the facia. Anti-suction vdve (see fig. 82-41 When the engine is switched off it is possible for some fuel to vapourize and a depression can then occur above the control piston when the fuel condenses. The depression would tend to rift the control piston and cause an excessively rich mixture when the engine is started. TSD 4737 82-9