Hi I have done a 2.0 16v conversion on my mk2 used all the running gear from passat and i had the passat running before the engine came out and i have used the KE-Motronic system its all wired up and worked fine last week apart from today. It was running it to full temperature for the first time to do the timing and it was on idle for about 5mins as and then it started to lower the revs, i noticed we had air in the system to turned it off let it cool a little and undid the expansion cap and filled it up . I go to restart the car and its is not firing, checking it we found there was spark but no fuel, After checking for fault codes on the 1551 it showed none apart from the occasional idle warm up valve its only occured twice in loads of other tests so i reckon we can ignore it. AT the mo it has no lambda connected but it should not affect the cold start. I also tried plugging in another temp sensor externally to make the ECU think the engine was cold again. Pulled the top rubber cover off the metering head and started it up and held the metering head up on my own, This worked. But it was very hard to hold it, as soon the fuel pump was on it pulled it down, I can`t see the engine being able to suck that hard . dunno Checked on the metering head the pressure regulator and could not get any sense out of checking the milli amps from metering head pressure valve. But it looks like it should do the start condition anyway, even with no signal. I checked the Ma in seris. ANother thing i have noticed is the starter motor seems to be a bit slow so i guess that would make less suction on the metering head. Swapped to a battery off my other car and made little difference Well normally i would just get on and try and fix this stuff but as there are 2 track days on next weekend i am kinda needing some ideas as me and Audiman have nearly come to a dead end on this one . ? Edited by: dUff
So the fuel pump is running but it's not delivering fuel? Take it you've got fuel pressure at the metering head base? Is it the control plunger sticking?
Maybe of help? http://www.autodiagnos.com/multitester/manuals/kejeteng.pdf http://www.audifans.com/archives/1997/10/msg00666.html Edited by: G_V_K
Fuel pump is running and we have pressure at the inlet of the m/head. BUT the flap is very hard to lift up especically when the fuel pump is running. Its being pulled down under fuel pressure. There is no way that the engine could lift that up!! If you hold the flap up and start the car it runs ok. Tried swapping the whole setup for another one, yet still the same. I am unfamiliar with this version of KE Motronic as not many cars had it fitted (thank god). Any help on this subject would be gratefully received.
is there a version of a warm up reg on KE afaik the wur uses fuel pressure to alter the mixture, perhaps the fuel pressure is being applied excessively cos of a fault? (that's the most tenuous thing ever - but i had to write something)
must say, i read this earlier and though the same sort of thing as dex. it's just an idea. i don't know if the ke-jet has a wur either, but it might be a thermo switch that has stuck on after you let the engine warm right up for the first time. if this was the case then a wur (or the equivalent) might be inreasing the control pressure in the system, making the plunger difficult to lift causing etc etc... it might even be the wur (or equiv) itself
As far as I remember KE doesn't have a WUR as the cold start mixture is controlled by the differential pressure regulator, the same device on the side of the metering head that controls the mixture during closed loop mode when the lambda's working. If the pressure is too high at the metering head then it's more than likely a fault with the differential pressure regulator on the side of the metering unit or the diaphragm pressure regulator which is the cylinder thing with 3 fuel lines and a vacum hose. There is quite a lot of resistence once the system is under pressure. Is it smooth when the pump is off? If not you need to check the airflow flap and metering head plunger.
Sounds like a similar system fitted to the old Escort RSTs, no WUR and a DPR on the side of the metering head.
Have tried swapping the metering heads! Made no difference, but it is true that once the fuel pressure has dropped ie after leaving pump off for a while, the flap then becomes easier to move. But of course when you try and start it the pressure is back up and the flap is stiff. Have also tried a different differential pressure regulator.
Well unless you've got something realy weird going on then there are only 3 items that can effect line pressure. 1) The differential pressure regulator on the metering head. 2) The diaphragm pressure regulator. 3) Possibly the accumulator (can't quite remember how that plums in). Have you tried adjusting the mixture on the allen key?
Just a thought guys but you haven't accidentally got the fuel lines on the wrong way round on the diaphragm pressure regulator have you?
That is a possibility I have just borrowed from work a Bosch Injection manual. It appears that the excess control valve pressure is sent back to the fuel tank. It may be that the return line has a blockage. I dont think we have the pipes on wrong as it was running for about 5 mins before we shut off. Will do some reading on KE motronic tonight to see if I can work out how the system works and why it isn't!!!
Mate just been reading up on this system. To test that pressure actuator (thing with on engine side of m/head) you just disconnect it and link the two wires using the ammeter. Not the way we tried!! LOL But it should run in like a limp home mode with it unplugged. It looks like the fuel pressure is too high some where within the m/head. But it may not start with this disconnected
I know the accumulator size for KE(motronic included) and Kjet is different, I am currently running a KE accumulator(smaller and the Kjet accumulator) and its more difficult to start when both hot and cold, this could be due to the different pressure on the accumulators going back to Kjet accumulator. Also i would stick with kjet as its a much simpler system and from our experience with especially the KE motronic system its a pain to keep it running sweetly way too many sensors, the good point of this system is that it has 2 knock sensors to keep pinking at bay.
