Engine Management and 29L Emission System (2,0 Litre Cosworth Variants) Index Description of System Operation .. 02, ‘Special Tool Recognition and General Equipment 08 Introduction to Fault Finding suena 08 Index = Fault Finding Charts we OF Fautt Finding Charts 6. se we wee 8 Turbo Boost Pressure Adjustment... see Technteal Oath we IMPORTANT MOTE - INTERIOR COURTESY LIGHT DELAY FUSE When performing breakout box checks, in addition to ensuring a1 electrical Toads are switched off, it 1s essential to remove the interior’ light delay fuse, located in the fuse box. Failure to remove this fuse will cause erroneous resistance readings. Ensure the fuse 1s refitted on completion of the breakout box checks. duly 1987 FORD SIERRA RS COSWORTH: SECTION 29L-O1E&P veuice system rest Engine Management and Em{ssion System RS COSNORTH The SIERRA RS COSKORTH is Fitted with turbocharger and a new electronically controlled injection/tg ‘thon system. This injection/ignition system plays an faportant part in achieving the high degree of performance and reliab{ifty in the Cosworth engine, by giving an increased precision in the metering of the air-fuel ratio and by optimising the control of the engine timing. The injection/ignttion system comprises = the engine management module = the control sensors (stgnal transmitters) supplying engine operating data to the module and the injectors, ignition amplifier module and speed contro? valve which are controlled by the module. Effects of the air-fuel ratio and engine timing. Accurate control of the air-fuel ratio and fonttion timing are essential to achieve full performance of ‘the SIERRA RS COSKORTH engine. Ideal air-fuel ratfo will ensure optimum combustion. An incorrect air- fuel ratio will result in the mixture being too Tean or too rich which will impair engine performance, fuel consuaption and ultimately exhaust emissfons. Ine electrenfcaTly controled injectlon/ignitfon system optiaises engine effictency under al1 opere 9 conditions (start-up in cold weather, driving off, part-throttle and full-load operation). Fig.l Effect of the air-fuel ratio on perfor sora Baia se Pete PE common enn 2 etm at al to spat rag Fie of et at wi Co Carbon monoxide Digikwn) & ge : BEEP oe A = Air fuel ratio CH . xen : Effect of the air-fuel ratio exhaust enisstons. duly 1987Engtne Management and Emissfon Syste wom Jo measure the intakessir volune, the SIERRA RS COSWORTH {nJection/ignition systen uses engine speed Tessie denstty. On the basts of the known air volume, the quantity of fuel 1s metered to achfeve the ancited atrcfuel mixture. Sensors In the system are used to adjust the basic atr-fuel wfxture to al] spectflc operating conditions. Engine speed and intake-atr dens{ty data enables the module to calculate the optimum ignition timing in all operating conditions. ‘The afreintake volune for each cylinder and working stroke 1s dependent on the following parameters: wate density in the inlet manffold and svept volure. the nodule calculates the air denstty fron the pressure and temperature of the intake air, This data Testored ta the module and the injectors are controlled in-relation to the engine combustion sequence Depending on engine Totde the cel very of fue} fo each, cylinder nay commence before te. inate stroke pepres and continue until the power stroke has begun. The duration of the injection process 1s Getermined by the module. ‘The overall system coaprises three sub-systems: = fuel systen 2 air intake/exnaust and turbo system 2 fnjectton/tgnttton systen Fuel system Comprising: tank, pump, fitter, fuel rail, pressure regulator, fuel injectors. Fue] 1s injected tnto the intake port of each cylinder upstrear of the folet valve. Air systen The system comprises: air cleaner, turbocharger, intercooler, intake manffold, throttle plenum butterfly assembly and idle" speed control valve. Manifold absolute pressure (MAP) sensor, fuel pressure regulator, speed control valve and air temperature sensor are connected to the inlet plenum. Electrical circuits Input signals are supplted to the module by the following (Sensor, general power supply} sensors: MAP sensor, air temperature sensor, throttle butter~ fly potentioneter (éo determine throttle opening), phase sensor Cgnition distributor), coolant temperature sensor and engine speed/TOC sensor. Power fs supplied to the module via: battery, ignition switch, power relay and fuse. Power 1s supplied to the fuel pump via: battery, ignition switch, power relay, fuel pump relay and fuse Ignition yoltage 4s generated 1n the tgnftion cof! by the ignt- Hon amplifier wodule; the precise tonition tinting being controlled by the engine nanagenent module. The low tensfon side of the ignition coll is supplied via: battery and tgattion switch. The high tension generated in the coi? 1s fed to the spark pligs via the distributor. The fuel ingectors are opened and closed by output stgnals fro ‘the modul auly 1987 FORD SIERRA RS COSWORTH: SECTION 29L-(