Bosch М1.5.4 fuel injection system for DOHC engine

1. The instructions given here refer only to the differences that apply to this engine. If a description of any work is not given, then it is understood that it is performed in the same way as described above. It should be borne in mind that some elements of the injection system are located in other places here, which does not correspond to the illustrations.

Throttle Potentiometer

1. For a DOHC engine, the potentiometer is installed in the location shown in illustration. Disconnect plug connection to remove (1) potentiometer (2) and remove the potentiometer by unscrewing the bolts.

Before installation, attach the throttle valve. Make sure the potentiometer is properly seated on the throttle. Connect the plug connection.

Fuel pressure control

1. Relieve the pressure in the fuel system, taking precautions. The regulator is located in the center of the hoses and the intake air hose. Removal and installation is carried out in accordance with the previously given description.

Replacing injection valves (injectors)

1. The work is much more laborious than the 2.0L engine, as it requires some preparation to get to the fuel distribution line and injection valves. For this reason, the present work is not described here.

Replacing the air quantity meter

The meter is located directly in front of the air filter and is inserted into the air intake hose. Removal and installation is carried out in accordance with illustr.

1. Remove clamp (1) from the air suction hose.

2. Disconnect the crankcase gas sampling hose at the point (2).

3. Remove clamp (3) from the intake air resonator.

4. Disconnect the plug connection (4) intake air temperature sensor.

5. Disconnect the intake air hose (5) from throttle body and air quantity meter (6).

6. Loosen clamp (7) intake air hose.

7. Remove the air quantity meter from the air filter housing. The meter is replaced as a set.

The meter is installed in the reverse order of its removal. Make connections in accordance with fig. higher.

Replacing the crankshaft TDC sensor

Contact the Head Engine electrical equipment.

Replacing the knock sensor

Contact the Head Engine electrical equipment.

Idle speed controller

1. To get to the idle speed regulator, it is necessary to remove the parts shown in illustration. 4.29. Removal and installation are carried out similarly to the operation in question for the OHC engine.

Intake air temperature sensor

1. The sensor is screwed into the intake air hose near the air filter inlet.

After disconnecting the plug connection and removing the intake air hose, the sensor can be pressed out with a sharp object (like a knife) from a hose. Loosen all the clamps shown in the illustration, disconnect the plug connection. Before installing the sensor in place, check the condition of the hose. Reinstall all removed parts.

Replacing the coolant temperature sensor

1. The replacement is simple. The sensor is located close to the ignition module and can be unscrewed after disconnecting the plug connection.

Attention! In this case, coolant flows out.