Audi 80 2.0E ABK Bad fuel consumption, Ignition Failure, smell of fuel:

[illi]

Hello everyone,
I'm new here, and I have a problem with my car (read another posts),

Specifications:
Model: Audi 80 (1992) B4, Type 8C
Engine: ABK 1984cc, 8v, Injection, (85KW, 115HP) (09/1991~07/1995)
Fuel consumption: 6.2/7.7/11.5 L/100km/90km/120km/h / urban per DIN 70030
Transmission: 5 Manual

For a long time my car has a bad fuel consumption, as opposed to what should be, its consumption is 1:6 (test). In the last few months I encountered difficulties starting it and I feel like the engine is flooded (so I had to disconnect the electric to the injectors, burn it, reconnect and then start). Sometime I'm afraid to turn it off because I don't know if it I will be able to start it over. This is not fun… When I drive and look at the mirror I see coins on the road fall down from my exhaust
I love this car, its straight, I maintenance it alone so I don't need to pay lots of money to the garage. I know I can relay it better then Japanese, Korean and American cars. The German car proved itself over the years. Of Corse everything must be maintained periodically.

Actions:
After I cleaned the whole engine with water pressure machine and made ​​sure the engine works, I replaced the air filter (4) and the plugs – didn't help.

1.jpg

I replaced the injectors (3)
(the other ones have been ultrasonic cleaned, all O-rings have been replaced, fuel filter in each injector replaced and still the engine has bad smell of fuel and high consumption.
2.jpg

I replaced the distributor Rotor & cap and the only thing is that the engine runs a little bit smoother.
3.jpg

ECU temp sensor (the other one is for temp gauge):
Is a resistor that should be about 300~400Ω around 80°C and about 2500Ω around 20°C.
Mine was fail: 70KΩ (High quality Siberian winter..). I replaced it and now there is much less smell of fuel, and the engine is working mush smoothly.
But when I press quickly the throttle still there is a little smoking (until stabilized)
4.jpg

Relay 30:
BOSCH cat #: 165 906 381
WA: #30
Material: Copper terminals, AgSno2 contacts, PA66 Plastic
I checked about this relay, and it's known as the ECU's relay. Its failure may cause:

• Erratic idle speed
• Engine running badly at no-load
• Engine stalling for no apparent reason
• Error 0532 ECU voltage too low
• Several errors logged by the ECU

The engine could still be running badly if the ECU relay is faulty and no errors were logged by the ECU.
This ECU relay also fits the following vehicles:

• Type 2 T4 (Bus T4, etc)
• Golf Mk 3 and Mk 4
• Vento
• LT Mk 2
• Audi A4, A6, 100 (1993(
• Audi 80 and 90 (1992-on(
• Audi Coupe
• Caddy (1996 – 2003(
• Passat Mk2 and Mk3, Santana
• Polo Mk2
• and several other VWs

I'll check it and if I have, then I'll replace it (also it can be fixed).

Lmbda sensor:
I know there is a lambda sensor in fuel injection systems but I looked up in the whole exhaust system under the vehicle and the only thing I found is CO test pipe to exhaust manifold (1):
6.jpg

Is there a "secret place" where the lambda sensor hiding so I can check it or replace it?

ECU:
This is the last thing I want to think about it because it's too expensive and in the most cases it is an electronic problem so "Back Engineering" can fix it but I don't have the schemes for it. I wish I could get these schemes. Anyone? J
Another thing, I read here that someone already tried replacing it and it didn't solve his problem (Bosch & Siemens brands).


I'll summarize:
This model was unique; the front discs, for example, are 256mm diameter (instead of 280mm). There were more changes, little ones.

1. Is there a lambda sensor in my ABK engine? And if so, where it is?
2. Does relay #30 should help to my problem?
3. Does this engine has "tunings"? And if so, then how?

Hope I gave whole information I had :

[scotty33]

The relay 30 would be my guess. They have a circuit board inside which suffers from poor soldering, either resolder or buy a new relay. A common problem:

Audi 80 2.0L ABK engine juddering/misfire - Page 5

There will be a lambda sensor, either on the front of cat convertor or Exhaust manifold

The mixture (CO) can be adjusted with hex key at the air 'mass/flow' meter. Best not to adjust this, there is likely to be something else wrong?

[merton1973]

i have an abk 80 1992 with 256mm discs and the lamda sensor is on the cat, just were the down pipe joins the cat with three bolts the lamda is at the front of the cat sort of on top of it. i had problems with my air flow metre and the engine was running lumpy and rich, the track wears out at the point the arm runs on, there is a repair run through on a polish audi 80 forum. do you have vag com? you can see if the sensor is working properly in measuring blocks. The relay is available for less than £10 so worth a try, having looked around alot i dont think there is much you can do with tuning but the digifant system needs to be set properly to work, dont bother trying to advance or retard the timing with the distributor as more than 1 or 2 degrees out and mine ran badly. the co cant be adjusted on the air flow metre with a hex key it can be adjusted were the resister track is via a spring and dial but dont do it as it wont fix whatever problem you have, the digifant system is a bit easy to mess up.

[merton1973]

heres a video i found that pointed me in the right direction,Rejuvenating a Bosch Motronic Air Flow Meter - YouTube but instead of bending the arm like they have i made the screw holes bigger that the track plate is mounted on so i could get the arm running in a better part of the track. the metre is the same bosch design and its the same as the abk . what about the fuel pressure regulator? i dont know if this would cause the amount of over fuelling you have but dont know what else in the fuel system it could be? also one other thing is the earth wire on the side of the head can cause problems with the ecu i think it is the main earth for it. maybe the carbon filter valve, is it the n80 valve, its has vacuum lines coming from the air inlet manifold if you hold it whilst you turn the throttle with the engine running you can feel it clicking.

[scotty33]

fwiw I just watched the You tube vid merton posted. the CO adjuster I referred to is under a round silver 'tamperproof' cap near the air hose 'spigot'. Top right of the unit as positioned when the vid starts. The 2E passat has this, as does the porsche, if the ABK does not, sorry for banging about nothing..

[zoli.ko]

Thanks for the tips, now it is like I changed the engine !!!!

[merton1973]

have you found the lambda sensor now? my ignition transformer (coil) and ignition module failed and now i fitted the new one my engine starts much better when hot, similar to yours flooding and hard to start, seems smoother when driving. maybe the fuel pressure regulator is not working and high fuel pressure is high fuel consuption, there is a small 6-8mm vacuum hose that goes to the end of the fuel rail to the throttle body that controls fuel pressure, check this?. The exhaust manifold often cracks on the earlier abk maybe this is letting air into the exhaust and the lambda is giving wrong info, my abk has this crack and i use this stuff QUIKSTEEL QUICKSTEEL THERMOSTEEL HIGH TEMP METAL REPAIR WELD GREAT STRENGTH | eBay but it needs replacing every six months or this one is ok BLUE MAGIC THERMO STEEL HIGH TEMP METAL REPAIR | eBay . good luck and happy xmas