Overload Relay location

Had problem with idle too high, found EGR badly damaged, blocked egr on manifold also blocked vacuum, found idle dropped, adjusted, now cold start not working, want to check OPV fuse.

Have replaced air filter, fuel filter, want to make test kit for fuel pressure need to get connector sizes as well. Really trying to sort injection since car will start and run but it needs tlc.

BTW thanks for the answer

Thanks, I've been reading the diagnostics/description and trying to test where I can. I would like to test the pressure regulator here's why :-

When I got the car it idled high, close to 10k, when starting it liked full throttle and the cold start would waver in for 10 secs or so. I tried to reduce the revs but couldn't.

Car overheated due to loss of coolant from long term avoidance of maintenance, refilled, changed thermo which was stuck open, once I did this I get some problems starting cold, backfiring uneven running but cold start operating.

Chasing this fault I find the EGR valve is completely broken, and must be causing a vacuum leak as well as opening and shutting the EGR valve with the vibration of the engine.

Placed a steel plate over the egr valve hole put broken egr valve on top and sealed plunger with gasket sealant car ran better initially, but cold starting still a problem although cold start operates.

Driving with engine at normal temp and suddenly revs drop to stalling, I limp home and adjust tickover at the base of the injection unit (lock nut and slotted thread), tickover stays lower than 10k which is good but now cold starts hard, likes no throttle while cold and ticks over low and lumpy, i.e. no cold start operating. So possibly cold start fails at the same time as tickover drops.

Is there a warm up regulator, or just pressure regulator, since there is no wiring to the pressure regulator or does it just rely on ambient temp?

Sorry for such a long post but I'm trying to wade through the info about K Jetronic and find out exactly what the 102 engine has going on.

Thanks for the explanation, I replaced the fuel filter but no change.

Right now I suspect the over voltage relay, took it out and it rattles, I will try to test/reflow the solder or replace it.

Car idles at 3-400 when started, start around 3-4 attempts, no throttle possible, no 1000rpm cold start period. will warm to 800 and run no problems.

Real problem identifying parts from theory on the car, e.g. where is cold start regulator?

air mixture is adjusted properly, does 102 have idle screw? as per page 45 of the maint. manual 0101-0750 from this site.

Hi John

How are things in Melbourne, thanks for suggestion, the problem here seems slightly different. I'm seeing smooth idle but just very low when cold and takes a few attempts to start. Warm starting and idle is great.

Just replaced the Overload Relay instead of testing, probably nothing wrong with the original!

Cold Start Injector now focus of attention, wondering is the thermo that controls cold start built into the injector?

On the 102.987 the temp gauge sender and egr vacuum switch are in that position on the block. Temp. gauge for cold start valve is a mystery to me and my dealership, they couldn't find the part on the EPC and nor could I.

I agree with you the cold start is at fault, I considered the fuel pressure control as I think this could cause similar symptoms (constant high pressure would stop the plunger rising further for cold idle), but they are not warm up versions not powered at least on the 102 so I've discounted it for now.

Fixwin, you wouldn't suspect a failed Overload Relay since that powers the cold start valve?

edit ** Overload relay actually powers Idle adjuster.

Thanks for the schematic, I had been looking at that on the russian epc site, but there is no sign of the cold start [u]sensor[u] on those pages.

The conversation I had with my local parts department suggested the sensor was built in to the cold start valve, I've scoured the whole EPC and can't find it.