Testing electronic ignition system with variable characteristics EZL

Transcription

1 Testing electronic ignition system with variable characteristics EZL Operation no. of operation texts and work units or standard texts and flat rates: Connection diagram for engine tester with oscilloscope B11/2 Coolant temperature sensor (EZL/KE, LH), 4- S29/2 Throttle valve switch, full load/idle speed pin recognition G1 Battery T1 Ignition coil L5 Crankshaft position sensor X11 Diagnostic socket/terminal block, terminal TD N1/2 EZL ignition control unit 10 Segments on flywheel/driven plate R4 Spark plugs 12 Vaccum line R16 EZL resistance trimming plug 030 Engine tester with oscilloscope S5/3 High voltage distributor Special tools Commercially available tools and testers Designation e.g. Make, order no. Page 1 of 17

2 Multimeter Sun, DMM-5 Fluke, Multimeter 23 Hermann, Avometer 2003 Engine tester Hermann, Datascope 9800 Bosch, MOT 301/400 Sun, 2110 BEAR, D AC E Pay attention to the safety regulations when working on the ignition system ( ). Switch off ignition when plugging in and unplugging the connectors at the EZL ignition control unit. Note If dealing with faults regarding handling, first of all test the ignition. Then, continue fault finding at the KE injection system. The test is divided into two sections: a) Engine not running b) Engine running In this section the basic functions of the ignition Faults in the ignition timing or at the system are tested. corresponding components can affect vehicle If the fault cannot be rectified, continue handling. troubleshooting in section b), "Engine running." Test data Resistances (test data from C) Ignition coil primary (terminals 1 and 15) Ignition coil secondary (terminals 1 and 4) k 8-13 Position indicator coil resistance (terminals 7 and 31d) 200 insulation (terminal 7 and ground) Distributor cap per terminal, distributor rotor, spark plug connector k Voltages, engine not running, ignition switched on Battery voltage V > 11.5 Terminals 15 and 31 (contacts 5 and 2 diagnostic socket) V > 11 Between terminals 15 and 1 (contacts 5 and 4 diagnostic socket) V 0 4-pin round connector, terminals 15 and 31 V > 11 4-pin round connector, terminals 16 and 31 V > 11 Page 2 of 17

3 Voltages at starting speed Battery voltage V 10 Ignition coil terminal 15 V 10 Ignition coil terminal 1 V Voltages at idle speed Battery voltage V Ignition coil terminal 15 V Ignition coil terminal 1 V Dwell angle At starting speed 1-30 At 3200 rpm Ignition timing point at starting speed in KW TDC 2 Page 3 of 17

4 EZL ignition timing point Engine EZL ignition control Engine speed 1/ Ignition timing point in CA before TDC unit min Page 4 of 17

5 Resistance trimming plug position or type of fuel without vacuum with vacuum National version Reference resistor 220 Idle speed Reference resistor 220 Idle speed National version Reference resistor 750 Idle speed Reference resistor Idle speed National version Reference resistor 750 Idle speed Page 5 of 17

6 Reference resistor 750 Idle speed Resistances of EZL resistance trimming plug (R16) Position Resistance EZL resistance trimming plug k "EZL-ECE" "EZL-KAT" "EZL" A S 1 1 B C 1.3 N 3 3 D S 4 E F N 6 G a) Engine not running Symbols for testers Contact Connector Symbols for test mode with multimeter Multimeter DC voltage mode Multimeter Resistance mode Oscilloscope Preconditions for test Note Spark plugs, ignition cables, distributor rotor If the specification of a main test step, e.g. test and distributor cap in proper mechanical and step 1.0, is in order, continue with the next main electronic order. test step, e.g. test step 2.0. Test e.g. by visual inspection, measuring If the specification of a main test step, e.g. test resistance and ignition oscilloscope. step 1.0, is not achieved, continue test with sub- Battery voltage V test step, e.g. test step 1.1. See appropriate wiring diagram volume for wiring diagrams. Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on Page 6 of 17

7 1.0 Voltage N1/2 Unplug 4-pin V Test voltage supply via supply round connector ignition lock, tml. 31 tml. 15 at EZL control Test ground cable, unit. Test wiring and contacts Ignition: ON according to wiring diagram, replace if necessary 1.1 Ground cable N1/2 Ignition: OFF <1 Open circuit in wiring tml Crankshaft L5 Ignition: OFF Replace crankshaft position position Unplug sensor (L5) sensor (L5) tml. 31d tml. 7 crankshaft position sensor connector (L5) at EZL control unit. 2.1 L5 Unplug US 1 V Signal too small or no signal crankshaft see replace position sensor, tml. 31d tml. 7 position sensor "diagram different voltage levels connector (L5) crankshaft test segments on flywheel/ at EZL control position driven plate (visual check) unit. sensor Signal in order replace Engine: start signal EZL control unit Starting speed. (L5)" 2.2 Insulation at L5 Ignition: OFF 200 k Visual check of control sensor coil Unplug cable, 7 crankshaft Replace crankshaft position tml. position sensor sensor (L5) connector (L5) at EZL control unit. Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 3.0 Dwell angle Engine tester Engine: start 1-30 Dwell angle not to tolerance at starting or replace EZL control unit speed 1-50 % No dwell angle test noload current cutoff 3.1 No-load X11 Ignition: ON 0 V Replace EZL control unit and current cutoff 5 4 ignition coil 4.0 Ignition coil T1 Ignition: OFF <1 Replace ignition coil (T1) primary tml. 1 tml.15 Disconnect cables at ignition coil 5.0 Ignition coil T1 Ignition: OFF 8-13 k Replace ignition coil (T1) tml. 1 tml. 4 Disconnect secondary cables at ignition coil 6.0 Primary Engine tester Engine: start Replace EZL control unit voltage 350 V Oscilloscope image: Parade primary Page 7 of 17

8 7.0 Primary Engine tester Engine: start See Replace EZL control unit current "diagram limiting Oscilloscope image: good Superposition image secondary superposition" (Diagnosis Manual Engine, Vol. 1, Register C) Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 8.0 Ignition Engine tester Engine: start 8-20 kv See test steps voltage Oscilloscope image: Parade secondary 8.1 Distributor cap Distributor cap Ignition: OFF Replace distributor rotor (each terminal Remove per individually) inside outside distributor cap. terminal Disconnect ignition cables. 8.2 Distributor Distributor Ignition: OFF Replace distributor rotor rotor rotor Remove distributor cap. and visual Middle Peak check 8.3 Ignition cable T1 S5/3 Ignition: OFF <1 Replace ignition cable terminal 4 at tml. 4 tml. 4 Disconnect terminal 4 igntion coil ignition cable (T1) terminal 4 at ignition coil (T1) and at distributor cap. 8.4 Ignition cables Ignition Spark Ignition: OFF Replace ignition cable with with spark cable plug Disconnect per spark plug connector plug connector ignition cable at ignition connector HT distributor cable (S5/3) and spark plug connector 8.5 Spark plugs Visual inspection Ignition: OFF Electrode Replace according to Remove all gap condition spark plugs. 0.8 mm 9.0 Ignition Engine tester Engine: start TDC 2 Test ignition coil and HT timing point Starting speed distributor at starting speed b) Engine running Page 8 of 17

9 Symbols for testers Contact Connector Symbols for test mode with multimeter Multimeter Resistance mode Oscilloscope Preconditions for test Engine at operating temperature. Pay attention to notes for work on breakerless Coolant temperature <95 C. transistorized ignition system ( ). Test ignition timing point at idle speed. Note Test ignition timing point at 3200/min with If the specification of a main test step, e.g. test and without vacuum (detach vacuum line at step 2.0, is in order, continue with the next main EZL control unit). test step, e.g. test step 3.0. Pay attention to resistance trimming plug position. If the specification of a main test step, e.g. test Switch off engine during test only if stated. step 2.0, is not achieved, continue test with subtest step, e.g. test step 2.1. See appropriate wiring diagram volume for wiring diagrams. Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 1.0 Ignition Engine tester Engine: start See table Test EZL resistance timing point Idle speed of ignition trimming plug (R16), timing Test EZL reference resistor points (R16/1) (Pay attention to national version and Part no.), Test throttle valve switch, full load/idle speed recognition (S29/2), Test pressure sensor, Test coolant temperature sensor (B11/2), Coolant temperature>95 C 2.0 EZL R16 Ignition: OFF See table Test values in resistance resistance 3 Compare engine of trimming plug, trimming version and resistances Replace resistance trimming plug resistance of EZL plug (R16) 1) triming plug trimming inscription. plug (R16) Unplug 4-pin coupling at EZL control unit. 1 ) Except Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on Page 9 of 17

10 2.1 EZL R16 Ignition: OFF A Replace EZL resistance resistance Compare engine B 2.4 k trimming plug trimming plug version and C 1.3 k 1 Middle B-G (R16) ) resistance D 750 trimming plug E 470 inscription (see F 220 table resistances G 0 EZL trimming plug (R16)). Unplug 4-pin coupling at EZL control unit. Test clockwise between middle and outer connector pins. 2.2 EZL reference R16/1 Ignition: OFF Replace EZL resistance resistor 3 Pay attention to trimming plug (R16/1) 2) national version and Part no., see table. Unplug 4-pin coupling at EZL control unit. 2.3 EZL reference R16/1 Ignition: OFF Part no. Replace EZL resistance resistor 2 1 Unplug EZL and trimming plug (R16/1) 2) reference value see resistor. table EZL reference resistor (R16/1). 1 ) Except 2) Only Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 3.0 Throttle N1/2 Ignition: OFF Idle Adjust or replace throttle valve switch, 2 position valve switch, full load/idle approx. Rectify open circuit in wiring speed 0. according to wiring diagram recognition (S29/2) Full load approx. 0. Part load position. See also table "resistance s at throttle valve switch full load/ idle speed recognition (S29/2)" Page 10 of 17

11 4.0 Pressure Engine tester Vacum line at When Check vacuum line from sensor EZL control unit vacuum intake manifold to EZL disconnected. line control unit for leaks. Coupling connected, If no fault found, replace disconnected ignition EZL control unit. from throttle timing valve switch. point must Engine: start advance. Engine speed/ gear lever position: idling. Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 5.0 Coolant N1/2 Ignition: OFF values, Replace cable according to temperature 1 Unplug 4-pin see wiring diagram. sensor coupling at EZL diagram Replace coolant temperature (B11/2) control unit, test coolant sensor (B11/2) values at two temperatur temperatures e sensor (2/4-pin) Example: + 20 C k + 80 C Ignition Engine tester Detach vacuum See table Replace EZL ignition control timing point line at EZL ignition unit control unit. timing Engine: start points 7.0 Dwell angle Engine tester Vacuum line Replace EZL ignition control at 3200 rpm and 4-pin unit coupling EZL control unit connected. Engine: start Test Test scope Test connection Operation/ Specificati Possible cause/remedy step Requirement on 8.0 HT Visual check Ignition: OFF Distributor cap, mechanical distributor Remove damage in HT distributor, (S5/3) distributor cap. replace HT distributor if necessary. Pay close attention to safety notes ( ). Page 11 of 17

12 9.0 Interference Ignition: OFF 1 k Replace faulty parts supression Remove resistors, distributor cap. distributor Measure cap, resistances distributor individually. rotor, spark plug connector 10.0 Ignition coil Engine tester Ignition: ON Good/ Replace ignition coil Engine: start poor, see Oscilloscop image: Idle speed analyzing Parade oscilloscop e image (Diagnosis Manual, Engine, Vol. 1, Register C). 1) Ignition voltage: (average value) 6-16 kv. Difference of cylinders to each other 3 kv. Ignition voltage rise: the ignition voltage measured at idle speed must rise by not more than 6 kv when engine speed is increased up to 3000 rpm by blipping the throttle. Combustion curve starting point: kv. Difference of the cylinders to each other Combustion time: ms. Difference of the cylinders to each other 0.3 ms. 0.3 kv. Location of components Round power supply connector at EZL ignition control unit (N1/2) Page 12 of 17

13 EZL ignition control unit (N1/2) Arrow 4-pin connector sensor EZL ignition control unit (N1/2) Arrow Vacuum line EZL resistance trimming plug (R16) A - B 2.4 k C 1.3 k D 0.75 k E 0.47 k F 0.22 k G 0 k Bottom part of connector, EZL resistance trimming plug (R16) Page 13 of 17

14 EZL reference resistor (R16/1) Part no. Resistance National version Diagnostic socket/terminal block (X11) Terminal TN EZL/KE, LH) coolant temperature sensor, 4-pin (B11/2) Connect 4-pin connector, coolant temperature sensor (B11/2) Pin assignment (positions stamped in connector) 1 EZL/AKR temperature sensor 2 KE temperature sensor 3 Ground, EZL/AKR ignition control unit 4 Ground, KE control unit Page 14 of 17

15 Coolant temperature sensor (B11/2), 2-pin Diagram, coolant temperature sensor (2/4-pin) High voltage distributor (S5/3) Page 15 of 17

16 Igition coil (T1) a Terminal 1 b Terminal 15 Connector, crankshaft position sensor (L5) Diagram, crankshaft position sensor (L5) signal Plug connection, throttle valve switch full load/idle speed recognition (S29/2x1) Page 16 of 17

17 Resistances at throttle valve switch full load/idle speed recognition (S29/2) Idle speed Full load approx. 0 approx. LL VL Idle contact Full load Page 17 of 17