15-1250 Testing electronic ignition system with variable characteristics EZL ‘Operation no. of operation texts and work units or standard texts ‘and fat rales: 15-1250. Connection diagram for engine tester with oscilloscope arve a rey Nw Rt ris. S50 =_- Coolant temperature sensor (EZUIKE,LH),4-pin S20/2 Battery Crankshaft positon sensor " ZL igniton contd unit xt ‘Spark plugs 10 EZL resistance vimming phig 2 High voltage distributor 030 RA 18.1132-1260" on fi Throtte valve switch, ful loadidle spo0d recognition gato cov Diagnoste sockevtorminal Block, terminal TD Seaman on toate pte Engine ster with osciloscopeSpecial tools Commercially available tools and testers Se 201 589 00 99 00. 15 54 Designation €.g. Make, order no. Multimeter ‘Sun, DMM-5 Fluke, Multimeter 23, Hermann, Avometer 2003 Engine tester Hermann, Datascope 9800 Aa Pay attention to the safety regulations when working on the ignition system (15-0505). ‘Switch off ignition when plugging in and unplugging the connectors at the EZL ignition contro! 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 In this section the basic functions of the ignition system are tested. W the fault cannot be rectified, continue trouble- shooting in section b), "Engine running,” ee PAIS 1132-12502 Bosch, MOT 301/400 ‘Sun, 2110 BEAR, D ACE b) Engine running Faults in the ignition timing or at the corresponding components can affect vehicle handling,Test data Resistances (test data from 0 - 100 °C) Ignition coil primary (terminals 1 and 15) 9 [03-06 Ignition coit secondary (terminals 1 and 4) ko [13 Position indicator coil resistance (terminals 7 and 31¢) 9 | 680-1200 insulation (terminal 7 and ground) _k@ | > 200 Distributor cap per terminal, @ | 700-1300 distributor rotor, spark plug connector Voltages, engine not running, ignition switched on Battery voltage v [> 115 Terminals 15 and 31 (contacts § and 2 diagnostic socket) V [> 11 Between terminals 15 and 1 (contacts § and 4 diagnostic socket) vo 4-pin round connector, terminals 15 and 31 vie 4-pin round connector, terminals 16 and 31 v[>1 Voltages at starting speed Battery voltage v]= 10 Ignition coil terminal 15 v [= 10 Ignition coil terminal 1 v [85-105 Voltages at idle speed Battery voltage v [13-445 Ignition coil terminal 15 v [13-145 Ignition coil terminal 1 v [rasa Dwell angle At starting speed 1-30" ‘At 8200 rpm 24 - 53° Ignition timing point at starting speed in ° KW [TOC +2° te 15.1192-125083EZL ignition timing point Engine EZL ignition control unit Engine speed Amin Ignition timing point in * CA before TOC. Resistance trimming plug position or type of fuel without vacuum with vacuum Basic version KAT/RUF and G) KAT, © KAT 103.940 103.941 103.942 103.943 003 645 95 32 003 545 96 32 005 545 84 32 005 545 86 32 006 545 73 32 006 545 75 32 008 545 61 32, 008 545 63 32 011 545 88 32 011 545 89 32 3200 25-29 19-23 40-44 Idle speed ‘Sand N TAY TA 103.980 003 645 1432 003 545 15 32 3200 1 leaded 23-27 39-43 Idle speed Premium e413 e413 3200 3! unleaded 19-23 39-43 Idle speed premim 8-13 813 103.981 103.983 103.985 004 545 44 32 004 545 46 32 005 545 85 32, 005 545 87 32 006 545 74 32, 006 545 76 32, 007 545 86 32 007 545 87 32 008 545 62 32 008 645 64 32 3200 27-31 40-44 21-25, 40-44 Idle speed 103.982 004 545 44 32 004 545 46 32 005 545 85 32 005 545 87 32 006 545 74 32 006 545 76 32 103.984 007 545 86 32 007 545 87 32 Sand N National versi ion GD 1986, GS) 198 6") 103.981 103.983 004 $45 69 32 005 545 49 32 005 545 88 32 3200 29-33 23-27 40-44 Idle speod Sand N TOC +2 TOC +2 ') For GH) KAT, CS) KAT, same values as basic version KAT. Se FA 15192-12504EZL ignition timing point Engine EZL ignition’ control unit Engine speed timin Ignition timing point in * CA betore TOC. Resistance trimming plug position or type of fuel without vacuum with vacuum National version @ 103.940 103.942 005 545 84 32 005 545 86 32 006 $45 73 32 006 545 75 32 008 545 61 32, 008 545 63 32 3200 Reference 19-23 40-44 {dle speed resistor 220 0 7A 7A 103.981 103.983 004 545 44 32 004 545 46 32 005 545 85 32, 005 £45 87 32, 006 545 74 32, 006 545 76 32 008 545 62 32, 008 545 64 32 3200 Reference 21-25, 40-44 Idle speed resistor 220 0 ear er National version 103.940, 103.942 005 545 84 32, 005 545 86 32 006 545 73 32 006 545 75 32 008 545 61 32 008 545 63 32 3200 Reference 25-29 40-44 Idle speed resistor 750 @ TA m1 103.981 103.983, 103.985 004 545 44 32 004 545 46 32 005 545 85 32 005 545 87 32, 006 545 74 32, 006 545 76 32 008 545 62 32 008 545 64 32 3200 Reference 27-31 40-44 Idle speed resistor 750 0 en en National version @ 103.940 103.942 005 545 84 32 005 545 86 32 006 545 73 32 006 545 75 32, 008 $45 61 32 008 545 63 32 008 545 95 32 009 545 79 32 3200 Reference 25-29 40-44 Idle speed resistor 750 0 ma ma 103.981 103.983, 004 $45 44 32 004 545 46 32 005 545 85 32 005 545 87 32 006 545 74 32 006 545 76 32 008 545 96 32 009 545 80 32 3200 Reference 27-31 49-44 Idle speed resistor 750 9 et eA 15.1192-125015Resistances of EZL resistance trimming plug (R16) Position Resistance EZL resistance trimming plug ka "EZL-ECE” "EZL-KAT™ "EZL" 1 1 2.4 1.3 0.75 0.47 0.22, O/T) Mo] al m)> sTelelsl2[slo STzlefojels a) Engine not running ‘Symbols for testers ~ Contact Connector ‘© Spark plugs, ignition cables, distributor rotor and distributor cap in proper mechanical and electronic order. Test e.g. by visual inspection, measuring resistance and ignition oscilloscope. © Battery voltage 11 - 14 V ee 15.1132-12506 Symbols for test mode with multimeter =O Multimeter DC voltage mode =@> Multimeter Resistance mode +@+ Oscilloscope Note If the specification of a main test step, e.g. test step 1.0, is in order, continue with the next main test step, 0.9. test step 2.0. It the specification of a main test step, 0.9. test step 1.0, is not achieved, continue test with sub-test step, ¢.9. test step 1.1 ‘See appropriate wiring diagram volume for wiring diagrams.Test | Test scope [Test connection [Operation’ | Specifi-._| Possible cause/Remedy step Requirement | cation 10 | Voltage Nia Unplug pin [11-14 V | Test voltage supply via supply < =O >-|round ignition lock, tml.31 tml 18 | connector at Test ground cable, EZL conteol Test wiring and contacts unit. according to wiring Ignition: ON diagram, replace if necessary 44 Ground Ne Ignition: OFF <1 | Open circuit in wiring cable + Oe tm. 31 2.0 | Crankshart us Ignition: OFF |680- | Replace crankshaft position position |—< =@"= >—|Unplug 1200.2 | sensor (L5) sensor (LS) |tmi.31d tml. 7 | crankshaft Position sensor ‘connector (LS) at EZL control unit at us ‘Unplug Us 21°V | Signal too small or no — =@+ >~| crankshaft see signal + replace position tml. 31d tml. 7| position sensor | "diagram | sensor, connector (L5) |crank- | different voltage levels -+ atEZL control | shaft | test segments on unit. position | fywheeldriven plate (visual Engine: start |sensor | check) Starting speed. | signal | Signal in order -» replace (5 | EZL control unit 22 | Insulation at L5 | ignition: OFF | 2200 k@ | Visual check of control sensor col |1 =@"+ >| Unplug cable, imi. 7 | crankshaft Replace crankshaft position position sensor ‘connector (L5) at EZL control unit sensor (L5) -_ RA 15.1192-12507Test [Test scope [Test connection [Operation | Specifi-_ | Possible cause/Remedy step Requirement _| cation 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 no- toad current cutott 3.1 |Nodload x1 lgnition: ON [OV Replace EZL control unit cure [5 —¢ =@"= > 4 and ignition coil cutott 40 [Ignition 1 Ignition: OFF | <1 | Replace ignition coil coll (T1) | tm, 1 =@'tmi.as | Disconnect primary cables at ignition coil 5.0 [Ignition 11 Ignition: OFF [8-13 k2 | Replace ignition coil coil (T1) tml, 1 =*@"*= imi, 4 | Disconnect secondary cables at ignition coil 6.0 | Primary | Engine tester Engine: start |200- | Replace EZL control unit voltage 350 V Oscilloscope image Parade primary 7.0 [Primary | Engine teste Engine: start |See | Replace EZL control unit current * diagram limiting | Oscilloscope image: good Superposition image secondary super- position” (iagno- sis Manual Engine, Vol. +, Register °) me a5. 1192-12500Test | Test scope |Test connection [Operation’ | Speciti- | Possible cause/Remedy step Requirement _| cation 8.0 ignition Engine tester Engine: start [8 - Soe test stops 8.1-8.5 voltage 20 kV Oscilloscope image: Parade secondary 8.1 | Distributor Distributor cap | Ignition: OFF |700- | Replace distributor rotor cap (each . Remove 1300 0 terminal —_ | inside outside | distributor cap. | per individually) Disconnect | terminal ignition cables. 8.2 | Distributor Distributor | Ignition: OFF |700- | Replace distributor rotor rotor rotor Remove 1300 2 o> distributor cap. | and Middle Peak visual check 8.3 | Ignition af 5/3] Ignition: OFF [<1 — | Replace ignition cable cable tml. 4 =@"= tml. 4 | Disconnect terminal 4 terminal 4 at ignition cable igntion coil terminal 4 at 1) ignition coil (71) and at distributor cap. 8.4 [Ignition Ignition ‘Spark | Ignition: OFF | 700- | Replace ignition cable with cables with | cable plug| Disconnect |1300 2 | spark plug connector spark plug connector |igntion cable | per connector ~O- at HT ignition distributor | cable ($513) and spark plug connector 85 |Spark plugs | Visual inspection ignition: OFF | Electrode | Replace according to Remove all | gap condition spark plugs. | 0.8 mm 3.0 Ignition —_ | Engine tester Engine: start [TDC | Test ignition coll and HT timing Starting speed | +2° | distributor point at starting speed =e FA 18 1122-12509b) Engine running ‘Symbols for testers < Contact = Connector Preconditions for test © Engine at operating temperature. © Coolant temperature <95 °C. ‘* Test ignition timing point at idle speed. ‘© Test ignition timing point at 3200/min with and without vacuum (detach vacuum tine at EZL control unit). Pay attention to resistance trimming plug position. ‘Switch off engine during test only if stated. AA 15.1192-1250710 ‘Symbols for test mode with multimeter =@*- Multimeter Resistance mode -@-~ Oscilloscope Pay attention to notes for work on breakerless transistorized ignition system (15-0505). Note If the specification of a main test step, e.g. test step 2.0, is in order, continue with the next main test step, @.g. test step 3.0. IF the specification of a main test step, e.g. test step 2.0, is not achieved, continue test with sub-tost stop, 0.9. test step 2.1 ‘See appropriate wiring diagram volume for wiring diagrams.Test |Test scope |Test connection |Operation’ | Specifi- | Possible cause/Remedy step Requirement _| cation 1.0 ignition | Engine tester Engine: start | See table | Test EZL resistance timing ldle speed — | of trimming plug (R16), point ignition | Test EZL reference resistor timing | (R16/1) (Pay attention to points | national version and Part o.), Test throttle valve switch, tull oadidle speed recognition (S29/2), Test pressure sensor, Test coolant temperature sensor (81/2), Coolant temperature >95 °C 20 0 [ez R16 | ignition: OFF | See table | Test @ values in resistance resistance |1 ~@*+ > 3|Compare of resis- | trimming plug, trimming ‘engine version | tances of | Replace resistance plug and resistance |EZL | trimming plug (R16) ") ‘timing plug | trimming inscription. | plug Unplug 4-pin | (R16) ‘coupling at EZL control unit. 1 Excont GS GD GD > PAS 192-1250"Test [Test scope |Test connection Operation’ | Specifi- | Possible cause/Remedy step Requirement _| cation a1 few Ignition: OFF [A = | Replace EZL resistance resistance Compare 8 2.4k2 | trimming plug trimming engine version |. 1.3k2 plug (R16) and resistance }D 750 2 4) trimming plug JE 470 0 inscription |F 220 0 (see table G oa resistances EZL trimming plug (R16). Unplug 4-pin coupling at EZL control unit. Test clockwise between middle and ‘outer connec- tor pins. 22 lez 16/1 | Ignition: OFF | Replace EZL resistance reference |. ~@"+ >— 3| Pay attention trimming plug resistor to national (r6/1) 2) version and Part no., see table. Unplug 4-pin coupling at EZL control unit. 23 fea Rigi Ignition: OFF [Part no. | Replace EZL resistance reference |2.— =@*+ — 1] Unplug EZL and @ | trimming plug resistor reference | value (Rieit) *) resistor. see table EZL reference resistor (ri6/) » ceo @ © @ 4 n¥@O@ Se A 15.1132-1250N2Test Test scope |Test connection Operation” | Speciti- | Possible cause/Remedy step Requirement _| cation 30 | Throttle Nuva Ignition: OFF | idle ‘Adjust or replace throttle valve LL @>>2 position | valve switch, switch, full approx. | Rectify open circuit in load/die 02 wiring according to wiring speed Full load | diagram recognition approx. (s2972) 09. Part load position See also table "re- sistances at throttle vaive switch full load’ idle speed re- ‘cognition (s292)" 40 [Pressure | Engine tester Vacum fine at |When — | Check vacuum line from sensor Ez contro! | vacuum | intake manifold to EZL unit dis- fine con- | control unit for leaks. connected. nected, | if no fault found, replace Coupling ignition | EZL contro! unit. disconnected | timing from throttle | point valve switch, | must Engine: start | advance. Engine speed’ gear lever position: idling. ee AIS 1192-125019Test [Test scope |Test connection | Operation’ —_| Specifi- | Possible cause/Remedy step Requirement | cation 5.0 Coolant N1/2| Ignition: OFF | Q values, | Replace cable according to tempera- | 1 =@'+ >~1]Unplug 4-pin | see aia- | wirng diagram. ture sensor coupling at. | grammed | Replace cootant tempera- (6112) EZL control | coolant | ture sensor (81/2) unit, test 2 | tempera- values at two | ture temperatures | sensor (2/4-pin) Example: + 20°C 2.28- 272k + 80°C 290- 3640 6.0 — [ignition | Engine tester Detach’ ‘See table | Replace EZL ignition timing vacuum fine at }ignition | control unit point EZL contro! | timing unit. points Engine: start 7.0 | Dwell angle | Engine tester Vacuum tine |24-59° | Replace EZL ignition ‘at 3200 rpm and 4-pin control unit coupling EZL control unit connected. Engine: start ee 84 15.1132-1250716Test [Test scope [Test connection [Operation | Specifi- | Possible cause/Remedy step Requirement _| cation ao [HT Visual check Ignition: OFF Distributor cap, mechanical distributor Remove damage in HT distributor, (S53) distributor cap. replace HT distributor i A necessary. Pay close attention to satety notes (15-0508). 2.0 — | interter- =O* Ignition: OFF |1kQ — | Replace faulty parts ence Remove supression distributor cap. resistors, Measure distributor resistances cap, distri- individually. butor rotor, spark plug connector 10.0 Ignition —_| Engine tester Ignition: ON [Good | Replace ignition coil coil Engine: start | poor, see Oscitloscop image: idle speed —_| analyzing Parade oscillo- scope image (Biagno- sis Manual, Engine, Vol. 1 Register ©). y Ignition voltage: (average value) 6 ~ 16 KV. Diference of cylinders to each other 3 kV Ignition voltage rise: the gnton voltage measured at dle speed must rise by not ore than 6 KV when engine speed is increased up o 3000 rom by blppng the vote ‘Combustion curve starting point: 0.6 ~ 1.2 KV. Dilorence of the cylinders to each othor 0.3 KV. ‘Combustion time: 1.9 - 2.5 ms. Dilerence of the cylinders to each other <0.3 ms. ee FA 15.1132-1250115Location of components Round power supply connector at EZL ignition control unit (N1/2) EZL ignition contro! unit (N1/2) ‘Arrow 4:pin connector sonsor EZL ignition control unit (N1/2) Avrow Vacuum line eA 15 1992-125016EZL resistance trimming plug (R16) ry B 24 Ko c 13 ka D 075 = ka E 047 ka F 022 4k G@ oo ka Bottom part of connector, EZL resistance trimming plug (R16) EZL reference resistor (R16/1) Part no. Resistance | National version 000 5402281 | 220 2 ® 000 502401 17500 [O@ Diagnostic socketterminal block (X11) “Torminal TN A 15.1132-1250017EZLKE, LH) coolant temperature sensor, 4-pin (8112) Connect 4-pin connector, coolant temperature sensor (B11/2) Pin assignment (positions stamped in connector) 2 3 4 EZUAKR tomporature KE tomporature sonsor (Ground, EZUAKR ignition contr nit (Ground, KE conal unt Coolant temperature sensor (81172), 2-pin —_ RA 15.1192-125018 EZL KE Biz KEDiagram, coolant temperature sensor (2'4-pin) High voltage distributor (S5/3) Igition coil (T1) Terminal 1 > Terminal 15 era 5.1192-1250719 #8 ve sessed genesd GUG0HE DEE ai tll ape i |, e eSConnector, crankshatt position sensor (L5) Diagram, crankshaft position sensor (LS) signal Plug connection, throttle valve switch full loadidle speed recognition (S29/2x1) Resistances at throttle valve switch full load/idle ‘speed recognition (S29/2) Idle speed approx. 0 Q Full load approx. © —3id P15-0240-13 fro: Lens 1: oO > aH 15.1192-1250/20 $20/2 ae contact Ful load