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Diagnostic Manual, Engines, Volume 4

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LOCATION:    9.3 ME - SFI (ME2.0)   >  24 Electrical Test Program - Ignition System Test


Electrical Test Program - Ignition System Test

WARNING!
Risk of severe injury when touching ignition parts which produce high voltages. Do not touch ignition components.
Persons with heart pacemakers are not to perform repairs on this type of ignition system.

Preparation for Test:
1. Review 11 , 21 , 22 entirely.
2. Ignition: OFF
3. Connect test cable with socket box to engine control module (N3/10), as per connection diagram, see 22

Test scope Test connection
Test condition Nominal value Possible cause/remedy
1.0 P 0 5 6 0
Engine control
module (N3/10)

Voltage supply
circuit 30


3
(3a)
N3/10



12
(4B)
Ignition: ON 11 - 14 V 1.1 - 1.2
1.1   Ground wire N3/10

3
(3a)

7
(7a)

112
(8f)

119
(15f)











X11/4
2

X11/4
2

X11/4
2


X11/4
2
Ignition: ON
Model 163:
Connect socket 8 to 16-pole connector.
11 - 14 V Wiring,
Model 202/208/210:
Output ground (W16/6), right component compartment.

Model 163:
Ground (W16), component compartment.
1.2
1.2   Voltage supply
circuit 30

X11/4
1


N3/10

12
(4B)
Ignition: ON
Model 163:
Connect socket 4 to 16-pole connector.
11 - 14 V Wiring,
Passenger-side fuse and relay module box (K40/4) or Fuse and relay box (F1).
2.0 P 0 5 6 0
Engine control
module (N3/10)

Voltage supply
circuit 87


8
(8a)
N3/10



2
(2a)
Ignition: ON 11 - 14 V 2.1 - 2.2
2.1   Electronics ground N3/10

8
(8a)





X11/4
2
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Output ground (W16/6), right component compartment.

Model 163:
Ground (W16), component compartment.
2.2   Voltage supply
circuit 87

X11/4
1


N3/10

2
(2a)
Ignition: ON
Model 163:
Connect socket 4 to 16-pole connector.

Ignition: OFF
11 - 14 V




< 1 V
Wiring,
Passenger-side fuse and relay module box (K40/4) or fuse and relay box (F1f22).
3.0   Ignition coil (T1/1)
Cylinder 1
Voltage supply
Primary coil a


Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



124
(20F)



125
(21F)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/1).
4.0   Ignition coil (T1/2)
Cylinder 2
Voltage supply
Primary coil a



Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



121
(17f)



120
(16f)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/2).
5.0   Ignition coil (T1/3)
Cylinder 3
Voltage supply
Primary coil a



Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



110
(6f)



111
(7f)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/3).
6.0   Ignition coil (T1/4)
Cylinder 4
Voltage supply
Primary coil a



Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



117
(13f)



118
(14f)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/4)
7.0   Ignition coil (T1/5)
Cylinder 5
Voltage supply
Primary coil a



Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



109
(5f)



108
(4f)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/5).
8.0   Ignition coil (T1/6)
Cylinder 6
Voltage supply
Primary coil a



Voltage supply
Primary coil b


3
(3a)



3
(3a)
N3/10




N3/10



123
(19f)



122
(18f)
Ignition: ON 11 - 14 V Wiring,
Models 202/208/210:
Fuses in passenger-side fuse and relay module box (K40/4f6),
Model 163:
Fuse and relay box (F1f26),
Ignition coil (T1/6).
9.0 P 0 3 3 5
CKP sensor (L5)
Signal







Voltage


93
(37e)





93
(37e)
N3/10






N3/10



94
(38e)





94
(38e)
Test with oscilloscope.
Starter: Crank
Engine: at Idle


Test with multimeter only
if oscilloscope is
unavailable.
Starter: Crank
Engine: at Idle
Signal: see
Figure 1 and 3.






> 2.0 V~
> 5 V~
Voltage
increases with
increasing rpm.
1.1 ,
Teeth on starter ring gear.
9.1   Resistance of CKP
sensor (L5)


93
(37e)
N3/10



94
(38e)
Ignition: OFF
Unplug connector E on
engine control
module (N3/10).



(at 20°C):
600 - 1200
Wiring,
L5
10.0 P 0 3 4 1
Camshaft Hall-effect sensor (B6/1)
Hall-effect signal




Voltage


95
(39E)




96
(40e)
N3/10





N3/10



96
(40e)




2
(2a)
Test with oscilloscope.
Engine: at Idle



Test with multimeter only
if oscilloscope is
unavailable.
Engine: at Idle
Signal: see
Figure 2 and 3.






1.2 - 2.2 V
Value changes.
10.1 ,
Wiring,
B6/1
10.1   Voltage supply to camshaft Hall-effect sensor (B6/1)
1
B6/1

3

Ignition: ON
Disconnect connector from Hall-effect sensor (B6/1) and test directly on sockets 1 (brown/green) and 3 (red/blue) of connector.
11 - 14 V Wiring.
11.0 P 0 3 0 0
P 0 3 0 1
Primary voltage
Ignition coil (T1/1),
Cylinder 1
Primary circuit a




Primary circuit b


124
(20F)




125
(21F)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 100%

Starter: Crank
200 - 350 V 11.1
11.1   Primary winding of T1/1
Primary circuit a and b


124
(20F)
N3/10





125
(21F)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/1
12.0 P 0 3 0 0
P 0 3 0 2
Primary voltage
Ignition coil (T1/2),
Cylinder 2
Primary circuit a




Primary circuit b


121
(17f)




120
(16f)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 100%


Starter: Crank
200 - 350 V 12.1
12.1   Primary winding of T1/2
Primary circuit a and b


120
(16f)
N3/10





121
(17f)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/2
13.0 P 0 3 0 0
P 0 3 0 3
Primary voltage
Ignition coil (T1/3),
Cylinder 3
Primary circuit a




Primary circuit b


110
(6f)




111
(7f)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 100%

Starter: Crank
200 - 350 V 13.1
13.1   Primary winding of T1/3
Primary circuit a and b


110
(6f)
N3/10





111
(7f)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/3
14.0 P 0 3 0 0
P 0 3 0 4
Primary voltage
Ignition coil (T1/4),
Cylinder 4
Primary circuit a




Primary circuit b


117
(13f)




118
(14f)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 5 millisec.

Starter: Crank
200 - 350 V 14.1
14.1   Primary winding of T1/4
Primary circuit a and b


117
(13f)
N3/10





118
(14f)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/4
15.0 P 0 3 0 0
P 0 3 0 5
Primary voltage
Ignition coil (T1/5),
Cylinder 5
Primary circuit a




Primary circuit b


109
(5f)




108
(4f)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 5 millisec.

Starter: Crank
200 - 350 V 15.1
15.1   Primary winding of T1/5
Primary circuit a and b


108
(4f)
N3/10





109
(5f)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/5
16.0 P 0 3 0 0
P 0 3 0 6
Primary voltage
Ignition coil (T1/6),
Cylinder 6
Primary circuit a




Primary circuit b


123
(19f)




122
(18f)
N3/10





N3/10




2
(2a)




2
(2a)
Test connection Note:
Individual primary pattern
Range: 400 V
Duration: 5 millisec.

Starter: Crank
200 - 350 V 16.1
16.1   Primary winding of T1/6
Primary circuit a and b


122
(18f)
N3/10





123
(19f)
Ignition: OFF


0.9 - 1.6
The resistance of a single coil at 20° C is approx. 0.6 .
Wiring,
T1/6
17.0 P 0 3 0 0
P 0 3 0 1
P 0 3 0 2
P 0 3 0 3
P 0 3 0 4
P 0 3 0 5
P 0 3 0 6
Firing voltage
Ignition coil (T1/1) to (T1/6)
 
Engine analyzer


Test connection Note:
See DM, Engines,
Vol. 1, section C

Starter: Crank
8 - 20 kV
The resistance of the secondary winding can not be measured due to an installed diode.
Spark plugs,
N3/10