STI Home
Diagnostic Manual, Engines, Volume 2

 Printable version
 5.1 Distributor Ignition System (DI)    >   24 Electrical Test Program - Test (Engine Runs)


Electrical Test Program - Test (Engine Runs)

Test step DTC Scope of test

Test connection

Test condition

Nominal value

Possible cause/remedy

1.0 Maximum retard setting on at least one cylinder has been reached

-

- - Increased knock tendency, i.e. due to poor fuel quality, carbon build-up, mechanical damage.
2.0 1) Engine coolant temperature
sensor (B11/2)

Fault circuit


13 (B.5)
N1/3





12 (B.4)
Ignition: ON
see table I. Wires,
Engine coolant temperature
sensor (B11/2),
2.1
2.1
Resistance

1




2
B11/2




B11/2


3




4
Ignition: OFF
Unplug connector on engine coolant temperature sensor (B11/2).
see table I. Engine coolant temperature
sensor (B11/2).
3.0 Ignition control module (N1/3)
Load sensor

Connect vacuum gauge.

Engine: at Idle >450 mbar Vacuum supply to N1/3 interrupted,
Ignition control module (N1/3).
4.0 Knock sensor (A16)

-

Ignition: OFF - Connector (1) for A16 not connected to ignition control module (N1/3),
Knock sensor (A16).
1) DTC is implemented in the ignition control modules made by Bosch, part no. 007 545 70 32, only as of production code 946.

5.0 Camshaft position
sensor (L5/1)

Signal


13 (B.5)




13 (B.5)
N1/3 2)




N1/3 3)





9
(B.1)




9 (B.1)
Engine: Start
Signal,
see Figure 8.



>0.25 V~
5.1
5.1
Resistance of camshaft position
sensor (L5/1)


13 (B.5)
N1/3





9 (B.1)
Ignition: OFF
Unplug test cable with connector B on N1/3.
900 - 1600 Wiring,
Camshaft position sensor (L5/1),
5.2
5.2
Insulation of camshaft position
sensor (L5/1)


13 (B.5)
N1/3





9 (B.1)
Ignition: OFF
Unplug test cable with connector B on N1/3.
> 20 k Wiring,
Camshaft position sensor (L5/1).
2) Test with oscilloscope.
3) Test with multimeter only if oscilloscope is unavailable.

6.0

AT only!
Transmission overload protection switch (S65)
Fault circuit

1
S65


2
Plug on S65 connected.
Unscrew threaded ring, push back rubber boot and measure voltage with points of multimeter leads.
Parking brake set.
Engine: at Idle
Selector lever in transmission range: P/N

D














> 4.7 - 5.3 V


< 1 V

Wires,
6.1
6.1
Transmission overload protection switch (S65)
Resistance

2
S65

1
Unscrew connector on transmission overload protection switch (S65).
Parking brake set.
Engine: at Idle
Selector lever in transmission range: P/N

D






> 20 k

< 1
S65,
7.0 Data line
between ignition control
module (N1/3) and
CFI control module (N3).

-

Visual inspection: Check if
N1/3 and N3 are correctly matched.
see Parts Microfiche.
Data line from N1/3 to N3,
7.1.
7.1   Wire for continuity
N3

26




N1/3

7
(A.7)
Ignition: OFF
< 1 Data line from N1/3 to N3,
7.2
7.2   Wire shorted to ground


5 (A.5)
N1/3





7 (A.7)
Ignition: OFF

200 Data line from N1/3 to N3.
8.0 Reference resistor (R16/2)


-

Visual inspection:
Check if R16/2 is properly installed and is correctly matched
Part number,
015 545 67 28.
8.1
8.1
Reference resistor (DI) (R16/2)

R16/2


Ignition: OFF
Unplug R16/2 from ignition control module (N1/3) (see Figure 2) .
2.4 k Reference resistor (R16/2),
If nominal value is obtained, replace ignition control module (N1/3).
9.0 TN-signal


2
(A.2)
N1/3





4 (A.4)
Engine: at Idle
6 V~ 9.1
9.1
Wire, TN-signal for continuity
N16
16




N1/3
4 (A.4)

Ignition: OFF

< 1 Wire from N1/3 to N16,
9.2
9.2
Wire, TN-signal shorted to ground


2 (A.2)
N1/3





4
(A.4)
Ignition: OFF
200 Wire from N1/3 to N16,
Ignition control module (N1/3).
10.0 Wide open throttle/closed throttle position
switch (S29/2)
Wide open throttle contact


2 (A.2)
N1/3




16 (B.8)
Ignition: ON
Accelerator pedal position:
Closed throttle

Wide open throttle


11 - 14 V

< 1 V
10.1
10.1
Wide open throttle/closed throttle position switch (S29/2)

2
S29/2x1


3
Ignition: OFF
Unplug connector (S29/2x1) on S29/2.
Accelerator pedal position:
Closed throttle

Wide open throttle




> 20 k

< 1
Wiring,
Wide open throttle/closed throttle position switch (S29/2).
11.0 4) Wide open throttle/closed throttle position switch (S29/2)
Closed throttle position contact


2 (A.2)
N1/3




15 (B.7)
Vacuum line remains connected to N1/3.
Ignition: ON
Accelerator pedal position:
Closed throttle

Partial load




< 1 V

11 - 14 V
11.1
11.1
Wide open throttle/closed throttle position switch (S29/2)
Resistance

2
S29/2x1


1
Ignition: OFF
Unplug connector (S29/2x1) on S29/2.
Accelerator pedal position:
Wide open throttle

Closed throttle




> 20 k

< 1
Wiring,
Wide open throttle/closed throttle position switch (S29/2).
4) DTC may be displayed even though there is no malfunction in the system. Control modules made by Bosch, part no. 007 545 70 32, as of production code 946 and those made by Siemens, part no. 007 545 71 32, as of production code 27/89, have had this problem corrected.

12.0 Output in ignition control module (N1/3)
Engine 104:

T1
Cir. 1




N1/3

1 (A.1)
Ignition: OFF
Disconnect terminal 1 on ignition coil (T1) .
< 1

Wiring,
Ignition coil (T1),
Ignition control module (N1/3).





2 (A.2)
N1/3





1 (A.1)

 
> 20 k






Cir. 1
T1

Cir. 15
Ignition: OFF
Disconnect ignition coil (T1).
0.3 - 0.6




Output 1 in ignition control module (N1/3)
Engine 119:

T1/1
Cir. 1



N1/3 1 (A.1)
Ignition: OFF
Disconnect terminal 1 on ignition coil 1 (right cylinder bank) (T1/1) .
< 1

Wiring,
Ignition coil (T1/1),
Ignition control module (N1/3).





2 (A.2)
N1/3





1 (A.1)

 
> 20 k






Cir. 1
T1

Cir. 15
Ignition: OFF
Disconnect ignition coil (T1/1).
0.3 - 0.6


13.0

Engine 119 only!
Output 2 in ignition control module (N1/3)


T1/2
Cir. 1




N1/3
6 (A.6)
Ignition: OFF
Disconnect terminal 1 on ignition coil 2 (left cylinder bank) (T1/2).
< 1

Wiring,
Ignition coil (T1/2),
Ignition control module (N1/3).







2 (A.2)
N1/3





6 (A.6)

 


> 20 k




T1/2
Cir. 1

T1/1
Cir. 15
Ignition: OFF
Disconnect ignition
coil (T1/2).
0.3 - 0.6


14.0 5) Crankshaft position
sensor (L5)


18




18
N1/3 2)



N1/3 3)




17




17
Starter: Crank



Starter: Crank
Signal, see Figures 6 and 7.


> 0.4 V~
14.1
2) Test with oscilloscope.
3) Test with multimeter only if oscilloscope not available.
5) DTC is implemented in ignition control modules made by Bosch, part no. 007 545 70 32, only as of production code 946, and in control modules made by Siemens,
only as of production code 27/89.

14.1
Resistance from crankshaft position sensor (L5)


18
N1/3



17
Ignition: OFF
Unplug connector (2) for L5 at ignition control
module (N1/3) (see
Figure 1).
680 - 1200 Wiring,
Crankshaft position sensor (L5),
14.2
14.2
Insulation of crankshaft position sensor (L5)


2
N1/3



7
Ignition: OFF
Unplug connector (2) for L5 at ignition control
module (N1/3) (see
Figure 1).
> 20 k Crankshaft position sensor (L5),
check flexplate segments.
15.0

Engine 104 only!
Load signal for 5-speed automatic transmission to transmission control
module (N15/1)


N1/3




Engine analyzer:
Primary pattern, measurement range 40 V, duration 100%,
auxiliary signal input.


6 (A.6)
Engine: at Idle
Electrical consumers shut off.
Vacuum connection on ignition control module (N1/3) connected.

Vacuum connection on ignition control module (N1/3) disconnected.



2 - 4 %
(Table II)
see Figure 25.

5 - 10 %
(Table II)
see Figure 26.
Ignition control module (N1/3),
Vacuum line,
Wiring.

Table I Engine coolant temperature sensor (B11/2) (4-pole)

Temperature (°C) Resistance ( ) at engine coolant temperature sensor (B11/2) Voltage (V) at engine coolant temperature sensor (B11/2)
- 20 15700 5.12 - 5.60
- 10 10000 4.49 - 5.11
0 5900 4.12 - 4.48
10 3700 3.77 - 4.11
20 2500 3.36 - 3.76
30 1700 2.92 - 3.35
40 1170 2.51 - 2.91
50 830 2.09 - 2.50
60 600 1.69 - 2.08
70 435 1.36 - 1.68
80 325 1.09 - 1.35
90 245 0.88 - 1.08
100 185 0.75 - 0.87

Table II Load signal from ignition control module to transmission control module (N15/1)

Engine speed
Load signal with vacuum
(mbar)
Load signal without vacuum
(mbar)

rpm 200 300 400 500 800 900 1000
600 1.1 1.8 2.5 3.3 5.4 6.1 6.2 On-off ratio
%
650 1.2 2.0 2.7 3.6 5.8 6.6 7.4
700 1.3 2.1 2.9 3.8 6.3 7.1 8.0
750 1.4 2.3 3.1 4.0 6.8 7.7 8.6