15-540 testing electronic ignition system with variable ... benz help pdf... · 15-540 testing...

15-540 Testing electronic ignition system with variable characteristics (EZL)

Preceding work:

Testing, adjusting engine (07.3-110)

Operation No. of operation texts and work units or standard texts and flat rates: 15-1250

Precondition for test

Spark plugs, ignition cables, distributor rotor and distributor cap in proper mechanical and electrical order.

Test e. g. by visual inspection, measuring resistance and ignition oscilloscope.

P15-0424-59

Connection diagram for engine tester with oscilloscope

N1/2 EZL control unitR4 Spark plugsR16 Resistance trimming plug (EZL)

B11/2 Coolant temperature sensor (EZL/KE)B17/1 EZL intake air temperature sensorG1 BatteryL5 Crankshaft position sensor

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T1 Ignition coilX11 Diagnosis socket/terminal block terminal TD1 Segments on flywheel/driver disc2 Vacuum line030 Engine tester with oscilloscope

S5/3 High voltage distributorS29/2 Full load/idle speed detection throttle valve

switchS65 Transmission overload protection switch

(only engines 102.983/99)

Note

Pay attention to the safety precautions (15-505) when performing work on the ignition system. Switch off ignition when unplugging and plugging in the connectors at the EZL control unit.

The test is split up into two sections:

A. Engine not runningThe basic functions of the ignition system are tested in this section.

B. Engine running

Fault sources in the ignition advance or at the

appropriate components may affect the handling of the vehicle.

If a complaint is received regarding the handling of the vehicle, first of all test the ignition system. Then, continue troubleshooting at the KE injection system.

Special tools

Commercially available testers

Multimeter e. g. Sun, DMM-5Fluke, Multimeter 23Hermann, Avometer 2003

Engine tester e. g. Hermann, Datascope 9800Bosch, MOT 301/400Sun, 2110BEAR, D AC E

Test data

Resistances (test data from 0-100° C)

Ignition coil primary (terminals 1 and 15) W 0.3-0.6

Ignition coil secondary (terminals 1 and 4) kW 8-13

Position sensor coil resistance (terminals 7 and 31d) W

insulation (terminal 7 and ground) kW

680-1200U 200

Distributor cap per terminal, W

distributor rotor,

spark plug connector

700-1300


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Voltages, engine not running, ignition switched on

Terminals 15 and 31 (contacts 5 and 2 diagnosis socket) V Battery voltage

Between terminals 15 and 1(contacts 5 and 4 diagnosis socket) V 0

4-pin round connector terminals 15 and 31 V Battery voltage

4-pin round connector terminals 16 and 31 V Battery voltage

Dwell angle

At starter speed 9-49° or 10-54%

At 3200/min 27-54° or 30-60%

Ignition point at starter speed in ° CS TDC F2°

Test ignition points with engine running (15-515).

Resistances of resistance trimming plug (R16)

Position Resistance EZL resistance trimming plug

"EZL-ECE" "EZL-KAT" "EZL"(102.983Std.)

"EZ-ECE-S" (102.983 R?F)

"EZL-KAT"autom.

"EZL-KAT"man.

A 1 W S 1 1 1 - -

B 2.4 kW 2 2 2 S S -

C 1.3 kW N 3 3 N - S

D 750 W 4 S 4 4 4 4

E 470 W 5 5 5 5 N N

F 220 W 6 N 6 6 6 6

G 0 W 7 7 7 7 - -

A. Engine not running


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Note

If the specified value of a test step, e. g. test step 1.0, is in order, continue immediately with test step 2.0.

If the specified value of step 1.0 is not in order, it is then necessary to continue with step 1.1.

Key to symbols:

c Multimeter direct voltage mode

b Multimeter resistance mode

e Oscilloscope

w Contact

v Connector

o Ground

On/off ratio readout

Test step/Test scope

Test connection Operation/Requirement

Specifi-

cation

Possible cause/Remedy

- 1.0

Voltage supply

N1/2

31 w cL15

Ignition: ON Battery voltage

Test wiring and contacts according to wiring diagram (from battery via ignition lock to EZL control unit).

2.0

Crankshaft position sensor L5

L5

31d wb L 7

Ignition: OFFDetach crankshaft position sensor connector at EZL control unit.

680-

1200 W

Replace crankshaft position sensor (L5).




Specifi-

cation


- 2.1 L5

31d wb L 7

Detach crankshaft position sensor connector at EZL control unit.

Engine: Start

see diagram

US U1 V

Signal too small/no signal: replace position sensor. Different voltage height: test segments. Replace EZL control unit.

- 2.2

Insulation of sensor coil

L5

w b L 7

o

Detach crankshaft position sensor connector at EZL control unit.

U200 kW Replace crankshaft position sensor.

- 3.0Dwell angle

Engine tester Engine: Start 9°-49°or 10-54%

Dwell angle not to tolerance:replace EZL control unit. No dwell angle: test stall current cutoff.


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- 4.1Stall current cutoff

T1

Kl. 1 c Kl. 15

T1

Kl. 1 c Kl. 15

Ignition: ON

Engine: Start

0V

0V

>0V

Replace EZL control unit and ignition coil.

Test wiring and contacts from EZL control unit to ignition coil or replace EZL control unit. Replace ignition coil.

- 4.2Ignition coil primary T1

T1

Kl. 1 b Kl. 15

Ignition: OFF

Unscrew wiring at ignition coil.

0.3-0.6 W

Replace ignition coil.




Specifi-

cation


- 5.0

Primary current

Engine tester

eScope image:primary parade

Engine: Start >200 V Replace EZL control unit.

- 6.0Primary current limiting

Engine tester

eScope image:Secondary overlap

Engine: Start see diagramReplace EZL control unit.

- 7.0Ignition voltage at terminal 4 ignition coil

Engine tester

eScope image:Secondary parade

Engine: Start U8 kV Test ignition cable terminal 4, distributor rotor, distributor cap and ignition coil.

- 7.1Ignition cable terminal 4

T1 S5/3

Kl. 4 b Kl. 4

Ignition: OFFDetach ignition cable terminal 4 at ignition coil and distributor cap.

<1 W Replace ignition cable terminal 4.

- 7.2Distributor rotor

Distributor

rotor

bMiddle Peak

Ignition: OFFRemove distributor cap.

700-1300 W

and visual inspection

Replace distributor rotor.

- 7.3Distributor cap

S5/3

bKl. 4 Carbon

Ignition: OFFDistributor cap removed and detach ignition cable terminal 4.

700-1300 W

per terminal and visual inspection

Replace distributor cap.




Specifi-

cation



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- 7.4Ignition coil secondary T1

T1

Kl. 4 b Kl. 1

Ignition: OFFUnscrew cables at ignition coil.

8-13 kW Replace ignition coil.

- 8.0Ignition voltage at single cylinder

Engine tester

eScope image:Secondary paradeHigh voltage clamp at cylinder ignition

cable (e. g. cylinder 3)

Engine: Start >6 kV Test distributor cap,distributor rotor,ignition cables with spark plugs.

- 8.1

Ignition cable with spark plug connector

bIgnition Spark

cable plug

connector

Ignition: OFFDetach ignition cable with spark plug connector at spark plug and distributor.

700-1300 W Replace ignition cable with spark plug connector.

- 8.2Spark plugs

Visual inspection Ignition: OFFRemove spark plug.

Electrode gap0.8 mm

Replace according to condition.

Test A completed.

B. Engine running

Pay attention to safety precautions (15-505).




Specifi-

cation


- 1.0

Ignition point

Engine tester Engine: Test at normal operating temperature at specified speeds and with/without vacuum.

see table (15-515)

Resistance trimming plug, coolant temperature sensor, throttle valve switch, vacuum advance, transmission overload protection (102.983/99).

- 1.1Resistance trimming plug (R16)

N1/2

o b L 3

Sensor

connector4-pin

Ignition: OFF

Detach sensor connector at EZL control unit. Pay attention to assignment engine/ resistance trimming plug.

depending on resist-

ance trimming plug setting, see table

Resistance trimming plug, cables, contacts.

- 1.1.1Resistance trimming plug (R16)

R16

v b KMiddle A-G

Ignition: OFFDetach resistance trimming plug.

see table Resistance trimming plug


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- 1.1.2

Cables and contacts

R16 N1/2

w b L 3

Sensorconnector

4-pin

R16

o b L

Ignition: OFFDetach resistance trimming plug. Detach sensor connector at EZL control unit.

> 1 W

>1 W

Replace cables or contacts.

Test negative cable to W11 or W10, replace.




Specifi-

cation


- 1.2Coolant temperature sensor (B11/2)

N1/2

o b L 1

Sensorconnector

4-pin

Ignition: OFF

Detach sensor connector at EZL control unit

at

80 °C290-360 Wfurther values, see diagram

Coolant temperature sensor (B11/2) Cables, contacts.

- 1.2.1

Coolant temperature sensor (B11/2)

B11/2

(2-pin)

o b LGreen/black

cable

B11/2

(4-pin)

v b K

Ignition: OFF

Detach sensor connector at EZL control unit

measure 2B diagonally

Replace coolant temperature sensor (B11/2) (07.3-251).

Replace coolant temperature sensor (B11/2) (07.3-251).

- 1.2.2

Cables and contacts

B11/2 N1/2

w b L 1

Green/ Sensorblack connectorcable 4-pin

Ignition: OFF

Detach connector at temperature sensor and sensor connector at EZL control unit.

<1 W

see note

Replace cables or contacts.

- 1.3

Throttle valve switch idle speed detection

S29/2x

2 v b K 1

Ignition: OFF

Detach coupling (S29/2x).

Idle position: < 1W

Other positions: 1

Set or replace throttle valve switch. Open circuit.




Specifi-

cation



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- 1.3.1

Cables and contacts

N1/2 N3

2 w bL13

Sensorconnector4-pin

Ignition: OFF

Detach sensor connector at EZL control unit and KE control unit.

< 1W Replace cable or contact.

- 1.4

Vacuum advance

Engine tester Engine: normal operating temperature, speed 1500/min. Detach vacuum hose at EZL control unit.

Fit on vacuum hose at EZL control unit.

Ignition point retarded

Ignition point advanced

Vacuum hose leaking.Connection at intake manifold blocked.Pressure sensor in EZL control unit faulty.

- 1.5 L5

31d we L 7

Detach crankshaft position sensor connector at EZL control unit. Engine: Start

see diagram

US U 1V

Different voltage heights:Test segments (visual inspection)Replace flywheel/driver disc with segments.




Specifi-

cation


- 1.6

Transmission overload protection, only engine 102.983/99 with automatic transmission

N1/2

o b L 4

Sensorconnector

4-pin

Depress

parking brake.

Pay attention

to safety

precautions.

Engine: StartIdle speed selector lever

position: "D"

Selector lever position:"P" or "N"

< 1W

1

Transmission overload protection switch (S65) CablesContacts

Transmission overload protection switch (S65) CablesContacts

- 1.6.1

Transmission overload protection switch (S65)

S65

v b K

Detach

connector at

transmission

overload

protection

switch S65.

Depress

parking brake.

Pay attention

to safety

precautions. Engine: Start Idle speed

selector lever

position "D"

Selector lever position:"P" or "N"

< 1W

1

Replace transmission overload protection switch (S65).

Replace transmission overload protection switch (S65).


? ? ?. 8




Specifi-

cation


- 1.6.2

Cables and contacts

S65 N1/2

w b L 4

Sensorconnector

4-pin

S65

w b o

Ignition: OFFDetach

connector at

transmission

overload

protection

switch (S65)

and EZL

control unit

(N1/2).

Ignition: OFFDetach connector at transmission overload protection switch (S65) and EZL control unit (N1/2).

< 1W

< 1W

Replace cable or contact.

Replace cable or contact.

- 2.0Dwell angle

Engine tester Engine speed

3200/min,

normal

operating

temperature.

Detach sensor

connector at

EZL control

unit and

vacuum line.

Engine: Start

27-54°or 30-60%

Replace EZL control unit.

- 3.0High voltage distributor/ distributor rotor

Visual inspection Ignition: OFFRemove distributor cap.

- Distributor cap,distributor rotor has cracks, interference suppression resistors faulty.




Specifi-

cation


- 3.1Distributor cap

S5/3

bIgnition: OFFRemove distributor cap.

700-1300 Wper terminal

Replace distributor cap.

- 3.2Distributor rotor

Distributor

rotor

bMiddle Peak

Ignition: OFFRemove distributor cap.

700-1300 Wand visual inspection

Replace distributor rotor.


? ? ?. 9

- 4.0

Scope images

Engine tester

eScope imagesParadeOverlapRaster

Engine: StartIdling speed.

see Diagnosis Manual Engine Volume 1

Ignition coilDistributorIgnition cablesSpark plugs

Test B completed.

EZL ignition control unit (N1/2)1 Vacuum connection

2 Coaxial connector for control cable from position sensor3 4-pin sensor connector

1 Coolant temperature sensor2 Throttle valve switch3 EZL resistance trimming plug4 not assigned (cable ends in harness

or intake air temperature sensor)4 4-pin supply connector

15 = Terminal 1516 = Ignition coil terminal 1TD = TD signal31 = Ground P15-2193-13

Crankshaft position sensor signal L5t1 1st segmentt2 2nd segmentd Period for one crankshaft

revolutionUS Voltage (U1V) P15-0216-13

Crankshaft position sensor connector L5Test resistance or voltage signal between connection 7 and 31d.

P15-0240-13


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Current limiting

P15-0244-55

Notes regarding testCoolant temperature sensor (B11/2)

Diagram of coolant temperature sensor (B11/2)

P15-0237-15

4-pin coolant temperature sensor

Pin assignment of coupling:1=EZL temperature sensor2=KE temperature sensor3=Engine ground at intake manifold for EZL4=KE control unit ground

Note

National version I 1988 without coupling

designations.

P07-2022-13


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When testing the coolant temperature sensor, measure the resistances 2B diagonally and compare.

P15-0171-13

Note regarding ignition distributorImproved distributor rotor with polyamid bush.

Production breakpoint: January 1989

Model Engine Engine end No. manual transmission

Engine end No. automatic transmission

124.023124.043124.083

102.982 130477 127198

201.024201.028

102.962102.985

21149830070

10889878183

Note regarding crankshaft position sensorPosition sensor of a further manufacturer.

Production breakpoint: October 1989

Model Engine Engine end No. manual transmission

Engine end No. automatic transmission

124.021124.081

124.023124.043124.083

102.963

102.982

041939

150880

011638

153461

201.035 102.990 002490 001002


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P15-0212-57A

EZL wiring diagram, engines 102.962/963/982/985 R?F/KAT

a To KE control unit, contact 13b To injection system intake air temperature sensorc To KE control unit contact 5d To KE control unit contact 21e Voltage supply terminal 30

Model 124: to fuse 9 via engine plug connection (X26), contact 3Model 201: to fuse 13 via electrical center coupling S, contact 11

f Voltage supply, terminal 15, unfused Model 124: engine plug connection (X26), contact 1Model 201: electrical center coupling S, contact 4

g Cable ends in wiring harnessh Equipment with terminal TD (e. g. tachometer,

fuel pump relay, KE control unit, compressor cutoff control unit)

z Connector sleeve (soldered connector in wiring harness)

B11/2 Coolant temperature sensor (EZL/KE/2 E-E)L5 Crankshaft position sensorN1/2 Transistorized ignition control unit (EZL)R16 Resistance trimming plug (EZL)S5/3 High voltage distributorS29/2 Full load/idle speed detection throttle valve

switch S29/2x Full load/idle speed detection throttle valve

switch plug connectionT1 Ignition coilW3 Ground, front left wheelhouse (ignition coil)W10 Battery groundW11 Engine ground (electric cable bolted on)X11 Diagnosis socket/terminal block terminal TD


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P15-0210-57A

EZL wiring diagram, engines 102.91/96/98 KAT as of 09/89

a To KE control unit contact 13b To KE control unit contact 7 (ground)c To KE control unit contact 5d To KE control unit contact 21e Voltage supply terminal 30

Model 124: to fuse 9 via engine plug connection (X26), contact 3Model 201: to fuse 13 via electrical center coupling S, contact 11

f Voltage supply terminal 15, unfused Model 124: engine plug connection (X26), contact 1Model 201: electrical center coupling S, contact 4

h Equipment with terminal TD (e. g. tachometer, fuel pump relay, KE control unit, compressor cutoff control unit)


B11/2 Coolant temperature sensor (EZL/KE/2 E-E)B17/1 Intake air temperature sensor (EZL)L5 Crankshaft position sensorN1/2 Transistorized ignition control unit (EZL)R16 Resistance trimming plug (EZL)S5/3 High voltage distributorS29/2 Full load/idle speed detection throttle valve

switchS29/2x1 Full load/idle speed detection throttle valve

switch plug connectionT1 Ignition coilW3 Ground, front left wheelhouse (ignition coil)W10 Battery groundW11 Engine ground (electric cable bolted on)X11 Diagnosis socket/terminal block terminal TD


? ? ?. 14

P15-0211-57A

EZL wiring diagram, engine 102.983 with automatic transmission

a Voltage supply terminal 30 to fuse 13 via electrical center coupling S, contact 11

b Voltage supply terminal 15, unfused, electrical center coupling S, contact 4

c To KE control unit contact 13d To KE control unit contact 5e To KE control unit contact 21f Voltage supply terminal 15, fused, fuse 10

looped via left heated washer nozzle or soldered connector in wiring harness

h Equipment with terminal TD (e. g. tachometer, fuel pump relay, KE control unit, compressor cutout control unit)




switch plug connectionS65 Transmission overload protection switchT1 Ignition coilW3 Ground, front left wheelhouse (ignition coil)W10 Battery groundW11 Engine ground (electric cable bolted on)X11 Diagnosis socket/terminal block terminal TDX26/4 Taillamp wiring harness/engine wiring harness

plug connection, 4-pin

NoteS65 and X26/4 not applicable with manual transmission.


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P15-0425-55

EZL wiring diagram, engine 102.99 with automatic transmission

a Voltage supply terminal 30 to fuse 13 via electrical center coupling S, contact 11

b Voltage supply terminal 15, unfused, electrical center coupling S, contact 4

c To KE control unit contact 13d To KE control unit contact 5e To KE control unit contact 7 (ground)f To KE control unit contact 21g Voltage supply terminal 15, fused, fuse 10

looped via tachometerh Equipment with terminal TD (e. g. tachometer,

fuel pump relay, KE control unit, compressor cutout control unit)




switch plug connectionS65 Transmission overload protection switchT1 Ignition coilW3 Ground, front left wheelhouse (ignition coil)W11 Engine ground (electric cable bolted on)X11 Diagnosis socket/terminal block terminal TDX26/4 Taillamp wiring harness/engine wiring harness

plug connection, 4-pin

NoteS65 and X26/4 not applicable with manual transmission.


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15-540 testing electronic ignition system with variable ... benz help pdf... · 15-540 testing...

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