EXIT

lectrical system, engine 1

 EXIT
15 Electrical system - engine

Job No.

Notes regarding work on transistorized ignition system ........................... 15 - 505

Function of distributor ignition system (DI) .................................... 15 - 510
Function of the breakerless transistorized ignition system (TSZ) ..................... - 512
Testing ignition point .................................................... - 515
Analyzing oscilloscope images ............................................. - 525
Replacing spark plugs ................................................... - 530
Removal and installation of ignition or high voltage distributor ....................... - 535
Testing distributor ignition system (DI) ........................................ - 540
Testing breakerless transistorized ignition (TSZ) ................................. - 542
Testing ignition advance in warm-up phase (only TSZ) ............................ - 543
Retrofitting corrugated hoses for ignition cables ................................. - 547

15 1
 EXIT

15-505 Instructions regarding work on transistorized ignition system

A. Safety precautions

increased requirements of modern engines in

respect of the ignition systems and the desire for
freedom from maintenance have led to the
standard use of electronic ignition systems.

As a rule, the ignition capacities of electronic

systems are higher than those of conventional
Gefghrliche Hochspannungy
systems; further increases in capacity are likely. Vorsicht bei Arbeiten an der
Consequently, electronic ignition systems Ztindanlage
operate in a power range which may be
Danger! High voltage
hazardous if contact is made with live parts or Observe caution when working
terminals (see warning plate). on the ignition system

Danger! Haute tension

Attention lors de travaux au
systeme d’allumage
Warning plate In engine compartment
PlS-0241-13

For this reason, the following safety precautions

should always be observed when performing
work on electronic ignition systems (distributor
ignition, TSZ):

l Before performing work at cranking speed,

e.g. testing compression or adjusting valve
clearance, switch off ignition and detach
control lead (arrow) at control module or plug
protective connector Part No.
102 589 02 21 00 into the diagnostic
connector.

TSZ ignition control module

15 0924-5051
 EXIT

l Persons with heart pacemakers should not

work on such ignition systems.
l Do not grasp or detach any components of
the ignition system at cranking speed or
when the engine is running.

tgnltion control module

l Perform removal and installation work on the

ignition system or connection and discon-
nection of sensors at ignition cables only
when the engine is not running and the
ignition is switched off.
l No adapters or plug-in sensors which are
metallically blank to the outside may be
installed in the ignition cables (e.g. cylinder
1).

. Instructions for avoiding damage to ignition system

The control module connectors may only

be unplugged and plugged in when the
ignition is switched off in order to avoid
damage to the ignition and TSZ control
modules.
Do not connect a test lamp to terminal 1 of
the ignition coil.
Terminals 1 and 15 of the ignition coil must
not be short circuited to ground, e.g. as an
anti-theft protection.
The threaded pins of the ignition coil have
different diameters (M5 and M6) to eliminate
the risk of incorrect polarity.
Install only genuine ignition system parts.
Do not operate ignition system at starting
speed unless all the ignition cables are fully
connected.

15 092440512
 EXIT

l The high voltage side of the ignition system

must have a load of at least 2 kR (distributor
rotor 1 kR, distributor cap per terminal 1 kQ)
to avoid damage to the ignition and/or TSZ
control modules. Do not install 5 k!J
distributor rotors for interference
suppression.
l The following work must not be performed at
starting speed or when the engine is
running:
- holding ignition cable 4 at a distance to
ground
- unplugging spark plug connector
- unplugging ignition cable 4 at ignition coil.
l The ignition control module is coated on the
rear with heat-conducting paste to improve
heat dissipation and covered with a heat-
conducting protective film. The protective
film must not be removed.
l If the short-circuit protection (cylinder
comparison) is operated and the engine
stops, the test cannot be performed with this
tester.
l A load of not more than 28 kV may be
applied to the ignition coil when performing
the separate ignition coil test in order to
avoid damaging the coil.
l If it is necessary to test the ignition spark
when rendering roadside assistance, this
must only be done with a spark plug at a
cylinder ignition lead. Ensure a good contact
to ground of the spark plug.
WARNING! Risk of shock!

C. lnstructlons for use of engine testers

l Connect and disconnect voltage clamp to

ignition cable 4 and trigger clamp to ignition
cable of cylinder 1 only when the engine is
not running and the ignition is switched off.

15.0924-50513
 EXIT

15-510 Function of distributor ignition system (DI)

Function diagram of distributor ignition system (DI)

Engine 102.985
8112 Engine coolant temperature sensor s2912 Full throttle/tdle speed detectlon throttle valve
Gt Battery switch
L5 Crankshaft posltlon sensor Tl lgnltron co11
Nl:Z Ignition control module Xl 1 Dlagnostlc connector/terminal block termmal TD
R4 Spark plugs
R16 Reference reslstor 1 Segments on driver disk
S5l3 High voltage distnbutor 2 Vacuum line

Engines 102.96/98 as of 09189

The intake air temperature sensor (B17il)
supplies its temperature values to the ignition
control module (intake air temperature sensor for
CFI system no longer equipped).

15.0924-51041
 EXIT

Components and function

ignition control module (N1/2)

1
Dwell and ignition
a n g l e +c o n t r o l

+
Ground point W3 controls
Front left wheelhouse Ground (-)

c
I I
Ignition coil

Ignition
control
module
(Nli2)

supplies
Transmission overload
protection switch controls
(S65) (only engines
102.98399 wtth
automatic
-4 Shift operations
I=+

transmlsslon) &,
1

Tachometer,
fuel pump relay,
compressor shutoff
control module,
CFI control module,
Engtnes 102.983199 etc.
 EXIT

The ignition control module is located on the left

wheelhouse panel.

It is installed with heat conducting paste to

improve heat dissipation. When exchanging this
part, the protective film must not be removed.
The film does not impair heat dissipation. The
ignition control module contains a
microcomputer, a pressure sensor and the
power output stage.

The ignition maps for typical load/engine speed

ranges and a fixed idle speed ignition map are 2 .
stored in the microprocessor of the ignition
control module.

The ignition control module detects the

momentary operating state of the engine from
various input signals. Engine speed and
crankshaft position are sensed by the position
sensor.

The optimal ignition point for this operating state

is output from the stored ignition maps by
analyzing all the input signals.
1 Vacuum connection
2 Coaxial connector for control lead from posItIon sensor
3 Sensor connector 4-pin
1 Engine coolant temperature sensor
2 Wide open throttle/closed throttle postion switch
3 Reference resistor
4 Vacant (lead ends in wiring harness)
or intake air temperature sensor
4 Supply connector 4-pin
15 = Terminal 15
16 = Ignition coil terminal 1
TD = TD signal
31 = Ground

15.0924-5 1013
 EXIT

The output end stage actuated by the micro- Note

computer switches the primary current of the If an interruption of the engine coolant
ignition coil between terminals 16 and 31 temperature sensor occurs (resistance 00 Q)
(4-pin supply connector). Bosch ignition control modules depart from the
fixed idle speed curve and select a certain
The familiar functions of dwell angle control, ignition point in the map, i.e. the ignition point is
primary current cutoff and primary current advanced.
limiting are still contained in the ignition control
module. At full load, the ignition point is determined by
the full load ignition curve. The ignition control
The speed-dependent TD signal is generated in module detects full load from the intake
the ignition control module (15-512). manifold vacuum and engine speed input
signals.
When the engine is started and up to approx.
450:min the ignition point is controlled only via At full load, the ignition point is advanced
the segment edges of the flywheel. Only when (higher engine torque), taking into account the
a certain engine speed is reached (approx. knock limit.
460Imin) is a transition made from the fixed
ignition point to the ignition point calculated for On engines 102.983199 two full load ignition
the momentary operating state. characteristic curves are stored. The ignition
point is determined as follows depending on the
In the warming-up range, various ignition maps switch position of the intake air temperature
are inhibited depending on coolant temperature sensor:
in order to reach the operating temperature as - By the advanced ignition characteristic
rapidly as possible. curve below +25 “C intake air temperature.
- By the retarded ignition characteristic curve
At idling speed and when decelerating a fixed above +25 “C intake air temperature.
ignition map is specified when the idle contact
of a throttle valve switch is closed. This is
influenced neither by the temperature sensor,
the intake manifold vacuum nor by the
reference resistor.

15.0924-51 oi4
 EXIT

On engines 102.96/98 as of 09:‘89 with intake If the engine coolant temperature exceeds 90
air temperature sensor, the ignition point is “C or 100 “C (depending on version), certain
retarded as the Intake air temperature rises. In ignition characteristic curves are retarded to
addition, an lgnrtron map is stored both for counteract a further temperature rise (boiling
automatic and manual transmission. These protection correctton).
maps are activated by the reference resistor.
On engines 102.96:98 as of 09;88 up to 08,89
The ignition points of certain ignition the use of the boiling protection correction has
characteristic curves can be altered with the been advanced from 100 “C to 90 “C engine
reference resistors. depending on the operating coolant temperature. From a coolant
state. temperature of 90 “C the ignition point is
retarded. The maximum retardation of 5” WA is
Two maps for the following operating modes are already reached at a coolant temperature of
stored in the ignition control module: 100 "C.

l For operation with catalytic converter (is Engines 102.996/98 as of 09189

activated via reference resistor). The use of the boiling protectron correction
begins from 100 “C.
The national version @ has a fixed resistance The retardation correction is:
reference resistor. 100 “C + retarded 2” CKA (crank angle)
110 “C -+ retarded 4” CKA
Note 120 “C + retarded 5” CKA
The ignition control module for engine 102.983
Standard has only one map. The ignition point A
IS altered for leaded and unleaded premium The correction of the boiling protection and of
grade fuel with a special resistance trimmrng the intake air are added, i.e. 120 “C coolant
plug (inscription EZL and digits l-7). temperature and 50 “C intake air temperature
produce a maximum retardation of 12” CKA.
Safety measures at control module
A safety retardation is automatically performed
in the event that one or several sensors of the
ignition system fail in order to protect the
engine.

15.0924-510:'5
 EXIT

The Ignition point test must be performed at an

engrne coolant temperature between 75 “C and
90 ‘C because of ‘he boiling protectron
correction as the ignition point is altered outside
of this temperature range. To avoid an incorrect
measurement of the ignition point, unplug
connector for the engine coolant temperature
sensor and feed in 320 12 ( = 80 “C engine
coolant temperature) with the resistance decade.

Engines 102.96:98
81112 Engine coolant temperature
sensor
Wl 1 Engine ground

Flywheel disk with segments

Two segments offset 180” (A) are installed to

the flywheel or to the flexplate.

As the segments pass the position sensor they

produce an alternating voltage as a result of
Induction.

Flywheel (manual transmlsslon)

15.0924-51016
 EXIT

Flexplate with rtng gear

(automatic transmission)

Position sensor (L5)

To activate the ignition control module, the
position sensor (L5) detects the crankshaft
position and the engine speed.

The position sensor is installed on the crankcase

above the starter flange.

The coil body projects to just before the

segments at the driver plate. Segment position
and engine speed are sensed without contacts.

When the engine is rotating an alternating

voltage is produced in the position sensor as a
result of induction. The peak value of the voltage
(U,) is approx. 1.5 volts at starter speed. As
engine speed increases, the voltage rises
(U, approx. 3 volts at 1200/min.).

15.0924-51 on
 EXIT

Note
Measure peak value of voltage (U,) with the
oscilloscope.

The crankshaft setting is detected from the

voltage as follows:

The front edge of the segment produces a

negative voltage signal.
The rear edge of the segment produces a
positive voltage signal.

Position sensor voltage signal

t1 1 st segment
t2 2nd segment
d Penod for one crankshaft revolution

The engine speed is determined by measuring

the period.

The alternating voltage of the position sensor is

passed along the control lead (coaxial lead) to
terminal 7 at the ignition control module. The
lead is a single-core cable and the screening is
used as a second lead.

If the ignition control module does not receive a

signal from the position sensor, the complete
ignition system is inoperative, e.g. an interruption
of the sensor coil can cause this.

The resistance of the position sensor between 31d

terminal (7) and (31d) is 680-1200 Q.

Notes regarding damage segments or

mechanical damage to position sensor:
l Alternating voltage of position sensor below
specification.
l Alternating voltage signals of individual
segments vary greatly.
l No alternating voltage signal.

P15-0240-13

15.0924-51018
 EXIT

Wide open throttle/closed throttle

position (WOTICTP) switch (S29M)
When the closed throttle contact of a WOTCTP
switch is closed (accelerator not depressed), the
fixed idle speed/deceleration ignition
characteristic curve is activated. The switching
signal passes through the WOTCTP switch
connector (S29/2xl) and the 4-pin sensor
connector (contact 2) to the ignition control
module.

Engine coolant temperature sensor (Bl l/2)

Temperature sensors are equipped with 2-pin or
4-pin (from approx. 09189) connections.

The temperature signal passes along the

green/black cable at the 4-pin sensor connector
(contact 1) to the ignition control module.
The engine coolant temperature sensor is
positioned at the front at the cylinder head.

Note
NTC = resistor with negative temperature
coefficient, i.e. the resistance is less in the warm
state.

2-pin engine coolant temperature sensor

(Bl l/2)
The engine coolant temperature sensor has two
NTC resistors, each with a single-pin connection.
One NTC for CR and one NTC for the distributor
ignition system.

Engines 102.961985
61 l/2 Engine coolant temperature
s8nsor

15.0924-51019
 EXIT

4-pin engine coolant temperature sensor

(Bl l/2)
It integrates two separate temperature sensors
(NTC) which do not have any electrical
connection to the housing of the engine coolant
temperature sensor.

One temperature sensor is for the distributor

ignition system (contacts 1 and 3) and one for
the injection system (contacts 2 and 4).
The connector of the engine coolant temperature
sensor is designed so that it can be plugged in
in any position. The two temperature sensors are
arranged diagonally.

Engines 102.96/‘98
81 112 Engine coolant temperature
sensor

15.0924-51 Oil 0
 . . . .iiii
EXIT

Pin assignment of coupling:

1 = Ignition temperature sensor
2 = CFI temperature sensor
3 = Ground W3, front left wheelhouse
4 = CFI control module ground

Notes regarding test

Engine coolant temperature sensor(61 l/2)
When testing the engine coolant temperature
sensor, measure the resistances 2 x diagonally
and compare. The resistances of the
characteristic curves are identical with those of
the previous version.

An electronic switch is incorporated in the intake

air temperature sensor which interrupts the
connection between terminal 2 and terminal 3
(ground) at temperatures 125 “C . Continuity
exists between the two terminals below this
temperature.

At terminal 1 the voltage for the electronic switch

is supplied from terminal 15 via fuse 10.

1 Voltage supply
2 lgnltion control module
3 Ground

15.0924-51 Oil 1
 EXIT

b) Engines 102.96/98 KAT as of 09/89

The intake air temperature sensor installed on
CFI now supplies its temperature values through
the sensor connector contact 4 to the ignition
control module. The resistance of the
temperature sensor (NTC) becomes smaller as
the temperature rises.

From an intake air temperature of 32 “C the

rgnrtion point is retarded and reaches its
maximum at 50 “C.
e. g.: 32 “C -+ retarded lo CKA
40 “C -+ retarded 5” CKA
50 “C + retarded 7’ CKA
Engines 102.96;98
El1 711 Intake air temperature sensor

Reference resistor
Two different types of reference resistors are
installed:

a) Variable resistance trimming plug (R16).

b) Reference resistor (R161’1) with fixed
resistance @.

Model 124 shown

R 16 Reference resistor

15.0924-510: 12
 EXIT

b) Reference resistor (R16A)

The reference resistor @16/l) has a fixed
resistance. The fixed resistances differ depend-
ing on Part No. as follows (see 15-515 for
assignment):

Model 201

Part No. Resistance

000 540 22 81 220 n

000 540 25 81 I 1300 n

000 540 26 81 I 2400 Q

A certain ignition map is activated in the ignition

control module with the reference resistor
@16/l).

Perform resistance measurement for testing the

reference resistor (R16il) at the ignition control
module between sensor connector (contact 3)
and ground.

High voltage distributor (W3)

The singular task of the high voltage distributor
is to distribute the ignition voltage. It is therefore
no longer possible to set the ignition point.
Activation and adjustment of the ignition point
are performed by the position sensor and the
ignition control module.

Interference suppression resistors: At distributor

cap per terminal 1 kQ, spark plug connector
1 kQ, distributor rotor 1kQ.
 EXIT

The distributor cap is attached to the high

voltage distributor with M-6 special bolts.
The special cap for long-range interference
suppression is mounted on the cap and attached
with two metal stars.

Ignition coil (Tl)

The ignition coil is matched to the ignition control
module to achieve a higher ignition energy. The
primary current can be further boosted as a
result of the high switching capacity of the
ignition control module. The primary winding is
designed as a very low impedance (0,3-0,6 Sz)
for this purpose.
Stall current cutoff and primary current limiting
enable the ignition coil to be operated without
ballast resistor. Consequently, current limiting by
the ballast resistor is eliminated. If the maximum P15-2139-13

primary current flows without limit in the ignition

coil (e.g. stall current cutoff defective), the
ignition coil is damaged after a short time by the
high level of heat developed.

For distinguishing:
The ignition coils of 4- and 6-cylinder engines
with distributor ignition systems are identical
Identification: yellow type plate.
The ignition coils cannot be interchanged with
ignition coils for a-cylinder engines (identification:
green type plate).
Pay attention to Part No. when exchanging.

Pay attention to instructions regarding work on

electronic ignition systems (16-505).

15.0924-510114
 EXIT

15-512 Function of the breakerless transistorized ignition system (TSZ)

Gl

P15-0422-35

Gl Battery S5/2 Breakerless distributor

Nl/l Transistorized ignition (TSZ) control module Tl Ignition coil
R4 Spark plugs x11 Diagnostic connector/terminal block terminal TD

Note
Installation survey of engines with breakerless Only a 4-pin connector is plugged in at the small
transistorized ignition system (TSZ), see transistorized control module (distinguishing
07.3-004. feature to ignition control module).

15.0924-512/l
 EXIT

Components and function

transistorized control module (NW)

ignition starter Voltage supply (+) Dwell angle control

swrtch (S21) Stall current cutoff
termrnal 15 Primary current limiting

controls

c
Ignition coil

transistorized
control
Inductron sensor In module
dtstnbutor (Nl/l)
I I

+
supplies
I

controls
1

Tachometer,
I
fuel pump relay
module,
compressor cutoff
control module,
CFI control module,
etc.

The transistorized control module is located on

the left wheelhouse panel. It is designed in
space-saving hybrid technology.

1 lgnrtion co11
2 transrstorized control module
3 Terminal block terminal TD
4 Diagnostic connector

15 0924-512/2
 EXIT

Pin assignment at transistorized control

module

l Green control lead from induction sensor in

distributor (coaxial connector).

0 4-pin round connector with terminals 15, 31,

16 and TD.

The electronic functions of primary current

limitation and stall current cutoff in the
transistorized control module enable the series
resistors in the primary current circuit to be
eliminated. Consequently, a higher ignition coil
primary current and higher ignition capacity are
possible.

The transistorized control module is activated by

induction sensor in the distributor.

The optimal capacity of the ignition system is

achieved by the dwell angle control in the
transistorized control module. The dwell angle is
controlled within the control range so that the
same primary current is always achieved
approximately in every operating state, i.e. at
different battery voltages and engine speeds.

As a result of the elimination of the series

resistors, the primary current is cut off by the
transistorized control module (stall current cutoff)
when the engine is not running and the ignition
is switched on. The primary current is connected
only once a certain pulse sequence is generated
by the induction sensor in the distributor.

The maximum primary current of the ignition coil

is determined by a current limiter in the
transistorized control module.

150924-51213
 EXIT

The current limitation (c) can be recognized on

the oscilloscope when the engine is at idle.
Current limitation is no longer visible from an
engine speed of approx. 2000imin.

The power output stage switches the primary

current of the ignition coil between terminals 16
and 31. In addition, the power output stage
performs the task of limiting the primary current.

a Opening angle
b Dwell angle
C Current limltlng

TD signal

The transistor engine speed (TD) signal is

produced in the transistorized control module.
This is an engine speed-dependent square-wave
signal.

d-100%99
The engine speed is detected by the number of
square-wave signals per minute.

When performing tests, the On time (t, e.g. 70%

P15-0215-13
of the individual square-wave pulses is measured
as dwell angle in degrees or as on’off ratio in
percent (related to period, d).

The TD signal can be measured:

l with the dwell angle tester or on/off ratio

tester in percent and degrees.

l with the voltage meter 6 volts up to 12 volts

direct voltage.

l with the oscilloscope - square-wave signals.

15.0924-51214
 EXIT

Note
No TD signal exists If a short to ground is
present at the connected equbment or at the
diagnostic connectorterminal block terminal TD
(Xl 1). To locate the problem, detach cable
connection (arrow). Rectify short to ground in
the respective circuit.

The following electronic components have a TD

connection, e.g.:
Tachometer, CFI control module, fuel pump relay
and compressor cutoff control module.

Ignition distributor (S5/2)

l The induction sensor is installed in the

distributor. It produces an alternating voltage
up to approx. 100 volts for actuating the
transistorized control module.

The alternating voltage passes along the

green control cable (coaxial cable) to the
ignition control module. The cable is a
single-wire lead. The screening is used as a
second lead.

l Engine speed-dependent ignition advance by

flyweights. Load-dependent ignition advance
by vacuum (above approx. 60 “C coolant
temperature).

l Interference suppression resistors: distributor

rotor 1 kQ (code number Rl, on rotor),
distributor cap 1 kQ per cylinder.

15.0924-5 12:5
 EXIT

Ignition coil (Tl)

The ignition coil is matched to the ignition control

module and designed for a higher ignition
capacity. Identification: yellow sticker.

The ignition coil must on no account be replaced

by one of the previous ignition coils.

Distinguishing features from previous ignition

coils are:
l The safety plug in the cover of the ignition
coil.
l A higher dome.
0 Cable connection at terminal 1 with
M5 thread.
0 Cable connection at terminal 15 with
M6 thread.

A 5.5 mm opening (arrow) which is sealed with a

plug is located in the cover of the ignition coil.
This cover detaches if an pressure as a result of
severe heat formation is produced in the ignition
coil by a defective output stage in the control
module. The ignition coil is provided with a cover
cap to prevent uncontrolled escape of the plug
or of the sealing compound.

Ignition cables
The partially screened spark plug and angled
distributor connectors are designed for high
ignition voltage.

An interference suppression resistor of 1 kS2 is

installed in the spark plug connectors. These can
be unscrewed (M3 thread).
 EXIT

15-515 Testing ignition point

Preceding work:

A. Vehicles with TSZ ignition system

Gl Battery Tl Ignition coil

Nl/l Transistorized ignition (TSZ) control module x11 Diagnostic connector/terminal block terminal TD
R4 Spark plugs 030 Engine tester with oscilloscope
S5l2 Breakerless distributor

Engine tester with oscilloscope (030) . . . . . . . . . connect to diagnostic socket (Xl 1).
Safety precautions . . . . . . . . . . . . . . . . . . . . . . observe (15-505). Selector lever in position P or
N. Apply parking brake.
Ignition point .......................... test at specified engine speed with or without
vacuum (see table).

15.0924-5 1511
 EXIT

Ignition point .......................... set by turning distributor. Then re-test.

Flywheel vacuum advance ................. test at specified engine speeds (see table).

Commercially available testers

Engine tester (engine speed, dwell angle, ignition angle, e. g. Bosch, MOT 002.02
oscilloscope, voltmeter Sun, 1019
 EXIT

lnition
1 hint (TSZ) basic version
I
Engine Type Distributor Vacuum installed
of Bosch No. advance value of
fue13) of ignrtior1 ignttion
point in point in
withouvwith “CKA “CKA
vacuum BTDC at BTDC at
starting
speed
without
vacuum

45001 at idle at idle 45001

min min
I
102.961 Jn-
3 237 002 084 27 8-12 8
eaded
3 237 002 059 without

102.985 Jn- 3 237 002 105 27 8-12 8

eaded without
See next page for footnotes.

m int
(TSI basic version
Engine Type of Distributor Test and setting Ignition point advance Vacuum Installed
:uel 3, Bosch No. data ‘) of ignitior n “CKA (crank angle) advance value of
point in“C K A before TDC of ignitio n ignitron
BTDC 2 1 Nithout vacuum point in point in
without/with “CKA “CKA
vacuum BTDC al BTDC al
starting
speed
without
vacuum

45001 at idle at idle 15001 3000/ 45001

min min min min

I
Jn- 0 237 002 094 5 24-28’)
102.961 eaded with
1984
102.961 D 237 002 098 10-14 22-26’) 14-l 8*) 5
102.985
as of
1983
) If norm :ompressron engines are opera d wfth fue of less than 98 RON mm. 88 IN) or fow-compressfon engmes wftn
less than 92 RON (mtn. 82 MON), the fgnftron pofnt should be retarded and adapted to the octane number of the fuel used. A
reference value for this adlustment IS: retard rgnrtion point by l-2 O CKA per 1 RON. The maxfmum retardatfon must not
exceed 6” CKA.
The Ignition correction should be entered by hand on the “engfne setting data” Information plate.
Thrs results m reduced oerformance and increased fuel consumption. In addition, the engfne must not be operated at full load.
The full rgnftron advance snould be reset as soon as fuel of the soecffied octane number IS again avaflable.
2) Test at 3500/min.
3) Vehicles wfth catalytfc converter must be ooerated wfth unleaded fuel.
4) This value must be ldentfcal with and wrthout vacuum when engine at normal ooeraring temperature: cneck lgnltlon advance In
warming-up phase If necessary (15-543).

15.0924-5153
 EXIT

8. Vehicles with distributor ignition system (DI)

PlS-0424-59

81112 Engrne coolant temperature sensor S65 Transmissron overload protection swatch
B17ft Intake air temperature sensor (only engines 102.983199)
Gl Battery Tl lgnrtion coil
L5 Crankshaft posrtron sensor x11 Diagnostic connector/termrnal block termrnal TD
N1/2 lgnrtron control module
R4 Spark plugs 1 Segments at flywheel/driver disk
R16 Reststance trimmrng plug (EZL) 2 Vacuum line
S5l3 High voltage drstributor 030 Engine tester with oscilloscope
52912 Wide open throttle/closed throttle posttron switch

15 0324-5t 514
 EXIT

Engine tester with oscilloscope (030) . . . . . . . . . connect to diagnostic socket (Xl 1).
Safety precautions . . . . . . . . . . . . . . . . . . . observe (15-505). Selector lever position P or
N. Apply parking brake.
Ignition point . . . . . . . . . . . . . . . . . . . . test at a engine coolant temperature for approx.
80 “C with or without vacuum at specified
engine speed (see table).

Engine 102.96/99 KAT as of 09189

Detach engine coolant temperature sensor
(El l/2) and intake air temperature sensor
(I31 70 ) for test.

Following the test, the DTC memory must be

erased (see 07.3-121, section “D”). Use
impulse counter scan tool 124 589 19 21 00 for
this or unscrewi screw on negative pole terminal
or battery.

Note
The ignition point cannot be set. If the ignition
point is incorrect, test distributor ignition system
(DI) (15-540).

Radio with code

Following repairs to the vehicle which involve
disconnecting the battery terminals, the radio
must be made operational again by entering the
code number. The CODE card must be available
when repairs are performed.

15.0924-515:5
 EXIT

Engine dersion Production Ignition control Engine Resistance Ignition Ignition

break module speed trimming plug point point
point Part No. 1 :min setting, type in “CKA in “CKA
Model year alternatively of fuel ‘) BTDC / BTDC

without with
vacuum vacuum
102.983 1986,1987 004 545 57 32 Reference 18-22 3, 29-33 3,
004 545 59 32 resistor
dling
750 n
14-18
-+- 14-18
102.985 1987/l 988 005 545 30 32 3200
005 545 32 32
Idling 18-12 18-12

102.985 1989 007 545 47 32 5)6) 3200 2 3 - 2 7 139-43

007 545 48 32 5)6)
dling 8-12 8-l 2

102.985 010 545 59 32 3200 Reference 22-26 ‘) 139-43 ‘)

010 545 60 32 resistor
dling 8-12 8-12
1.3 kR
(man. transm.)
2.4 kS2
(aut. transm.)
I) Manual transmlsslon.
2) Automatlc transmlsslon.
3) Intake atr temperature sensor connector dlsconnected.
4) Resistance tnmmlng plug positjon results from setttng.
5) These lgnltlon control units may also be tnstalled In vehicles pnor lo 08188. In th1.s case the Ignition point values are altered as
shown in the table. The resstance trimmmg plug setting “7” IS no longer permitted for these lgnltlon control umts.
6) Test lgnltlon point at 80 “C coolant temperature by unplugging the temperature sensor connector 61 l/2 and feedIng In 320 Q
with resistance decade betweengreen/black cable (coolant temperature sensor coupltng 4-pin, contact 1) and engine ground.
7) Vehicles with catalytic converter must be operated with unleaded fuel.
8) Reference resistor (resistance 0~ Q) not fitted to vehicles with tgnltlon control urxt 003 545 70 32.
9) For testing, detach the Intake air temperature sensor and coolant temperature sensor connectors. Test tgnltion point at 80 “C
coolant temperature by feedlng In 320 R with resistance decade between contact 1 at 4-pin connector and engine ground.

Note
lgnltlon control unit with Ignition map for manual and automatic transmission (actuated by different EZL resistance
trimming plugs), bolllng point correctlon (max. 5 “CKA), intake air correction (max. 7 “CKA) and safety retardation (6 “CKA)
In the event of open clrcult 10 reference resistance trimming plug.

15.0924-515:6
 EXIT

Special tools

124 569 09 63 OC

Commercially available testers

Engine tester (engine speed, dwell angle, ignition angle, 8. g. Bosch, MOT 002.02
oscilloscope, voltmeter) Sun, 1019

Note
The ignition point test must be conducted at an
engine coolant temperature between 75 “C and
90 “C because of the boiling protection
correction as the ignition point alters outside of
this temperature range. To avoid an incorrect
measurement of the ignition point, detach
connector for the engine coolant temperature
sensor and feed in a resistance of 320 Sz (=
80°C engine coolant temperature) with the
resistance decade.

Engines 102.96/98
Bl l/2 Engine coolant temperature sensor
Wl 1 Engine ground

15.0924-515n
 EXIT

Pin assignment of Cpin engine coolant

temperature sensor (B1112):
1 = Ignition temperature sensor
2 = CFI temperature sensor EZL KE
3 = Ground W3, front left wheelhouse
4 = CFI control module ground

EZL

Engines 102.96/98 KAT

as of osias
Bl l/2 Engine coolant temperature sensor
B17/1 Intake ar temperature sensor

t 5.0924-515!8
 EXIT

15-525 Analyzing oscilloscope images

Description of oscilloscope image

Good image

Note
Primary current limiter (7) is only operative up to
approx. 2000Imin.

0 %
Pl5-0004-57

Ignition voltage line 6 Decay process

Ignition voltage 7 Primary current limiting
Combustion period 6 Opening section
Combustion voltage 9 Closing section (dwell angle)
Combustion voltage line

15 0924-52511
 EXIT

Good image

1. Secondary parade

[WI

P ls-ooo5-57

15.0924-52512
 EXIT

Good image

2. Secondary grid

15.0924525/3
 EXIT

Good image

3. Secondary single image

IS

15.0924-52514
 EXIT

Good image

4. Secondary single image

[WI
20

lo

%
,
0

15.0924-52515
 EXIT

Good image

5. Primary parade

[VI
400

2.og

0
P 15-ooo9-57

15.0924-525/6
 EXIT

Good image

6. Primary single image

15.0924-52517
 EXIT

Good image

7. Blipping throttle

Test requirement: Repeatedly accelerate engine

to approx. 3000/min by blipping throttle.

Note
l As a result of the acceleration process,
several cylinders are recorded in turn
according to the firing sequence, 8. g. image
example (1 st 3rd 4th 2nd, 1 st 3rd 4th 2nd,
etc.)
l The ignition voltage rises uniformly at all the
cylinders during the acceleration phase. The
ignition voltage rise must not exceed
6 kV.

CkUl 1

P15-0011-57

i 5.0924-52518
 EXIT

Good image

8. Primary current limitation

Note
Primary current limitation may occur
intermittently at individual or at all cylinders at
engine speeds above 2000/min with and without
load.

15.0924-52519
 EXIT

Fault image

9. Ignition voltage too high/combustion period

shorter.

Test requirement: May occur at any engine

speed with or without load.

Cause
Spark plug electrode gap too large; additional
spark gap at secondary side; fuel/air mixture too
lean.

P 1s-aot3-57

15.0924-525110
 EXIT

Fault image

10. Ignition voltage too low/combustion period

longer.

Test requirement: May occur at any engine

speed with or without load.

Cause
Spark plug electrode gap too small;
fuel/air mixture too lean;
compression loss.

[kVl
I

I-
.
P 15-001447

15.0924-525/l 1
 EXIT

Fault image Note

If engine running is rough (does not run on all
11. Decay process too high cylinders) after start, the engine should be
switched off at operating temperature and
Test requirement: Accelerate engine repeatedly restarted after a lengthy period (approx.
to approx. 3000/min by blipping throttle or run 30 minutes) to obtain a better diagnosis.
engine under load on roller dynamometer. It is essential to pay attention to test
requirement when repeating the starting
Cause operation.
Fuel/air mixture at one cylinder too lean.
AWarning!
Problem may only occur briefly.

[kVl

P 15-QQ1.5-57

15.0924-525/l2
 EXIT

Fault image

12. Decay processes too high.

Test requirement: Accelerate engine repeatedly

to approx. 3000imin by blipping throttle or run
engine under load on roller dynamometer.

Cause
Fuel/air mixture on all cylinders too lean.

P15001657

15.0924-525113
 EXIT

Fault image

13. Higher combustion voltage > 1.5 kV at single

cylinder.

Test requirement: May occur at any engine

speed with or without load.

Cause
Soot, oil, lead deposits on spark plug.
Too high ohmic resistance at secondary side.

1
[kUl

P 15-QQ17-57
1

15.0924-525114
 EXIT

Fault image

14. Higher combustion voltage > 1.5 kV at all

cylinders.

Test requirement: May occur at any engine

speed with or without load.

Cause
Too high ohmic resistance at secondary side.

crl a
i
- r/ P 15-0018-57

15.0924-525115
 EXIT

Fault image

15. Ignition voltage < 8 kV at terminal 4

Test requirement: Starting speed.

Cause
Ignition coil

Note
Engine does not start

[kvl
10

c
i-

loo 80 60 40 20 0 ii.
P ,E.-%l19-51

15.0924-525116
 EXIT

Fault image

16. Ignition voltage < 6 kV at single cylinder

Test requirement: Starting speed

Cause
Ignition coil

Note
Engine does not start

c kV1

15.0924-525117
 EXIT

Fault image

17. No decay process

Test requirement: Starting speed

Cause
Ignition coil or ignition control module.

Note
Engine does not start

15.0924-525118
 EXIT

Fault image

18. Too few decay processes

Test requirement: May occur at any engine

speed with or without load.

Cause
Ignition coil or ignition control unit

[WI
20 I
1
.

10 I

0I--
.

PlS-OO22-57

15.0924-525119
 EXIT

Fault image

19. Too few decay processes.

Test requirement: May occur at any engine

speed with or without load.

Cause
Ignition coil or ignition control module.

23

13

15.0924-525120
 EXIT

15430 Replacing spark plugs

Spark plug connector . . . . . . . . . . . . . . . . . . . . loosen by turning to left and right and pull off.
Blow out recesses with compressed air.
Ignition cables . . . . . . . . . . . . . . . . . . . . . . . . . clean, when installing, ensure the ignition cables
are correctly laid.
Firing sequence: l-4-3-2
Spark plugs . , . . . . . . . . . . . . . . . . . . . . . . . . . remove, install, use only approved spark plug
wrench (with Nm limiter “B”).
A 102589020900
B 16258901 0900
C Vehicle tool

Installation note
Install only approved spark plugs with tapered
seat (a).
Tightening torque 20 Nm.

15.0924-530/l
 EXIT

1 s-535 Removal and installation of ignition or high voltage distributor

-
Precedmg work:

Tl s5/3 s29/2 81711 65

mew m?

Distributor cap . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on.

With TSZ, vacuum line and sensor cable (2) . . . . detach at distributor, fit on.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . set to ignition TDC of No. 1 cylinder by aligning
markings on distributor rotor (3) and distributor
housing (1). In addition, the pointer (8) on timing
case cover must be above the TDC mark of
vibration damper (arrow).

Caution!
Crank engine only in direction of rotation.
Distributor mounting (5) ................... loosen. Remove distributor.

15.0924-535/l
 EXIT

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . set engine to ignition TDC by aligning the

pointer (8) on timing case cover exactly to TDC
mark of vibration damper.
Sealing disc and distributor rotor (3) . . . . . . . . . install at distributor. Align distributor rotor to
marking on housing. Insert distributor.
With EZL ignition system, align screw in middle
of oblong hole (pay attention to note).
With TSZ ignition system, set ignition point
(15-515).
Screw (5) ..................... . . . . . . . tighten.
Ignition cables ................. . . . . . . . Install. Firing sequence l-4-3-2

Note
It is not possible to set the ignition point on the
EZL ignition system by turning the high voltage
distributor. The ignition point is determined by
the Ignition control module. Test distributor
ignition system, if necessary (15-540).

If the engine has been cranked with the

distributor removed, set ignition TDC of No. 1
cylinder (05-215).

15.0924-53512
 EXIT

15-540 Testing distributor ignition system (III)

Preceding work:
Testing, adjusting engine (07.3-l 10)

Precondition for test

Spark plugs, Ignition cables, distributor rotor Test e. g. by visual inspection, measuring
and distributor cap in proper mechanical and resistance and ignition oscilloscope.
electrical order.

P15-0424-59

Connection diagram for engine tester with oscilloscope

Bll!Z Engme coolant temperature sensor N1/2 lgnltlon control module
617/l Intake air temperature sensor R4 Spark plugs
GI Banefy R16 Reference reslstor
L5 Crankshaft postlon sensor

15.0924-540/l
 EXIT

s513 High voltage distnbutor 1 Segments on flywheel/driver disc

s29/2 Wide open throttle/closed throttle posItIon switch 2 Vacuum line
Tl lgnttlon co11 030 Engine tester with oscllloscooe
x11 Dlagnostlc connector/terminal block termmal TD

Note
Pay attention to the safety precautions B. Engine running
(15-505) when performing work on the ignition Fault sources in the ignition advance or at the
system. Switch off ignition when unplugging and appropriate components may affect the handling
connecting the connectors at the Ignition control of the vehicle.
module.
If a complaint is received regarding the handling
The test is split up into two sections: of the vehicle, first of all test the ignition
system. Then, continue troubleshooting at the
A. Engine not running CFI system.
The basic functions of the ignition system are
tested in this section.

Special tools

I1245890963001 i 201 589 00 99 001

Commercially available testers

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

Engine tester e. g. Hermann, Datascope 9800

Bosch, MOT 301:400
Sun, 2110
BEAR, D AC E

15.0924-54032
 EXIT

Test data

Resistances (test data from O-100” C)

Position sensor coil resistance

(terminals 7 and 31d) n 660-l 200
insulation (terminal 7 and ground) kR 2 200
Drstributor cap per terminal, n 700-l 300
distributor rotor,
spark plug connector

Voltages, engine not running, ignition switched on

Terminals 15 and 31 (contacts 5 and 2 diagnostic connector) Battery voltage
Between termrnals 1.5 and 1
(contacts 5 and 4 diagnosis socket) V 0
4-pin round connector terminals 15 and 31 V 1 Battery voltage
4-pin round connector terminals 16 and 31 V Battery voltage

Dwell angle

Ignition point at starter speed in ’ CKA ITDC 220

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

15.092&540:3
 EXIT

A. Engine not running

Note key to symbols:

If the specified value of a test step, e. g. test +=@@- Multimeter direct voltage mode
step 1 .O, is in order, continue immediately with q Multimeter resistance mode
test step 2.0. -O-_ Oscilloscope
- c Contact
If the specified value of step 1.0 is not in order, Connector
it is then necessary to continue with step 1 .l. T Ground

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readout

1.0 N112 Ignition: ON Battery Test wiring and contacts

Voltage 31 d-J=@+- 15 voltage according to wiring diagram
SUPPlY (from battery via ignition
lock to Ignition control
module).

2.0 L5 Ignition: OFF Replace crankshaft position

Crankshaft 31d _c+@+-- 7 Detach sensor (LS).
position crankshaft
sensor L5 position sensor
connector at
Ignition control
module.

15.0924-54014
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readoui

L5 Detach see Signal too small/no signal:

31d _t---o*_- 7 crankshaft diagram replace position sensor.
position sensor Different voltage height:
connector at test segments. Replace
Ignition control Ignition control module.
module.
Engine: Start
. . ,............,.... ,.... ................. ...................... ...........................................
2.2 L5 Detach 1200 kR Replace crankshaft position
Insulation of ---c q-7 crankshaft sensor.
sensor coil L position sensor
connector at
Ignition control
module.

3.0 Engine tester Engine: Start 9O-49” Dwell angle not to

Dwell angle or tolerance:
1 o-54% replace Ignition control
module. No dwell angle:
test stall current cutoff.

4.1 Ignition: ON IV Replace Ignition control

Stall current Cir. 1 GCir. module and ignition coil.
cutoff

Engine: Start 3V Test wiring and contacts

from Ignition control module
to ignition coil or replace
Ignition control module.
Replace ignition coil.
>ov
.................. ......................... ....................
..( ............. ..........................................
4.2 Tl Ignition: OFF 3.3- Replace ignition coil.
Ignition coil Cir. 1 *Cir. Unscrew 3.6 R
primary Tl wiring at
ignition coil.

15.0924-54015
 EXIT

On/off Test step/ Test connection Dperation/ Specifi- Possible cause/Remedy

ratio Test scope qequirement cation
readout

5.0 Engine tester !ngine: Start >200 v Replace Ignition control

Primary module.
current Scope image:
primary parade

6.0 Engine tester %gine: Start see Replace Ignition control

Primary diagram module.
current Scope image:
limiting Secondary
overlap

7.0 Engine tester fngine: Start r0 kV Test ignition cable terminal

Ignition 4, distributor rotor,
voltage at Scope image: distributor cap and ignition
terminal 4 Secondary parade coil.
ignition coil
. . . . . . . . . . . . . . .~ . . . . . . . . . . . . . . . . . . . . . . . . ..t.......... ..,......,..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..__....._...
7.1 Tl s5i3 gnition: OFF Cl52 Replace ignition cable
Ignition Cir. 4 * Cir. 4 Detach ignition terminal 4.
cable :able terminal
terminal 4 t at ignition
:oil and
distributor cap.
. . . . . . . . .................... ................. ,...,,...,..... . . . . . . . . . . . . . . .._..............._...._.....
7.2 Distributor gnition: OFF 700- Replace distributor rotor.
Distributor rotor qemove 1300 sz
rotor * distributor cap. and
Middle Peak visual
inspec-
tion
............. ....................... ................. ,........,..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 s5i3 gnition: OFF 700- Replace distributor cap.
Distributor * Distributor cap 1300 Q
cap Cir. 4 Carbon ,emoved and per
detach ignition terminal
:able terminal and
1. visual
inspec-
tion

15.0924-54016
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement :ation
readou

7.4 Tl Ignition: OFF 3-13 kQ Replace ignition coil.

Ignition coil Cir. 4 ++ Cir. 1 Unscrew
secondary cables at
Tl Ignition coil.

8.0 Engine tester Engine: Start >6 kV Test distributor cap,

Ignition distributor rotor,
voltage at Scope image: ignition cables with spark
single Secondary parade plugs.
cylinder High voltage clamp
at cylinder ignition
cable (e. g. cylinder
3)
. . . . . . . . . . . . . . ,,..........,,,................. ..,...................~ .,,..........,,,..........................
8.1 * Ignition: OFF Replace ignition cable with
Ignition Ignition Spark Detach ignition spark plug connector.
cable with cable plug :able with
spark plug connector spark plug
connector connector at
spark plug and
distributor.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..f.. ..,,................... ............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._........
8.2 Visual inspection gnition: OFF flectrode Replace according to
Spark plugs qemove spark Jap condition.
3lug. I.8 mm

Test A completed.

15.0924-540/7
 EXIT

B. Engine running

Pay attention to safety precautions (15-505).

On/off Test step1 Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readoui

1.0 Ingine tester Engine: Test see table Reference resistor, coolant
gnition point at normal (15-515) temperature sensor,
operating WOTCTP switch, vacuum
temperature at advance, transmission
specified overload protection
speeds and (102.983199).
with/without
vacuum.
............. ............................... . . . . . . .._............. ,............. .....................................
1.1 N112 Ignition: OFF depend- Reference resistor, cables,
qeference 1. **3 Detach sensor ing on contacts.
*esistor Sensor connector at reference
[R16) connector Ignition control resistor
4-pin module. Pay setting,
attention to see table
assignment
engine/
reference
resistor.
................ ..,,........................... .,........,,.......... .......... ...................................
1.1.1 R16 Ignition: OFF see table Reference resistor
Reference -++- Detach
resistor zdle A Z reference
(Rl6) resistor.
,.................. . . . . . . . . . . . . . . . . . . . . . . . . . ...................... ........... . . . . . . . ..t..............................
1.1.2 316 Nli2 Ignition: OFF >lsZ Replace cables or contacts.
Cables and -_c **3 Detach
contacts Sensor reference
connector resistor.
4-pin Detach sensor
connector at
Ignition control
module.
>l R Test negative cable to Wl 1
or WlO, replace.

15.0924-54018
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readou

1.2 N1/2 Ignition: OFF at Coolant temperature sensor

Engine -L_ *)-1 Detach sensor 80 “C (B1112)
coolant Sensor connector at 290- Cables, contacts.
temperature connector Ignition control 360 R
sensor 4-pin module further
(Bl li2) values,
see
diagram
............. . . . . . . . . . . . . . . . . ...................... . .._.......... .................................
1.2.1 Bl l/2 Ignition: OFF Replace coolant
Engine Detach sensor temperature sensor (B1112)
coolant ;ot-(2-pz connector at (07.3-251).
temperature Green/black Ignition control
sensor cable module
(B1112)
B1112
measure Replace coolant
2 x dia- temperature sensor (B1112)
gonally (07.3-251).
.............. . . . . . . . . . . . . . . ,....................., .......... ..................................
1.2.2 B1112 N112 Ignition: OFF <l ff? Replace cables or contacts.
Cables and Detach see note
contacts connector at
black connector temperature
cable 4-pin sensor and
sensor
connector at
Ignition control
module.
............. ........................... ...................... ............. ...........................................
1.3 s2912x Ignition: OFF Idle Set or replace WOTCTP
WOTCTP 2 , * -1 Detach position: switch. Open circuit.
switch connector < 1R
closed (S2912x). Other
throttle positions:
position x)
detection

15.0924-54019
 EXIT

Onioff Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readoul

N3 Ignition: OFF Replace cable or contact.

Cables and - 13 Detach sensor
contacts Sensor connector at
zonnector Ignition control
I-pin module and
CFI control
module.
. . . . . . . . . . . . . . .._.. . . . . . . . . . . . . . . . ...................... .......... ...........................................
1.4 Engine tester Engine: normal Ignition Vacuum hose leaking.
Vacuum operating ooint Connection at intake
advance temperature, ?etarded manifold blocCFld.
speed Pressure sensor in Ignition
1500imin. control module faulty.
Detach
vacuum hose
at Ignition
control Ignition
module. ooint
advancec
Connect
vacuum hose
at Ignition
control
module.
............... . . . . . .._.............. ............. .................................
1.5 Detach see Different voltage heights:
3ld -c-o-> crankshaft jiagram Test segments (visual
position sensor inspection)
connector at Js 2 1v Replace flywheel/driver disc
Ignition control with segments.
module.
Engine: Start

15.0924-540/l 0
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readou

1.6 N112 Depress Transmission overload

Transmis- -L. -++-4 parking brake. protection switch (S65)
sion Sensor Pay attention Cables
overload connector to safety Contacts
protection, 4-pin precautions.
only engine Engine: Start
102.983199 Idle speed
with selector lever
automatic position: “D”
transmission
Selector lever Transmission overload
position: protection switch (S65)
“P” or “N” Cables
Contacts
........ ............ . . . . . . . . . . . . . . . . . . ............... ..................................
1.6.1 S65 Detach Replace transmission
Transmis- _-=@-, connector at overload protection switch
sion transmission (S65).
overload overload
protection protection
switch switch S65.
(S65) Depress
parking brake.
Pay attention
to safety
precautions.
Engine: Start
Idle speed
selector lever
position “D” < lsz

Selector lever lJ Replace transmission

position: overload protection switch
“P” or “N” (S65).

15.0924-540/l 1
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readout

1.6.2 565 Nli2 Ignition: OFF Replace cable or contact.

Zables and - c +YY-4 Detach
zontacts Sensor connector at
connector transmission
4-pin overload
protection
switch (565)
and Ignition
control module
(N1/2).
< lsz Replace cable or contact.
Ignition: OFF
Detach
S65 connector at
A* - L transmission
overload
protection
switch (S65)
and Ignition
control module
(N112).

2.0 Engine tester Engine speed 27-54” Replace Ignition control

Iwell angle 3200/min, nodule.
normal ;:-60%
operating
temperature.
Detach sensor
connector at
Ignition control
module and
vacuum line.
Engine: Start

3.0 disual inspection Ignition: OFF Distributor cap,

iigh voltage Remove distributor rotor has cracks,
listributorj distributor cap. nterference suppression
distributor pesistors faulty.
‘otor

15.0924-540112
 EXIT

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readout

3.1 Ignition: OFF 700- Replace distributor cap.

Distributor Remove 1300 R
cap distributor cap. per
terminal
........ ................ ................................ ....................... ............. . . . . . . . . . .. .. . . . . . . . . . ... . . ... . . . . .. . . . ... .
3.2 Distributor Ignition: OFF 700- Replace distributor rotor.
Distributor rotor Remove 1300 R
rotor * distributor cap. and
Middle Peak visual
inspec-
tion

4.0 Engine: Start see Ignition coil

Scope At idle. scope Distributor
images Scope images images Ignition cables
Parade 15-525 Spark plugs
Overlap
Raster

Test B completed.

15.0924-540/l 3
 EXIT

Crankshaft position
sensor signal LS
t1 1 st segment
t2 2nd segment
d Per& for one crankshaft
revolution
Us Voltage (2 1V)

Crankshaft position sensor connector L5 , - 3 1 d

Test resistance or voltage signal between
connection 7 and 31d.

P15-0240-13

J(kV)
lo-

~- Schliel3 .I

45 4QC 35’ 30‘ 25 20’ 153 10 5” 8 Zyl.

I I I L I 1
1 / I
90 80’ 70‘ 60 5b 40’ 30’ 20 10; 4 Zyl.
1 -1 I I I /
60 50‘ 40 30 20 m 6 Zyl.
P15-0244-55

Current llmlting

15.0924-540114
 EXIT

Notes regarding test

Engine coolant temperature sensor (61 l/2)

2oooo

10000
Boca
e.ooo
4000
3000

Diagram of coolant
temperature sensor (I31 l/2)

4-pin engine coolant temperature sensor

Pin assignment of connector:

1 = Ignition system temperature sensor EZL KE
2 = CFI temperature sensor
3 = Engine ground at intake manifold for DI
4 = CFI control module ground
EZL
KE
Note
National version @ 1988 without connector
designations.

When testing the engine coolant temperature

sensor, measure the resistances 2 x diagonally
and compare.
 EXIT

Note regarding ignition distributor Production breakpoint: January 1989

Improved distributor rotor with polyamid bush. Model Engine Engine end Engine
No. manual end No.
transmission automatic
transmission
201.024 102.962 211498 108898
201.028 102.985 30070 78183

15.0924-540:16
 EXIT

s513 S 2912 817/i B1112

w3
II
b d

o,xg”:5* --&-0,75gnisw 1
0,75suige--+-C,5gn

R,:a,

Distributor ignition system wiring diagram, engines 102.96:98 KAT as of 09;89

81112 Engine coolant temperature sensor (DKFI) To CFI control module contact 13
817/l Intake air temperature sensor (DI) To CFI control module contact 7 (ground)
L5 Crankshaft postton sensor To CFI control module contact 5
N1/2 Translstortzed lgnltlon control module (DI) To CFI control module contact 21
R16 Reference resstor (DI) Voltage supply terminal 30
S5i3 High voltage dlstnbutor Model 201: to fuse 13 wa electrical center
S29l2 Wide open throttle/closed throttle postlon switch connector S. contact 11
S29/2xl Wide open throttle/closed throttle posItIon switch f Voltage supply terminal 15, unfused
plug connectlon Model 201: electrlcal center connector S,
Tl lgnitlon c o i l contact 4
W3 Ground, front left wheelhouse (ignltlon coil) h Equipment with terminal TD (e. g. tachometer,
WlO Battery ground fuel pump relay, CFI control module, compressor
Wll Engtne ground (electric cable bolted on) cutoff control module)
x11 Diagnosis socket’terminal block terminal TD z Connector sleeve (soldered connector in wiring
harness)

15.0924-540! 17
 EXIT

15-542 Testing breakerless transistorized ignition (TSZ)

Precedmg work:
Testing, adjusting engme (07.3-l 10)

Precondition for test

Spark plugs, ignition cables, distributor rotor Test e. g. by visual inspection, measuring
and distributor cap in proper mechanical and resistance and ignition oscilloscope.
electrical condition.

Connection diagram for engine tester with oscilloscope

Gl Battery S512 Breakerless dlstnbulor
Nl/l Transrstonzed ignltlon (TSZ) control module Tl lgmtlon co11
R4 Spark plugs Xl 1 Dtagnostlc connector/terminal block termmal TD
030 Engine tester with oscilloscope

15 0924442 1
 EXIT

Note
Pay attention to the safety precautions
(15-0505) when performing work on the ignition
system. Switch off ignition when unplugging and
connecting the contacters at the TSZ control
module.

Special tool

1201 589 00 99 00)

Commercially available testers

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

Engine tester e. g. Hermann, Datascope 9800

Bosch, MOT 3011400
Sun, 2110
BEAR, D AC E

Test data

Resistances (test values at approx. 20 “C)

Ignition coil primary (terminals 1 and 15) n 0.5-0.9
Ignition coil secondary (terminals 1 and 4) kQ IS-16
Induction sensor Coil resistance
(terminals 7 and 31d) n 600f 100
Insulation (terminal 7 and ground) k!J > 200
Distributor cap per terminal, sz 700-l 300
distributor rotor,
spark plug connector

15.0924-54212
 EXIT

Voltages, engine not running, ignition switched off

Terminals 15 and 31 (contacts 5 and 2 diagnostic connector) Battery voltage

Between terminals 15 and 1

(contacts 5 and 4 diagnostic connector) V

Dwell angle
At starter speed 17-34”

15.092444213
 EXIT

nition oint ITSi national vers ioln

-I
Engine Type
fue13)
Distributor
3osch No.

1
Test and setting
value ‘) of
gnition point in
“CKA BTDC + 1
tiithout;with
Jacuum
Ignition advance in “CKP Vacuum
BTDC
kthout vacuum
advance
of ignitior
ooint in
“WA
3TDC at
-----I
Installed
value of
ignition
point in
“WA
before
TDC at
starting
speed
without
vacuum
1.5001 idling Idling 1500; 3000:’ 15001
nin min min nin

un- I 237 002 094 5 with 19-252) ?4-28*)

102.961 leaded
1984

102.961 I 237 002 098 22-26*) 14-l 8*)

102.985
as of
1983
) If normi :ompressron engines are opera I with fuc?I c)f less thar 38 RON mm. 88 I IN) or low-compressron engrnes wrtn
fuel of less than 92 RON (min. 82 MON), the lgnrtron pornt should be retar sd and adapted to the octane number of the fuel
used. A reference value for thus adjustment IS: retard rgnrtron pornt by 1 - 2” CKA per 1 RON. The maxImum retardabon must
not exceed 6” CKA.
The lgnrtlon correctlon should be entered by hand on the “engine settrng data” InformatIon plate.
The result IS reduced power output and increased fuel consumptron. In addrtron, the engrne must not be operated at full load.
The full ignltlon advance should be re-set as soon as fuel of the specified octane number IS agaln avallable.
2) Test at 3500imln.
3) Vehicles wtth catalytic converter must be operated with unleaded fuel.
4) This value must be identrcal at normal operatrng temperature of engrne with and wrthout vacuum: test ignrtron advance In the
warmrng-uo phase if necessary (15-543).
 EXIT

Note Key to symbols:

If the specified value of a test step, e. g. test q Multimeter direct voltage mode
step 1.0, is in order, continue immediately with q Multimeter resistance mode
test step 2.0. -O_ Oscilloscope
--x Contact
If the specified value of step 1.0 is not in order, Connector
it is then necessary to continue with step 1.1. T Ground

On/off Test step/ Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readout

1.0 Nl!l Ignition: ON Battery Test cables and contacts

Voltage 31 -(-++- 15 voltage according to wiring diagram
supply (from battery via ignition
lock to TSZ control
module), ground connection
(W3).

2.0 Connector Ignition: OFF 600 Sz Replace induction sensor.

Induction 31d J++- 7 Detach +100 !A Test cables and contacts
sensor induction from TSZ control module to
sensor distributor.
connector at
TSZ control
module (green
cable).
............ ........................ ....................... ............... . . . . . . . . . . .._......_.......................
2.1 Sensor coil Detach 2200 kR Replace induction sensor.
Insulation of _l-*_ induction
sensor coil sensor cable
connector at
distributor.

3.0 Engine tester Engine: Start 7-34” Dwell angle not to

Dwell angle tolerance:
of (TD replace TSZ control
signal) module. No dwell angle:
test stall current cutoff.
Pay attention to notes on
TD signal (15-512).

15.0924-54215
 EXIT

On/off Test step/ Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readout

4.0 Ignition: ON Replace TSZ control

Stall current Cir. 1 &Cir. module and ignition coil.
cutoff
Engine: Start Test cables and contacts
from TSZ control module to
ignition coil or replace TSZ
control module.
Replace ignition coil.
.................. . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................
>ov
,.............. ............................................
4.1 Tl Ignition: OFF 0.5 Replace ignition coil.
Ignition coil Cir. 1 *Cir. Unscrew 0.9 51
primary Tl cables at
ignition coil.

5.0 Engine tester Engine: Start Replace TSZ control

Primary module.
voltage Scope image
Primary parade

6.0 Engine: Start see Replace TSZ control

Primary diagram module.
current Scope image
limiting Secondary
overlap

7.0 Engine tester Engine: Start ha kv Test ignition cable terminal

Ignition 4, distributor rotor,
voltage at Scope image distributor cap and ignition
terminal 4 Secondary parade coil.
ignition coil
.................... . . . . . . . . . . . . . . . . . . . . . . ........................ . . . . . . . . . . ............................................
7.1 Tl 332 Ignition: OFF <l Q Replace ignition cable
Ignition Cir. 4 * Cir. 4 Detach ignition terminal 4.
cable cable terminal
terminal 4 4 at ignition
coil and
distributor cap.

15.0924-54216
 EXIT

On/off Test stepi Test connection Operation/ Specifi- Possible cause/Remedy

ratio Test scope Requirement cation
readou

7.2 Distributor Ignition: OFF 700- Replace distributor rotor.

Distributor rotor Remove 1300 a
rotor * distributor cap and
Widdle Peak visual
inspec-
tion
............... .......................... .................... ............ ...........................................
7.3 S5l2 Ignition: OFF 700- Replace distributor cap.
Distributor Cir. 4 * Car- Distributor cap 1300 n
cap bon removed and per
detach ignition terminal
cable terminal and
4. visual
inspec-
tion
.................. . . . . . . . . . . . . . . . . . . . . . . . . .................. . . .....................................
7.4 Asual inspection Ignition: OFF Distributor cap,
Distributor Remove distributor rotor has cracks.
cap/rotor distributor cap.
............. ,....................,.,.....,. .................. . . . . . . ..f..................................
7.6 Ignition: OFF 6-16 kQ Replace ignition coil.
Ignition coil Zir. 4 + Cir. 1 Unscrew
secondary cables at
Tl ignition coil.
8.0 Engine tester Engine: Start ~6 kV Test distributor cap,
Ignition distributor rotor,
voltage at Scope image ignition cables with spark
single Secondary parade plugs.
cylinder iigh voltage clamp
at cylinder ignition
:able (e. g. cylinder
3)
........... ,.....,............. . . . . . . . . . . . . . . . . . . . . . . . . ..................... ............ ...........................................
8.1 -=@- Ignition: OFF 700- Replace ignition cable with
Ignition gnition Spark Detach ignition 1300 a spark plug connector.
cable with :able plug cable with
spark plug connector spark plug
connector connector at
spark plug and
distributor.

15.0924-542f7
 EXIT

On/off Test step/ Test connection Operation/ Specifi- possible cause/Remedy

ratio Test scope Requirement :ation
readou

3.2 Visual inspection Ignition: OFF 3ectrod Replace according to

Spark plugs Remove spark gap condition.
plugs. I.8 mm

3.0 Engine tester Engine: see table Setting of vacuum advance

gnition point Test at normal Ignition advance in warm-up
operating chase
temperature at (15-545).
specified
speeds and
with/without
vacuum.
. . . . . . . . . . . . . . . . . . . . . .._.................. . . . . . ...........................
Engine tester Engine: gnition Vacuum hose leaking
vacuum Normal Ioint Connection at intake
advance operating ,etarded manifold blocked.
temperature, Vacuum unit faulty.
speed approx. Distributor faulty.
1500:min.

Detach gnition
vacuum hose. Ioint
Fit on vacuum idvance
hose.

15.0924-54218
 EXIT

U(kV)

i
5
I

I __ SchlleO.j- ~ -- -
t

45 40. 35’ 30' 25 20' 153 10 5' 6 Zyl

+ 1 I 1 /I I 1 II
90 80 70' 60 ’ 50 40 30' 20 10. 4 Zyl.
I
T I 1
60 50 40 30 20 6 Zyl.

L
Current hmltlng

induction sensor connector ,---31d

Test resistance between connections 7 and 31d.

PlS-0240-13

Test insulation of induction sensor coil to ground

( 2200 kQ).

15.0924-54219
 EXIT

Ignition coil (Tl)

If plug (arrow) pressed out, replace.

r
x11

Tl

TSZ wiring diagram

Nl/l Transrstonzed rgnrtfon control module

5512 Drstnbutor
Tl lgnrtron co11
w3 Ground, front left wheelhouse (ignttion cod)
x11 Dragnostfc connector/terminal block termfnal TD
a Equipment wrth termfnal TD
(e. g. tachometer, fuel pump relay, CFI control module,
compressor cutout control module)
b Voltage supply terminal 30
Model 201: to fuse 13 vta electrical center coupling S,
contact 11
C Voltage supply terminal 15, unfused
Model 201: electrical center coupling S. contact 4
 EXIT

15-543 Testing ignition advance in warm-up phase (only TSZ)

Engine 102.961 Basic Version

P15-0201-37

Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connect (16415).

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . warm up to approx. 80 “C engine coolant
temperature. Run at idle speed and take reading
of ignition point.
Vacuum line ......................,.... white/red, detach at therm0 valve (3).
The ignition point must not alter.

If the ignition point alters, check whether

vacuum lines are correctly laid and leaktight.
Check therm0 valve. The therm0 valve should
have clear passage above approx. 60 “C.

15.0924-5431
 EXIT

Vacuum line . . . . . . . . . . . . , . . . . , . whitelred, detach at thermovalve (3) and plug

the vacuum connection at thermovalve. The
ignition point must be advanced approx. 8 -
12”.

If the ignition point is not advanced, check

restrictor (1) for clear passage, check valve (2)
and vacuum unit at distributor for leaktightness.

Function description
To improve the perfprmance in the warm-up
phase, the ignition point is advanced 8 - 12”
CKA via the vacuum unit at the distributor up to
a coolant temperature of approx. + 60 “C in
addition to the centrifugal advance.

Below approx. 60 “C engine coolant temperature

(therm0 valve closed) the vacuum passes from
the intake manrfold via the restrictor (1) and
check valve (2) to the vacuum unit at the
distributor when the engine starts.

The check valve (2) ensures that the maximum

vacuum IS retained at the distributor ‘(also when
accelerating) which results in the additional
ignrtion advance via the vacuum unit.

Above approx. 60 “C the thermovalve (3) opens,

and the vacuum is reduced at idle speed to the
throttle valve assembly.

A restrictor (1) is installed to ensure that the

vacuum for the other connected components
cannot escape through the connection at the
intake manifold at idle speed.
 EXIT

etrofitting corrugated hoses for ignition cables

Corrugated hoses (a) 0 13 mm and

(b)BlOmm . . . . . . . . . . . . . . . . . . . . . . . . . . cut to size according to table as protection
against beech martens biting through cables.
Push corrugated cables (a) 0 13 mm and (b)
0 10 mm approx. 10 mm together.
Spark plug connector . . . . . . . . . . . . . . . . . . . . unplug, plug in. Unscrew spark plug connector
from ignition cables, screw on.
Push corrugated hoses onto ignition cables.
Angled connector at distributor .............. unplug, plug in. Unscrew angled connector from
ignition cables, screw on.
Push corrugated hoses appropriate length onto
ignition cables.

Length (mm)* Assignment

Corrugated hose 0 10 mm (total length approx. 1260 mm)

4 110 Ignition cable at spark plug connector

2 125 Ignition cable at distributor, cylinders 1 and 4
1 175 Ignition cable at distributor, cylinder 2
1 75 Ignition cable at distributor, cylinder 3
1 320 Ignition cable from distributor to ignition coil
Corrugated hose 0 13 mm (total length approx. 300 mm)

10 30 1 ea. at each spark plug and angled connector

* Maximum length; shorten ignition cable accordingly, if necessary.

15.0924-547/l
 EXIT

Parts
Designation Part No.
Corrugated hose (10 mm diameter) running meters 000 159 01 83
Corrugated hose (13 mm diameter) running meters 000 159 02 83
Available from: ZEG Germershelm

Time allowed
Basic work: 02-l 508/01
Combined work: 02-l 509/O 1