Warning: Before disconnecting any wires (including high voltage) in the ignition system, the ignition must always be switched off. If this is not done, there is a risk of damage to the integrated circuit parts and electric shock.
Self-monitoring system
1. The FEI control unit is equipped with a fault memory that only functions when the ignition is on. The fault memory is cleared when the ignition is turned off. If a malfunction occurs that could damage the engine, a warning light will illuminate on the instrument panel. The light should come on whenever the ignition is on and go out when the engine is running. If this does not happen, then there is probably damage in the electrical circuit of the engine. However, what can happen if the fuel is too low in octane, because the knock sensor will be continuously activated at the control limit.
2. If the warning light does not illuminate, remove the cover from the fuse block and connect a known-good fuse across the fuel pump relay contacts. The lamp should be lit while the fuse is connected. If not, check wiring for breaks.
3. First check the fuses 13, 24 and 28 and the warning light for correct operation. Also check the intake manifold ground wire. Turn off the air conditioner (if installed), then turn on the ignition.
4. Start the engine and warm up the vehicle for at least five minutes, during which the engine speed should exceed 3000 rpm several times and the accelerator pedal should be fully depressed briefly.
5. Start the engine at idle speed. Do not increase engine speed during the following tests.
6. Connect a known-good fuse across the fuel pump relay test terminals for at least four seconds.
7. Remove the fuse, then count the number of flashes given by the warning lamp. The sequence begins with a beep lasting 2.5 seconds and a pause lasting 2.5 seconds, then pulses are given after 0.5 seconds. Calculate each group of signals and the result will be a number with four digits, after which there will be four signals of 2.5 seconds. A pause will indicate the end of the damage warning signal. If no damage is found, code 4444 will be given (four groups of four).
8. Check the amount of damage by repeating the procedure from point 6.
9. Control unit KE III-Jetronic (NG engine) the damage memory can be viewed in the same way. See details in Section 3.
10. NG engine codes are explained in the following table.
- 1111 Control unit
- 2121 Throttle switch I
- 2122 Speed signal from the FEI control unit
- 2123 Throttle switch II
- 2141 Knock control at the limit
- 2142 knock sensor
- 2223 Altitude sensor
- 2232 Air flow meter potentiometer or control unit signal KE III
- 2233 Voltage for load and height signals from the KE III control unit
- 2312 coolant temperature sensor
- 4431 idle speed stabilization valve
- 4444 No damage detected
- 0000 Code Completion
11. Explanations of flashing codes for the PS engine are given in the following table.
- 2141 Detonation control limit
- 2142 Knock sensor defective
- 2222 FEI control unit pressure sensor defective or throttle switch II defective
- 2221 Defective intake manifold vacuum hose to FEI control unit
- 2312 coolant temperature sensor
- 4444 No damage detected
- 0000 Code Completion
12. Verification of individual details is given in the following paragraphs. Before attempting to remove any parts, the bonding wiring must first be checked. Note that incorrect ignition timing can cause the knock sensor to fail.
Ignition coil
13. Be guided Chapter 6, paragraphs 1-4, but note the resistances given in Specifications.
FEI control unit
14. If the self-monitoring system shows damage in the control unit, then it must be replaced. However, the following procedure can be carried out on the PS engine.
15. First check that the knock sensor is working.
16. Start the engine at idle speed.
17. With a strobe light connected, check the ignition timing and measure it.
18. With the engine running, remove the white vacuum hose from the throttle (i.e. FEI control unit hose), then increase the engine speed to 3000 rpm.
19. Note the ignition timing setting and derive from this the value noted in point 17. The result should be approximately 7°.
20. Replace the control unit if the value given in point 19 is not obtained.
Distributor hall sensor
21. The following test is necessary if there is no spark from the ignition coil.
22. Squeeze the spring clip, disconnect the wiring connector from the power output unit on the ignition coil.
23. Connect a diode tester between terminals 2 and 3 on the connector.
24. Turn the engine over with the starter, the LED should light up, indicating that the Hall effect sensor is functioning properly.
25. If the LED is off, connect a voltmeter (preferably digital) between the two outer clips on the connector. Turn on the ignition, the voltmeter should show at least 9 volts.
26. Reconnect the connector, then pull back the rubber boot and expose the clip.
27. Connect a diode tester between the center clamp connector and the positive battery terminal.
28. Turn the engine over with the starter, the LED should light up, indicating that the Hall sensor is functioning properly. If the LED does not light up, either the Hall sensor or the FEI control unit is faulty.
Power output block
29. First check that the ignition coil is in good condition, guided Chapter 6.
30. Squeeze the spring clip, disconnect the wiring connector from the power output unit on the ignition coil.
31. Turn on the ignition, connect the voltmeter (preferably digital) between the two outer clips on the connector. If the battery voltage is not registered, check the wiring.
32. Connect a diode tester between terminals 2 and 3 on the connector.
33. Turn the engine over with the starter, the LED should light up, indicating that the Hall effect sensor is functioning properly. If not, check the Hall sensor.
34. Turn off the ignition and reconnect the connector.
35. Disconnect the wiring from the Hall sensor on the distributor.
36. Connect a voltmeter (preferably digital) between clamps 1 (-) and 15 (+) on the ignition coil, then turn on the ignition.
37. On the PS motor, first the voltage should be 2 volts, then go down to zero within 1-2 seconds.
38. Connect the center clamp of the Hall sensor wiring to ground. The voltage should briefly rise to 2 volts, then drop to zero within 1-2 seconds.
39. If not, replace the power output unit or control unit. Also check for sealant leaks from the ignition coil. If yes, replace the ignition coil.
FEI control unit multi-pin plug
40. The following tests require the use of a digital multimeter, which must be set to the correct measuring range before connecting to the clamps, otherwise electrical parts may be damaged.
41. Make sure the battery is in good condition. Switch off the ignition.
42. Remove the trim on the right side of the driver.
43. Remove the screws and lower the block.
44. Disconnect the multi-pin plug and, if necessary, the vacuum hose.
45. Guided by fig. 4.8, connect a voltmeter between terminals 3 and 5. The instrument should show battery voltage.
46. Connect a voltmeter between terminals 3 and 6. With the ignition on and throttle closed, the meter should indicate battery voltage.
47. Connect a voltmeter between terminals 3 and 8. With the ignition on and throttle wide open, the meter should indicate battery voltage.
48. Connect a voltmeter between terminals 3 and 10. With the ignition on, the meter should indicate battery voltage.
49. Connect a voltmeter between terminals 4 and 5. With the ignition on and with the fuel pump relay contacts connected, the meter should indicate battery voltage.
50. Switch the instrument to resistance measurement mode. Disconnect the multi-pin plug from the KE-Jetronic control unit, then connect an ohmmeter between terminal 2 on the FEI control unit and terminal 25 on the KE-Jetronic control unit. The device should show 0 ohms.
51. Disconnect the multi-pin plug of the power output unit, short-circuit terminals 2 and 3. Connect an ohmmeter between terminals 3 and 12. The instrument should indicate 0 Ω.
52. Disconnect the wire contact of the knock sensor and close all three clamps. Connect an ohmmeter between terminals 13 and 14. The meter should read 0 ohm.
53. Disconnect the wire contact from the Hall sensor and close the outer clamps. Connect an ohmmeter between terminals 7 and 15. The meter should read 0 ohm.
54. Short-circuit the center and brown-white wires on the Hall sensor. Connect an ohmmeter between terminals 7 and 9. The meter should read 0 ohm.
55. Check that the wiring is connected to the temperature sensor. Connect an ohmmeter between terminals 3 and 1. The resistance must be within the tolerances shown in fig. 4.9 according to temperature.
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