Volvo 819 E Service Manual
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Volvo 819 E Service Manual

Volvo 819 E Service Manual

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TP 31397/1
Section 2 (28)
Ignition systems
700
1982-
July 1989

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  • Page 1 Section 2 (28) Ignition systems 1982- July 1989 TP 31397/1...
  • Page 2 This manual may therefore show ich do not apply to ca rs in you r count Volvo owners planning to export their carls) to another country should investigate the applicable safety and ex- haust emission requirements.

  • Page 3: Table Of Contents

    Group Ignition systems Contents Group 28 Ignition systems Contents Introduction Design and function: Overview Review electronic ignition systems ......•... Review of electronic ignition systems (type EZ-K ..•. . . • . . . General Function ignition system combustion theory brief...
  • Page 4 Group 28 Ignition systems Contents Test ipment ..• ..•..• ..•...••..•..•..•..••..•..•..Instructions ......•...

  • Page 5: Introduction

    (deceleration) conditions ignition retardation in individual cylinders eliminate knock. Volvo markets a wide range of models with a series of engine options. This, combined with rapid developments the field of electronics, means that a wide...

  • Page 6: Design And Function: Overview

    Group Ignit;on systems Design function Overview Review of electronic ignition systems - I 28" IlENIX The above figure shows major componen ts of each of the systems described below. Summary Control system The control unit (A ) houses electronic circuits and various program functions needed to compute...
  • Page 7 Group Ignition systems Design and function electronic ignition systems TSZ: electronic ignition system in which function performed by contact breaker points in conventional sys- tems carried by an inductive pulse generator. (Roughly translated, the abbreviation TSZ which stands for Transistor Spolen lundung - means 'Transisto rized...

  • Page 8: Ez-K

    Group Ignition systems Design function - Overview Review of electronic ignition systems - II (Type EZ-K and Rex-I) 102K 117K 118K 115K 116K REX- The illustration shows the main components of type EZ-K and Aex-I ignition systems. Common features An abbreviation of the German term Elektronischer Zundung m it Klopfregulung (roughly, 'Electronic ignition...
  • Page 9 EZ-K system to be used by Volvo, EZ-102K remained in production only for a year before being superseded by more up-to-date variants according as the new family of engines was introduced.
  • Page 10 Group Ignition systems Design and function Overview YEAR ENGINE IGNITION SYSTEM B 28 A 82-85 TSZ-4 82-86 82-86 B 19 E TZ-28H TZ-28H TZ-28H MOTRON'C 8200 MOTRONIC MOTRONIC 200 K RENI REX-I 84 (USA) l02K 8230 l17K EZ· l17K 118K EZ-118K 85-86 EZ-11...

  • Page 11: General

    Group Ignition systems Design and function - General General Function of ignition system; combustion theory in brief Correct ignition tim ing The function ignition system is to ignite compressed fuel/air mixture each cylinder at exactly he cor- rect instant. Ignition is followed by propagation of a...
  • Page 12 Group Ignition systems Design and function General late ignition Late ign ition reduces engine power since pist on is ravelling downwards from when the pressure ise oc- curs. result, engine does not ilize he full energy content of the fuel Although concentrations unde-...

  • Page 13: Ignition Systems - Basic Parameters

    Group Ignition systems Design and function - General Ignition systems - basic parameters The ignition system control unit must be supplied with certain basic information in order compute the frequency rate ignition pulses must be delivered the spark plugs, when relation to the position the par- icula...
  • Page 14 Group Ignition systems Desig function - General Fig. 1 'Hot' Fig. 2 'Cold' plug • Spark plugs : Use of correct type of spark plug, correctly insta lled replaced at the re commend ed intervals, essential to he satisfactory operation of system.

  • Page 15: Contact-Breaker Versus Electronic Systems

    Group Ignition systems Design and function General '0· 0·1 ° Contact-breaker versus electronic systems Figure {AI shows the tim curve tact-breaker ignition system, illustrates settings with wh an electronic system is programmed, in the form a three-dimensional map_In each case, both engine speed and load are taken...

  • Page 16: Components

    Group Ignition systems Design and function - Components Components Control unit control unit in an electronic ignition system continuously computes the optimum based information supplied by the various sensors, which combine provide unit with an extremely accurate picture of engine run- ning conditions.
  • Page 17 Group Ignition systems Design and function Components Output unit digital information supplied by microprocessor fed 10 output unit conversion into the ignition lses fed to th power stage. (This may either integral part he control unit or a separate unit Depend program selected at he particular instant,...

  • Page 18: Control Unit, Power Stage And Ignition Coil Configurations

    Group Ignition systems Design function Components Control unit, power stage ignition coil configurations control unit. power stage ignition coil configuration may take one of four different forms. a general rule, con trol unit delivers ignition pulses to the power stage (which controls the current in...

  • Page 19: Power Stage And Ignition Coil

    Group 28 Ignition systems Design and function Components Power stage and ignition coil Function of power stage power functions as an electronic switch controlling current in ignition coil command from control unit (31. (The illustration shows the components of EZ-K system. In the Renix-F system, the power stage integral...
  • Page 20 Group Ignition system Design and funct - Components REX-I General Since it not technically practical to control unit to regulate the relatively h igh current ignition coil pri· mary, this function performed by a power stage which employs control signals from the control unit to vary both charging time coil...

  • Page 21: Distributor

    Group Ignition systems Design and function Components Distributor Function The function of the distributor conduct the high-tension pulse from the ignition coil the appropriate spark plug. A distributor fitted with Hall generator also provides information on engine speed with the aid of the trigger rotor driven by the distributor shaft.

  • Page 22: Speed And Crankshaft Position Information

    Group Ignition systems Design and function - Speed and crankshaft position information Speed and crankshaft position information Hall generator Function location The Hall generator (1) supplies control uni with information on engine speed crankshaft position. The de- vice mounted inside distributor cap.
  • Page 23 Group Ignition systems Design and function Speed and crankshah position information Signal increases from 0 to 5 Control unit starts to compule tim ing of ne)(l ignition pulse. A2 Signal from 5 to Conlro unit commences ignition counldown and delivers ignition pulse as computed.

  • Page 24: Speed/Position Pick-Up And Flywheel Configuration

    Group Ignition systems Design and function Speed and crankshaft position information Inductive speed/position pick-up Function location purpose of the speed/position pick-up (1) is to supply the control unit with information on engine speed crankshah position. The pick-u mounted close to the flywheel carrier plate automatic models), the...
  • Page 25 Group 28 Ignition systems Design and ction - Speed and crankshaft position information Advantages Ignition systems employing inductive speed/position pick-ups pulse generators as they also known) provide more accurate speed and crankshaft position signals than th equipped w ith Hal generators to the fact that former...
  • Page 26 Unlike starter motor ring gear, which mounted on the flywheel. the profile used signal generation is usually an integral part of the component. Volvo ignition systems are supplied mainly by manufacturers Bosch of Germany and Bendix, France. Among several different profiles must be used. while other factors.

  • Page 27: Load Information

    Group Ignition systems Design and function - Engine (oad in formatio Engine load information Intake manifold vacuum The control unit supplied with information on engine load through the from intake manifold. load information through vacuum line When the engine load is low. throttle only panially open...

  • Page 28: Fuel Injection System Control Unit

    Group Ignition systems Design ction Engine load information Fuel injection system control unit (LH-2.1. LH-2.2. LH-2.4) The fuel syst em con unit (1j supplies ignition system control unit with info rmation on engine load. based on signals from an air mass meter (3), the quant induction being...
  • Page 29 Group Ignition systems Design function Regina fuel injection REGINA REX-I REX-I Regina fuel injection system General njection system con trol unit suppl the ignition system control unit with information on engine load- acting, other words, as a 'sensor' for the latter.

  • Page 30: Compensation Functions

    Group Ignirion sysrems Design and function Compensation functions Compensation functions Theory of knock Knock is caused onation fuel/air mixture in the combustion chamber. What knock Detonation may occur either aher las before (as in the mix- ture is ignited at two more points chamber combustion progresses...
  • Page 31 Group Igni rion sysrems Design and function functions Knock threshold Under certain condit ions, however, combination of high perlormance and fuel consumption demands that the engine runs as close as possible the knock threshold. closer curve to the threshold higher efficiency of fuel utilization.

  • Page 32: Knock Sensor

    Group Ignition systems Design and function - Compensation functions Knock sensor Function knock sensor used to detect engine knock, enabling he con trol unit (2) take the appropriate action by tard ignition. Constructi The knock sensor (see p icture consist of a casing housing a...
  • Page 33 Group Ignition systems Design and function Compensation functio Variants three different types of knock sensor used are illustrated above. Type (B) is used on EZ-102K. and on EZ-117K and EZ-118K systems from 1985 1986. Type (C) is used on EZ-116K systems from 1987 as well...

  • Page 34: Knock Control

    Group Ignition systems Design and function - Compensation functions 0'_2 _3· 0'_4 r--- r--- r--- Knock control The kno ck sensor moniiors the combust process continuo usly. knock occurs, the device delivers a special sig. the control unit, which takes corrective retarding the ignition cylinder...
  • Page 35 Group Ignition systems Design and function - Compensation functions · • • Timing compensation applied different ignition systems to correct knock Fig. 3: basic timing as computed max. knock-controlled retardation knock retardation step re-advance step re-advance interval The following a summary compensation values applied by the various systems...
  • Page 36 Group Ignition systems Design ction - Compensation fu nctions _3° Ii" • ..• .. alllcd REX-I Rex-I Rex-I system, program functions which con trol the tendency engine knock are somewhat differ- ent to those in the EZ-K systems. differences are described following pages.
  • Page 37 Group ignition systems Design function Compensatio n fun ctions Reason for different re-advance rates 'Faster' re-advance rates are possible in lower speed ranges since ition then takes place when the piston closer TDC and risk knock consequently, lower. Fast re-advance more advantageous since it serves increase the mean...
  • Page 38 Group Ignition systems Design and functio n - Compensation functions _8° REX-I Load-controlled retardation Function Since a sudden increase in load greatly reases the risk of knock, control un it incorporates a fun ct n which tards ing sharply brief period under these condit ions.
  • Page 39 Group Ignition systems Design and function Compensation functions · • •• • •• • • _4· • • • • ••• REX-I Adaptive timing retardation Background/funct If normal eng ine load exceeded longer than usual (for example, when the driven up a long ine, is pull-...
  • Page 40 Group Ignition systems Design function - Compensation functions the load temporarily reverts to normal (b) during the adaptive retardation period (e.g. trailer road becomes downhill), timi ng will be returned to the basic setting (a). If engine speed load sub- sequently change (within 10-mi...

  • Page 41: Knock-Controlled Fuel Enrichment

    Group 28 Ignition systems Design and function Compensation functions Knock-controlled fuel enrichment Knock-control fuel enrichment means that the injector opening period extended to enrich the fuel/air mixture, reducing the combustion temperature and brin ging the uncontrolled combustion under control. The function acti- vated if the ignit...

  • Page 42: Throttle Switchlidling Switch

    Group Ignitio systems Design and function Throttle switchlidling (air control) switch Function and location throttle switch supplies signal the ignition system control unit when the throttle fully closed. signal o enable e con rol unit select setting which suit able idli engi ne braking...

  • Page 43: Temperature Sensor

    Group Ignition s ystem Design and function Compensation functions Temperature sensor Function location control unit (1) compensates timing for engine temperature with the aid the temperature sensor (2). This function is used to adjust the timing at temperatures deviating from the normal operating range (i.e.
  • Page 44 Group Ignition systems Design and nction Compensation functions Theory of temperature-compensated timing advance Advancing ignition timing increases the cylinder temperature while reducing exhaust gas temperature. Un- certain conditions, this also yields a reduction temperature. higher cylinder temperature is due to the higher pressure of fuel/air mixture as it is ignited, while the lower exhaust gas...

  • Page 45: Tsz

    Group 28 Ignition systems Design and function - System descriptions B28AJEJF TSZ is type of electronic ignition system in which an inductive pulse generator performs function of the contact points. (Roughly translated, abbreviation TSZ means 'Transistorized coil ignition'.) The pulse generator transmits information t...
  • Page 46 Group Ignition systems Design and function System descriptions TZ·28H TZ-28H B19E1ET, B23E, B230A The 'control unit' (210) consists of a number of electronic circuits operating a power circuit which controls the pri- mary current in the ignition coil. 'control unit' interrupts current on receipt an ignition...

  • Page 47: Renix-F

    Group nition ystems Design function System descriptions RENIX RENIX-F B200K (The above illustration and following text based the B engine used the 740) The system consist an electronic control (1) which is supplied with engine speed and crankshaft position sig- nals by an inductive...
  • Page 48 Group Ignition systems Design and function System descriptions • RENIX-F Control unit connections Supplies speed signals to rev counter (86). Connects con trol unit (406) ground. 3. Receives supply from battery ignition switch {21. 4. Receives engine speed and crankshaft position signals from speed/position pick-up (407...

  • Page 49: Ez·l02K

    Group Ignition systems Design and function - System descriptions 102K EZ-102K 823FT (760,1984 with 823FT) sensors supply control unit (1) with a series of signals which descri be the engine running conditions. control unit uses the signals to compute the optimum timing transmits the necessary ignition pulses to...
  • Page 50 Group Ignition systems Design and function System descriptions 102K Control unit connections 1. Receives power from battery rough ignition switch (2). Transm its speed signal to fuel system control unit (217) Connected to ground by throttle switch (198) when throttle 5.
  • Page 51 Group Ignition systems Design and function System descriptions 117K EZ-117K B230FIFT F/FT; (740 B 230 B 230 control unit computes e optimum timing based on signals from the various sensors and transmits ignition pulses the power stage (2) at exactly the right instant.
  • Page 52 EZ-117K Control unit connections Supplies fault indication signals test term inal (267) when test diode is connected Supplies power to Hall generator distributor (5). supply from battery across ignition switch (2). Grounded by throttle switch (198) when throttle closed Receives load signal from fuel system...

  • Page 53: Ez-118K

    Group Ignition systems Design and ctio System descriptions -118K EZ-118K B200E, B230E and B230K con trol unit computes optimum timing on the basis information from various sensors and trans- /21. mits the necessary ignition pu lses 10 power stage wh ich controls curren the primary winding...
  • Page 54 Group Ignition systems Design and function System descriptions • EZ-118K EZ-1 18K -Idling compensation EZ-118K may be provided with one or idling compensa tion functions ifthe car is equipped with automatic trans- mission and/or air conditioning. If ei ther function is activated, [he control unit will advance the timing at ling...
  • Page 55 Group Ignition systems Design and ction System descriptions EZ-118K EZ·118K - Fuel cut-off 230 K variants only) control unit (1) supplies signal to the solenoid (25) under engine braking condi tion s (when engine speed high) provided that the idling switch (19) simultaneously indicates that the throttle closed.
  • Page 56 Group Ignition systems Design and function System descriptions • " • ,. • " • " • 118K 141114 Control unit connections 3. Supplies fault indication signals to test terminal (267) when test diode is con nected. Supplies power to Hall generator in distributor (5).

  • Page 57: Ez-115K

    Group fgnition systems Design and function - System descriptions EZ-115K EZ-115K B280EIF ntrol unit (1) computes the optimum timing on basis of information from the various sensors and delivers an ignition pulse at exactly the correct instant to the power stage which responds by making and breaking the current in the...
  • Page 58 Group Igni tion s ystems Design and fun ctio System desc riptions 115K EZ-115K - 1 cylinder detector Since the 280 eng ine is equipped w ith twin knock sensors (one r each bank of cylinders), control unit must o distinguish between the two in rder to determ ine which cylinder is kno...
  • Page 59 Group 28 Ignition ystems Design function System descriptions • • • • " • • '.71 EZ-115K Control unit connections Receives signal from temperature sensor (84) (7/16). Transmits fault signals to test term inal (417) (17/4) when test d iode connected.

  • Page 60: Ez-116K

    Group 28 Ignition systems Design and function System descriptions EZ-116K B 234 B204E and B230F control un it computes optimum timing basis of information from the arious sensors. power stage (2) makes breaks the rrent in the primary winding the ignition coil (3) in response ignition pulses...
  • Page 61 Group 28 Igni tio systems Design and function System descriptions • • • • • • EZ-116K Control unit connections Transmits signals diagnostic unit (482) during fault tracing. 2. Receives analogue engine temperature signal from emperature sensor (84). Transmits knock-co ntrolled fuel enrichment signal...
  • Page 62 Group Ignition systems Design function - System descriptions • • • b ,.B REX-I Control unit connections Transmits signals to diagnostic un it (482) when fault traci Signals are transmined diagnostic it when ap- propriate diagnostic functions are selected temperature signal from temperature sensor...
  • Page 63 Group Ignition systems Design and function System descriptions • • Banery t98 Thronle switch 218 Knock sensor 5 Distributor control 6 Spark plug Speed/position pick-up warning lamp Power stag elignit ion coil Coolanttemperalure sensor Regina control unit 86 Speedometer 482 Diagnostic unit 16.
  • Page 64 Group Ignition systems Design and function - System descriptions EZ-116K EZ-116K end Rex-I - Oiegnostic system The EZ-116K1Rex-1control unit (1) incorporates diagnostic which greatly facilitates fault tracing and monitor- ing of system. e system features two separate test functions self-diagnostic function whereby the diag- nostic...
  • Page 65 Group Ignition systems Design and function System descriptions Functional test program system monitors the operation certain components swil ches operation items question. When the component or switch is operated with a procedure, the LED displays a 3-digit code in confirma- tion.
  • Page 66 Group Ignition systems Design and function System descriptions EZ-116K steps must be carried out ensure codes: - The coding cable must be connected socket 6. - The ignition must be switched on without starting engine (i.e. the key must be turned to switch position II). Pushbutton A must then be pushed once or twice·...
  • Page 67 Group Ignition systems Design and function - System descriptions • The above figures illustrate construction of the diagnostic unit (1), connections, sequence of events which occurs in course of commun ication between unit and ition system control unit during fault tracing Construction and connections (Picture...
  • Page 68 Group 28 Ignition systems Design and function System descriptions t12V II ' Signels to diegnostic unit (Picture In this mode, the diagnostic circuit in the control unit reads the selected test function program and determines, as ap- propriate, which fault/acknowledgement code is to be displayed by the LED to report fault...
  • Page 69 652. voltage. currenl and resistance measurement 9724 Ohmmeter/ diode testet' for resistance measurement ..Volvo Mono-Tester for measurement timing angle 992' checking timing Plain text reader - for displaying fault codes in plain text...
  • Page 70 Group Ignition systems General instructions Instructions for work on ignition systems Resistance measurement must be alsconnected from terminals items to be tested. approx. 20"C (68·FI. NOTE: The expanston plug on 8 venically installed tion coil must be provided with a plastic cap.
  • Page 71 Group Ignition systems General instructions Important Warning! The ignilion system operates at high power and dangerous voltage levels in both the low and high- tension circuits. Dangerous voltages are present at points system, including connectors etc. Switch off the ignition: when connecting and disconnecting...
  • Page 72 Group Ignition systems Specifications Group 28 Ignition system Type..• . . . • Breakerless Firing order: B28, B280 1-6-3-5-2-4 Other engines ..•..• ..•..1-3-4-2 Ignition timing (BTDC with vacuum advance unit disconnected) 12.5 .7 rls Engine...
  • Page 73 Group Ignition systems Speci fications Ignition coil Primary nding resistance (across term inals 1 and 8l9E, B19ET. B23E. B23FT. B230A 0.6-0,90 B23ET 0.50 B 200 B 230 B 230 B 230 280. 0.6-0,90 B2OOET, B230ET B230F 0,35-0,650 Secondary winding resistance (across termi nal 1 and HT term...
  • Page 74 ..•..• gap, or-stator, ....• .• 828A/E Bosch part No .....•..0237 402 013 Volvo part No......•..• 269191 Direction rotation Clockwise Pulse generator coil resistance, ..• •..540-660 gap, rotor-stator, min.
  • Page 75 Group 28 Ignition systems Specifications Centrifugal advance unit B19E, B23E 12.5± Total advance, distributor degrees Advance commences at distributor speed, (r/mi (400-500) Settings 5° at distributor speed, ..... • • ..• • ..20-26 (1200-1560) (r/min) ....•.. • ..10"...
  • Page 76 Group 28 Ignition systems Specifications Settings ..•..•..16.5-20.5 dist ributor speed, (r/min) • (1000-1250) distr ibutor speed, 25-29 (r/m !n ....•..(1500--1750) Max. advance at dist ributor speed, 31.7 (r/min ) ....•..(1900) Vacuum advance unit B19E, B23E Positive Direction advance ±...
  • Page 77 Group Ignition systems Specifications Timing curves B230A Direction of advance Positive • • Total 7.5±1 commences at vacuum. mm Hg .03-2.80 in Hg) 165-210 '" 5· vacuum, mm Hg (3 .18-4 • vacuum, mm Hg ..•..advance at vacuum, mm Hg (4.63 •...
  • Page 78 Group Ignition systems Specifications Ignition leads Engine B 19E B19ET 270 479·9 11984) 275690-6 (1984) 270479· 9 (1984) B23ET 270479· (1984) B23FT 828A 275688-0 (1984). 270 560-6 (1985-87) 275689-8 (1984). 270 561-4 (1985-87) B2SE B28F 275689-8 (1984). 270 561-4 (1985-87) 270748·7 (1985-87).
  • Page 79 Group 28 Ignition systems Specifications EZ-115K B2BOE B2BOE B2BOF Engine Scandinavia 827-3 1 389 597-4 1 274828-1 Control unit 1 332 584-0 332 584-0 Power stage 332 584-0 Knock sensors 367 643-2 367 643-2 643-2 Temperature sensa 346 030-8 346 030-8 346030-8 Throttle switch...
  • Page 80 Group Ignition systems Fault tracing Breakerless ignition systems Contents Pa•• Ignition coil and ignition leads A1-A3 Distributor - general 81-811 82-86 Distributor cap and rotor arm ....• ..83-84 Timing advance ....• •..•.... 85-811 Static timing ..
  • Page 81 Group Ignition systems Fault tracing 137 S26 6-cylinder 4·cylinder...
  • Page 82 Group Ignition systems Fault tracing, TZ-28H Place distributor into Remove rotor arm. Remove trigger rotor irclip. Remove trigger rotor using two round-bladed screw- drivers (dia. .20'"). upwards. NOTE: Do not press against rotor vanes damage result. Take care ensure that locking p fall distributor.
  • Page 83 Group Ignition systems Fault tracing, TZ-28H Turn Hall generator counterclockwise pos- sible. Release and remove vacuum advance unit. lift Hall generator unit and connector out of distrib- utor. Install Hall generator unit and connector n distributor secure loosely w ith two screws.
  • Page 84 Group Igni tion ystems Fault trBcing, TZ·28H Insert and tighten all screws. Insert connector securing pin trigger rotor locking pin circlip TOe. Ensure that eylinder is Turn rotor arm clockwise about BO° from mark dis- tributor housing Place distributor position. Rotor arm should be aligned with...
  • Page 85 Group Ignition systems Faul tracing, H. Fault tracing - EZ-102K The following procedure provides a systematic check inspection of complete ignition system If the engine started, commence fault tracing w ith the test diode establish the source fault. Otherwise. proceed page 136.
  • Page 86 Group 28 nition systems Fault tracing, EZ·102K Symptom: Engine does not start Fault tracing First check whether or not the fault is in the ignition system checking a spark at one of the plugs. Disconnect a plug lead. connect it to a spare plug operate starter...
  • Page 87 Group Ignition systems Fault tracing, EZ-102K Fault tracing, EZ-102K Check secu of ground leads at terminals on intake manifold (twin black leads). Check LT supply to ignition coil and power stage Switch ignition. Measure voltage between ignition coil terminal 15 and ground.
  • Page 88 Group Ignition systems Fault tracing, 102K ignition coil primary winding and leads Measure resistance between termina ls 1 and power unit connector. (This equiva lent of measuring re sistance across ign it ion coil termina 1 and clud ing leads.l (See w ng diagram Readi...
  • Page 89 Group ignition s ys tems Fault tracing, EZ·102K stage ground lead easure resistance between connector terminal 2 ground. Resistance should be ohm. reading is different : Check lead (see wiring diagram). Ground term ina l is intake manifold. Check screen connections Check that...
  • Page 90 EZ-117K Ignition system (8230 FIFT) • • • • " " " " Bl.R·W Y·R...
  • Page 91 EZ-117K Ignition system (8230 FIFT) Clim control Connector, 1 Battery RH A-post Fuel system control unit switch Connector. A-post 218 Knock sensor Ignition coil houling Connector 81 LH wheel 5 Distributor 224 Radiator thermostat Ground term inal on intake m.nifold Con1rol unit 6 Spark...
  • Page 92 EZ-118K Ignition system (8230 K, 8200/230 E) " " " " • • " " • " " " " " • R·W...
  • Page 93 EZ-118K Ignition system (B 230 K, B 200/230 E) Radiator fan thermostat Connector, RH A-post 1 Battery Control unit Ignition switch Connector, LH A-post 267 Test connector Ignition coil Connector at LH wheel housing 271 fuel cut-off solenoid 5 Distributor Ground termina intake manifold Microswitch...
  • Page 94 EZ-116K Ignition system (B 234 F, B 204 E) OR-R " " • " , • • " , " • • " " •...
  • Page 95 EZ-116K Ignition system (B234F, B204E) Battery 218 Knock sensor A-post Ignition 260 Control unit Connector, LH A-post LH wheel nousing 13 Pulse generator Ignition coil Distributor Ground term inal intake m.nifold 472 Fuel system control unit bulkhead 6 Sparit plugs Diagnostic unit 11 Fusebox LH wheel...
  • Page 96 Group Ignition system Fault tracing, Rex·1 N. Fault tracing - Rex-I with self-diagnostics B 230 F engine (Federal USA) The Rex-l ignition system features self-diagnostics, the functions which are incorporated control All fault codes will be erased NOTE the busbar 30 supply disconnected.
  • Page 97 Group Ignition systems lt tracing, Rex-' Control function 1 fault Control unit fault . Replace unit. Knock sensor signal absent. See N25. Fuel system load signal absent. N23. Pulse generator absent intermittentl y. See N24. Engine temperatu sensor faulty. Control function 2 Switch on ignition.
  • Page 98 Group Ignition s ystems Faul tracing, Rex-' Engine does not start Check control unit and power stage ground connections Grou nd leads (brown and black) should be tightened secu rely to terminals on ntake anifold. Check for spark at spark plugs Caution! Fuel system control...
  • Page 99 Group Ignition system Fault tracing, Rex-' Undo control unit The ignition must be switched whenever the connector disconnected reconnect- Remove panel under leh-hand side instrument panel. Release connector catch and separate connector from control Remove protective cover from connector Caution insert inst rument probes...
  • Page 100 Group Ig ni tion system Fault tracing, Rex-I Checking diagnostic unit Switch on ignition Connect test lead socket Measure voltage between control unit connector termi- nail (yellow/red and ground Instrument should read approx. Depress pushbutton. Voltmeter should read Measure unit connector if voltage is not present at control unit or if instrument reads...
  • Page 101 Ignition systems Fault Rex-I diagnostic test lead Connect probe diode tester pin under and black probe t est lead operating correctly if diode tester gives indica- tion. Replace diagnosl unit if no indication observed. Check for voltage at control unit Switch on ignition Measure...
  • Page 102 Group Ignitio s ystems Fault tracing, Rex-J Check throttle switch Measure resis ance ween contro l unit connect or t ermi nal 7 (orang e) and ground. Resistance shou ld be a ohm. Depress accelerat or until th rottle switch opens slightly.
  • Page 103 Group Ignition systems Fault tracing, Rex-' Check pulse generator Measure resistance between connector terminals (red) and 23 (blue). Resistance shou be approx. 240 ± ohm. " Check that screen is connected to terminal • • • • • 144 8 Check knock sensor leads...
  • Page 104 Group Ignition systems Fault tracing, Rex-I Undo connectors. coil from power stage Remove both mounting screws with a Torx TX 215 screwdriver and lift off ignition Measure resistance across ignition coil terminals Measure resistance across terminals and·) as il- lustrated. Resistance should be approx.
  • Page 105 Group Ignition systems Fault tracing, Rex-I Check ignition coil/power stage ground connec- tions Measure resistance between terminal B 3-pole con- nector ground. Resistance must exceed ohm. If resistance is too high, clean ground connection and/or replace ground lead as required. 146 729 Measure resistance between terminal A in 2-pole con- nector...
  • Page 106 Rex-I Ignition system (8230 F) • " • " • " • • '" •...
  • Page 107 Rex-I Ignition system (8230 F) 198 Throttle switch Connector, ttery Ignition switcn Connector, A-post Knock sensor Connector Distributo Contro unit wheel housing. single-pole Pulse generator 6 Spark plugs 420 Power Ground terminal on intake manifold 11 Fusebox Combined instrument (CEL) Fuel system control unit...
  • Page 108 Index Index "g. Adaptive timing retardation ..• • ..generato 20-21 , 98-102. 128-130. 141-144 Ballast resistor: Ignition coil. 69, 72, 77- 78. AJEJF 6-cylinder engines Ign ition coil/power stage Basic parameters 11- 13 Ignition tim ing table Centrifugal advance ·...

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