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Pmseng PDF
Pmseng PDF
Foreword
The Multi-Tester plus/pro software cassette is the component that gives
the diagnostic equipment its unique test characteristics: the software cassette
stores all data required to allow the test system to operate.
The software cassette can be replaced easily, enabling the Multi-Tester plus/pro
to be adapted to the troubleshooting job at hand rapidly.
These Troubleshooting Instructions describe how to use the equipment on
Bosch or Siemens fuel injection systems type PMS.
The Multi-Tester plus/pro checks all input and output signals that have
bearing on the control system and can also diagnose a faulty control unit.
Copyright AUTODIAGNOS
The contents of this document can be changed without notice and should not therefore
be regarded as binding to AUTODIAGNOS.
AUTODIAGNOS is not responsible for any errors which may appear in this document.
In any event, AUTODIAGNOS accepts no liability for any loss or damage arising from
the use of this document nor of the hardware or software described herein.
Neither the whole nor any part of this document may be copied, reproduced or
duplicated in any material form, except for personal use, without the prior written approval
of AUTODIAGNOS. Neither may the contents be passed on to third parties or used in any
other unauthorised manner.
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PMS CONTENTS
Contents
Foreword .......................................................................................................... 1
System Description .......................................................................................... 3
General ......................................................................................................... 3
Summary – car models ............................................................................ 3
Sensors, signals and swithches ................................................................ 3
Control functions ...................................................................................... 3
Users Guide ..................................................................................................... 4
Connection of equipment .............................................................................. 4
Starting the program ..................................................................................... 5
Program structure ......................................................................................... 9
Programs and tests .................................................................................... 10
Monitor test ............................................................................................. 11
Fault messages .................................................................................. 12
To delete recorded faults .................................................................... 13
Fault detected ..................................................................................... 14
Snapshots (Multi-Tester pro only) ....................................................... 15
Running test ........................................................................................... 16
Edit ......................................................................................................... 17
Special Tests .......................................................................................... 18
Static test / Continuous static test ....................................................... 21
Battery ................................................................................................ 22
Sensor power ..................................................................................... 22
Lambda sensor ................................................................................... 23
Coolant temperature ........................................................................... 23
Air temperature ................................................................................... 24
ISC-potentiometer .............................................................................. 24
Throttle potentiometer ........................................................................ 25
Battery constant ................................................................................. 25
Throttle test ........................................................................................ 26
Trouble-Shooting Procedure ....................................................................... 27
Fault Tracing ............................................................................................... 29
Locating Faults ............................................................................................... 35
Index ............................................................................................................... 47
Interface - Signal Locations ............................................................................ 48
Wiring Diagram ............................................................................................... 49
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SYSTEM DESCRIPTION PMS
System Description
General
PMS is a control system for fuel injection, ignition, idle speed and others.
PMS controls the fuel supply through four injection valves. In order to
calculate the amout, the system utilizes the readings of one throttle
potentiometer, a MAP-sensor, the readings of a lambda sensor, an air
temperature and an engine temperature sensor.
Control functions
• Control of injection valve(s).
• Control of fuel pump relay.
• Control of idle speed.
• Control of pre-heating of inlet air.
• Control of lambda pre-heating
• Control of ignition timing.
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PMS USERS GUIDE
Users Guide
Connection of equipment
1. Preparations
Extension cable
Control system
F1 F2 F3
Multi-Tester pro
YES NO
HELP
EXIT ENTER
Power supply
YES NO
HELP
EXIT ENTER
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STARTING THE PROGRAM PMS
Working procedure
1. All fields in the display are tested
(i.e. are illuminated)
(Multi-Tester plus only). MULTI-TESTER plus
If no software cassette is installed or
the cassette is incorrect, only the first
and third row become illuminated.
At this point the display’s contrast can
be adjusted. Adjust the potentiometer
to right of the switch inside the cassette
opening (using a small screwdriver).
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PMS STARTING THE PROGRAM
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QUESTIONS DURING INITIALIZATION PMS
YES/NO
TYPE SELECTION
AIR CONDITIONER?
YES/NO
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PMS CANCEL
7. Cancel
To cancel work with the Multi-Tester plus/pro:
• Switch off engine.
• Disconnect the power cable from the unit.
• Disconnect the battery’s positive terminal.
• Remove the adapter and re-connect the car’s wiring harness to the
control unit.
• Re-connect the battery’s positive terminal.
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PROGRAM STRUCTURE PMS
Program structure
SELF-TEST
AUTODIAGNOS
MULTI-TESTER
Start menus
VIEW SNAPSHOTS
VIEW GRAPHS
ADAPTER CONNECTED
VER:XXXXXXXXXXXX
Questions which
depend upon lambda
sensor, idle control,
number of cylinders, etc.
FAULT DETECTION
IN MONITOR TEST?
Condition:
Fault present
YES/NO
YES
RUNNING TEST FAULT DETECTED
(in the background)
HELP
Condition:
FAULT MESSAGE
Fault present
DELETE RECORDED
FAULTS HELP MESSAGE
STATUS MESSAGE
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PMS PROGRAMS AND TESTS
Monitor test
General
In Monitor test, values such as engine speed and coolant temperature are
displayed.
Monitor test – with fault detection
This test is used to detect incorrect input and output signals to/from the
various control systems. An fault is recorded if a signal deviates from its
pre-programmed standard value. The fault is recorded until it is deleted
manually or the power supply is interrupted.
• Up to five faults can be recorded each time Running is executed.
• Each primary fault can lead to a number of secondary faults.
• The Multi-Tester plus/pro stores all faults (primary and secondary)
temporarily and offers an assessment of which is the primary fault.
This is important in order to carry out repair work. Fault information
is saved and displayed.
• The same fault cannot be recorded twice in succession.
• Order of priority of fault registration:
1. Power supply
2. Frame connections to the control system
3. Sensor signals which affect the basic functions of the engine
4. Other signals
Warning! If the display is to be read whilst driving the test should
be performed by two people.
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MONITOR TEST PMS
Monitor test
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PMS FAULT MESSAGES
Fault messages
Each fault has the following information associated with it:
• Fault message
• Help message
• Status message
EXIT EXIT
TOTAL
NUMBER OF HELP ↓ /↑
↑
FAULT MESSAGE FAULT MESSAGE
FAULTS:
First Fifth
EXIT
HELP
HELP
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TO DELETE RECORDED FAULTS PMS
EXIT/HELP
4. Exit delete
MONITOR TEST
When all faults have been deleted, the
RUNNING TEST
instrument returns to the “Choice of
test” menu.
↑ /↓ /ENTER
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PMS TO DELETE RECORDED FAULTS
Fault detected
FAULT FOUND
TO READ FAULT
MESS. PRESS HELP
TO STOP: EXIT
HELP
EXIT
TOTAL NUMBER OF HELP 1st FAULT 5th FAULT
FAULTS: (1-5) MESSAGE ↓ /↑
↑ MESSAGE
EXIT
EXIT / HELP EXIT / HELP EXIT / HELP
MONITOR TEST
RUNNING TEST
↑ /↓
↓ /ENTER
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SNAPSHOTS PMS
Automatic snapshots
When the Multi-Tester pro finds a fault, all the values in the monitor list
are saved automatically as a snapshot. The Multi-Tester pro can store up to
five snapshots. The number of snapshots stored is shown at the bottom of
the display.
Manual snapshots
Press ENTER to create a manual snapshot. Up to five manual snapshots can
be stored. Here too, the number of snapshots stored is shown at the bottom
of the display.
Viewing snapshots
To view snapshots, press EXIT, then HELP. Then move the cursor to VIEW
SNAPSHOT with é/ê and press ENTER. The manual snapshots appear first.
The number of the current snapshot is shown at the bottom of the display.
To view the next snapshot press è. Press EXIT to quit.
To delete manual snapshots, move the cursor to DELETE SNAPSHOT with ê.
Press ENTER, then YES.
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PMS RUNNING TEST
Running test
General
This test is used to detect incorrect input and output signals to/from the
various control systems. An fault is recorded if a signal deviates from its
pre-programmed standard value. The fault is recorded until it is deleted
manually or the power supply is interrupted.
• Up to five faults can be recorded each time Running is executed.
• Each primary fault can lead to a number of secondary faults.
• The Multi-Tester plus/pro stores all faults (primary and secondary)
temporarily and offers an assessment of which is the primary fault.
This is important in order to carry out repair work. Fault information
is saved and displayed.
• The same fault cannot be recorded twice in succession.
• Automatic test restart when the engine is restarted
(appropriate for long-term tests).
• Signal values cannot be studied.
• Order of priority of fault registration:
1. Power supply
2. Frame connections to the control system
3. Sensor signals which affect the basic functions of the engine
4. Other signals
Warning! If the display is to be read whilst driving the test should
be performed by two people.
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EDIT PMS
Edit
Edit can be used to turn off the error diagnosis for signals which for some
reason are not connected to the interface. This may accur if you are testing
a different year model of the car than the one that was available when
developing the program for the actual control system.
At the start all signals are switched on.
When the operator answers the introduc-
tory questions, Multi-Tester plus/pro
shuts out non-relevant signals.
EDIT
Error diagnosis for other signals can be
switched on and off. Press ENTER to
change the signal’s status. When you
press HELP, more information on the
actual signal is displayed. #XX GROUND ON
All changes will be erased when the
Multi-Tester plus/pro is disconnected
from power.
Note
If error diagnosis is disconnected, this #XX GROUND OFF
can lead to other errors being reported.
For example, if error diagnosis for a main
ground or power supply is disconnected,
then signals that depend on them can be
reported as faulty.
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PMS SPECIAL TESTS
Special Tests
Special tests allows detailed study of certain signals.
The following functions are provided for Special Tests.
Graphical display (Multi-Tester pro only)
• All signals that are presented in the form of voltage (V) in Monitor
mode are displayed graphically.
• Press é/ê to reach the required signal and press ENTER.
• To see all functions press HELP. To return, press any key.
The timebase of the X-axis is shown bottom right on the display. It is
marked with a black square. To reduce/increase the timebase, press ç/è.
The shortest timebase is 2 seconds and the longest is 1024 seconds.
The amount above the Y-axis indicates the scaling. Pressing F3 toggles
the highlight between the scale factor and the offset bottom left on the
display. Depending on which is highlighted, the setting is changed by
pressing é/ê. The minimum and maximum values for the scaling are
200 mV and 15 000 mV, and for the offset 0 V and 14 V.
The offset moves the curve in the Y-direction.
• Min/max is displayed top right on the display and applies to the curve
currently displayed. When a snapshot has been taken, min/max is
replaced by new values.
To view snapshots, press EXIT twice, then press HELP. Move the cursor
to VIEW GRAPHS with é/ê and press ENTER. The current snapshot and
the number of snapshots stored are shown at the top of the display.
Press è to view the next snapshot. Press EXIT to quit.
To delete graphical snapshots, move the cursor to ERASE GRAPHS with ê.
Press ENTER, then YES.
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SPECIAL TESTS PMS
The software for the PMS system includes following special tests:
Static test
Checks the signals when the ignition is >STATIC TEST
on but the engine is not running.
Battery
Displays the battery voltage and the >BATTERY
minimum and maximum values.
Lambda sensor
Displays signal voltage from the lambda >LAMBDA SENSOR
sensor and the minimum and maximum
values.
Coolant temperature
Displays the signal voltage from the >WATERTEMP.
coolant temperature sensor and the
minimum and maximum values.
Air temperature
Displays the signal voltage from the air >AIRTEMP.
temperature sensor and the minimum
and maximum values.
ISC potentiometer
Displays the signal voltage from the >ISC-POT
potentiometer ISC and the minimum and
maximum values.
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PMS SPECIAL TESTS
Throttle potentiometer
>THROTT.POT. Displays the signal voltage from the
throttle potentiometer as well as
minimum and maximum recorded values.
Battery constant
Displays the battery voltage and the
>BATTERY CONST
minimum and maximum values.
Throttle test
>THROTTLE TEST Tests the throttle potentiometer.
Checks signal levels and continuity.
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SPECIAL TESTS PMS
Static test
Continuous static test STATIC TEST
These tests detect incorrect input and
output signals from the control unit when
the ignition is on but the engine is not
running. Conditions:
A fault is registered if any signal differs Ignition is on
from the pre-programmed standard Engine is not running
value. The fault will be held in memory
until it is erased manually or until the
power is broken. Tests of
all
Starting conditions for the test:
signals
• The ignition should be on.
• The engine should not be started.
If the ignition is off, you will be asked
FAULT MESSAGE
to turn it on. If the engine is started
the test will not be carried out and the
program will return to the special tests
menu.
After all the signals are controlled, the
text NO FAULTS FOUND appears on the dis-
play or if any faults are located then
FAULTS EXIST will appear.
If the continuous static test is selected,
then all signals will be tested continu-
ously until EXIT is pressed, the ignition is
switched off or the engine is started.
If faults are found then this will appear on
the display. To view these faults press HELP.
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PMS SPECIAL TESTS
Battery
This test demonstrates the voltage level
BATTERY
of the car’s battery.
The test displays the actual value together
with the minimum and maximum values
recorded. This enables the battery voltage
Condition:
during for example the starting phase to be
Ignition is on
measured.
Starting conditions for this test:
• The ignition has to be turned on.
#XX BATT XX.X V This test will continue until EXIT is pressed
MIN: XX.X V or until the engine is stopped.
MAX: XX.X V
EXIT
Sensor power
SENSOR POWER This test demonstrates the power voltage
to the throttle potentiometer.
The test displays the actual value together
with the minimum and maximum values
recorded.
Condition:
Ignition is on Starting conditions for this test:
• The ignition has to be turned on.
This test will continue until EXIT is pressed
or until the engine is stopped.
#XX POWER X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
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SPECIAL TESTS PMS
Lambda sensor
This test demonstrates the signal voltage LAMBDA SENSOR
of the lambda sensor.
The test displays the actual value together
with the minimum and maximum values
recorded. This makes it possible to check
Condition:
that the sensor is working and swings
Running engine
between extreme positions 0 and 1 V
approx.
Starting conditions for this test:
• The engine has to be running. #XX LAMBDA XXX mV
This test will continue until EXIT is pressed MIN: XXX mV
or until the engine is stopped. MAX: XXX mV
EXIT
Coolant temperature
This test demonstrates the signal voltage WATERTEMP.
of the coolant temperature sensor.
The test displays the actual value together
with the minimum and maximum values
recorded.
Condition:
Starting conditions for this test: Ignition is on
• The ignition has to be turned on.
This test will continue until EXIT is pressed
or until the engine is stopped.
#XX TEMP X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
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PMS SPECIAL TESTS
Air temperature
AIRTEMP. This test demonstrates the signal voltage
of the air temperature sensor.
The test displays the actual value together
with the minimum and maximum values
recorded.
Condition:
Ignition is on Starting conditions for this test:
• The ignition has to be turned on.
This test will continue until EXIT is pressed
or until the engine is stopped.
#XX AIR X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
ISC-potentiometer
ISC-POT This test demonstrates the signal voltage
of the ISC-potentiometer.
The test displays the actual value together
with the minimum and maximum values
recorded.
Condition:
Ignition is on Starting conditions for this test:
• The ignition has to be turned on.
This test will continue until EXIT is pressed
or until the engine is stopped.
#XX ISC-POT X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
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SPECIAL TESTS PMS
Throttle potentiometer
This test demonstrates the signal voltage THROTT.POT.
of the throttle potentiometer.
The test displays the actual value together
with the minimum and maximum values
recorded. Condition:
Starting conditions for this test: Ignition is on
• The ignition has to be turned on.
This test will continue until EXIT is pressed
or until the engine is stopped.
#XX THROTT X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
Battery constant
This test demonstrates the voltage level BATTERY CONST
of the car’s battery.
The test displays the actual value together
with the minimum and maximum values
recorded. This enables the battery voltage Condition:
during for example the starting phase to be Ignition is on
measured.
Starting conditions for this test:
• The ignition has to be turned on.
This test will continue until EXIT is pressed #XX BATT XX.X V
or until the engine is stopped. MIN: XX.X V
MAX: XX.X V
EXIT
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PMS SPECIAL TESTS
Throttle test
THROTTLE TEST This test involves a comprehensive check
of the signal levels of the throttle poten-
tiometer and the condition of the poten-
tiometer pathways. The test can for
example detect signal interruptions that
Conditions: originate from a bad carbon path.
Ignition is on Starting conditions for the test:
Engine is not running
• The ignition has to be turned on.
• The engine should not be running.
If the ignition is off, you will be asked
Calibration of
to turn it on. If the engine is started,
full load and idle
the test will not be carried out and the
running values
program will return to the special tests
menu.
Firstly, a calibration is carried out for the
Multi-Tester plus/pro pre-programmed
Test of values for full load and idle running. This is
continuity to guarantee the Multi-Tester plus/pro
function as its values can differ for
different vehicles. You will be asked to give
full throttle and then release the
accelerator completely.
FAULT MESSAGE Then you will have to press down the
accelerator slowly. A check is now being
carried out to control that there is no
break in signal from the throttle poten-
tiometer. If the accelerator is depressed
too quickly during this part of the test,
you will be asked to release it and slowly
depress the accelerator again.
If faults are found then this will appear on
the display. To view these faults press HELP.
26 A01090238-1 / 96-07-01
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TROUBLE-SHOOTING PROCEDURE PMS
Trouble-Shooting Procedure
General
Many faults can be detected by using the Multi-Tester plus/pro (with the
appropriate software cassette) only. As an additional aid, each software
cassette has a dedicated troubleshooting manual.
However, when troubleshooting, the following points should be observed:
• Faults of intermittent character, e.g. faulty switch contacts, are often
difficult to observe in the workshop. In such cases, those components
which are considered potential causes of the fault should be swapped
out, each in turn, followed on each occasion with a test drive with the
Multi-Tester plus/pro connected.
• NB: the fault rate for control units is relatively low. More likely causes
of failure are harness connectors, cabling, sensors or switches.
• Whenever resistance or voltage supply measurements are being taken at
the harness connector by the control unit, the Autodiagnos Break-out Box
(A0201/A0202) and associated Break-out Box adapter should be used to
avoid destroying the harness connector’s sheathing. This is to ensure
good electrical contact and to avoid damage to or a short circuit across
the harness connector’s sheathing.
The troubleshooting manuals include two chapters important to trouble-
shooting.
The Fault Tracing chapter includes a brief signal description for each pin
and three columns (the pin number means the number in the control unit’s
harness connector). The three columns enumerate the quantities to be
checked by the various tests. In the rightmost column the corresponding
section in the Locating Faults chapter is also included (see figure below).
A01090238-1 / 96-07-01 27
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PMS BLANK PAGE
28 A01090238-1 / 96-07-01
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FAULT TRACING PMS
Fault Tracing
Pin F1 Ground
MONITOR SPECIAL RUNNING
“F1 GROUND” Static test: check of Continuous test of
(OK/ERR) ground level. ground level.
Desired value: 0 V
See chapter
Locating Faults ➧1
Pin F2 Power from ignition switch (terminal15)
MONITOR SPECIAL RUNNING
“F2 BATT” (V) Static test: check of Continuous test of
voltage level. voltage level.
Battery: display of Desired value: 12–14 V
power variation. See chapter
Locating Faults ➧2
Pin F3 Shift-point retard
MONITOR SPECIAL RUNNING
“F3 DELAY” (ON/OFF) Not tested. Not tested.
Pin F4 TPM
MONITOR SPECIAL RUNNING
“F4 TEMPOMAT” Not tested. Not tested.
(ON/OFF)
Pin F5 Ground
MONITOR SPECIAL RUNNING
“F5 GROUND” Static test: check of Continuous test of
(OK/ERR) ground level. ground level.
Desired value: 0 V
See chapter
Locating Faults ➧1
Pin F5 Ground
MONITOR SPECIAL RUNNING
“F5 AUTO” Not tested. Not tested.
(P/N/DRIVE)
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PMS FAULT TRACING
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FAULT TRACING PMS
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PMS FAULT TRACING
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LOCATING FAULTS PMS
Locating Faults
1
Check of ground connection to PMS, pin F1, F5, F9 and M9
These contacts are the control unit’s ground connection.
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin F1, F5, F9
respectively M9 and ground. Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
2
Check of power supply from ignition switch (terminal 15) to
PMS, pin F2
This is an input signal to the control unit from the ignition switch.
It indicates that the ignition is on.
1. Turn on the ignition and measure the voltage at the ignition coil’s positive
pole (terminal 15). Desired value: 12–14 V
Possible cause of fault: Wiring, connectors or ignition switch.
2. Turn the ignition off and disconnect the two 17-pin connectors from the
control unit. Connect the Break-out Box (A0201/A0202) and the adapter
(A020230) to the car’s wiring harness only. Do not reconnect the control
unit.
3. Measure the resistance of the cable between the Break-out Box, pin F2
and ignition switch, pin 15. Desired value: 0 Ω
Note
The terminal 15 supply provides the stop signal for the Multi-Tester plus/pro
test program. This means that an absent signal is interpreted as a stopped
engine. Nevertheless, a faulty signal will be detected at the start of the test.
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PMS LOCATING FAULTS
3
Check of signal from lambda sensor to PMS, pin F6
This is an input signal to the control unit from the lambda sensor.
It is only found on cars fitted with catalytic converters and is used for
the fine adjustment of the ratio of fuel to air to approx. 1:14.6 (by weight).
This ratio is called lambda = 1.
The following test conditions must be met as the Multi-Tester plus/pro
checks that the lambda sensor signal level lies between 0 and 1 V:
• engine temperature must exceed +70°C
• the engine must not be idling – some sensors cool down after long
periods of idling and oscillation ceases.
• the engine must not be at full throttle – the sensor signal then
becomes constant at approx. 1V.
• Fuel cut-off should not be activated – the sensor signal then becomes
constant at approx. 0 V
• Engine speed below 2.500 rpm.
1. Check the sensor’s pre-heating (if fitted) by measuring the voltage at the
sensor connector while the engine is running. Desired value: 12 V
2. Run the engine until it reaches operating temperature and maintain engine
speed at approximately 2.500 rpm. Execute the LAMBDA SENSOR special
test and confirm that the lambda sensor signals fluctuate between 0 and 1
V. The signal should oscillate about once a second. Oscillations of longer
duration indicate that the sensor may be polluted and should be replaced.
3. Turn off the ignition and disconnect the two 17-pin connectors from the
control unit. Connect the Break-out Box (A0201/A0202) and the adapter
(A020230) to the car’s wiring harness only. Do not reconnect the control
unit.
4. Measure the resistance between the Break-out Box, pin F6 and ground.
If the reading is approximately 0 Ω the sensor has short-circuited and is
no longer functioning. Repeat the measurement at the sensor connector
to determine whether the short circuit is in the sensor or the cable
between the sensor and the control unit.
36 A01090238-1 / 96-07-01
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LOCATING FAULTS PMS
4
Check of ground connection to lambda sensor to PMS,
pin F7
This contact is the control unit’s ground connection.
1. Disconnect the two 17-pin connectors from the control unit and connect
the Break-out Box (A0201/A0202) and the adapter (A020230) between
the car’s wiring harness and the control unit.
2. Measure the resistance between the Break-out Box, pin F7 and ground.
Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
5
Check of control signal to fuel pump relay from PMS, pin F8
This is a control signal from the control unit. The signal is grounded to activate
the pump relay after the engine has been turned over by the starter motor.
There are several possible causes for an absent signal including:
• Discontinuity in the wiring or connectors.
• A defective or absent main input signal to the system, such as:
– ground connection
– power supply
– crankshaft sensor
• Faulty control unit, although this is most unlikely as the failure rate for
control units is very low.
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance of the cable between the Break-out Box, pin F8
and fuel pump relay pin 3 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
3. Connect the Break-out Box and the adapter (A020230) between the car’s
wiring harness and the control unit.
4. Turn on the ignition and measure the voltage between the Break-out
Box, pin 5 and ground. Desired value: 12 V
Possible cause of fault: Wiring or connectors.
A01090238-1 / 96-07-01 37
TROUBLE-SHOOTING
PMS LOCATING FAULTS
6
Check of constant power supply from battery to PMS,
pin F10
This connection provides the control unit with a constant power supply from
the battery to maintain retention of those presets the control unit has “learnt”.
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin F10 and the
battery’s positive pole. Desired value: 0 Ω
Possible cause of fault: Wiring, connectors or fuse.
3. Measure the voltage between the battery’s positive pole and ground.
Desired value: 12–14 V
Possible cause of fault: Battery.
7
Check of engine speed signal to revolution counter from
PMS, pin F13
This is an output signal from the control unit indicating engine speed for
the car’s tachometer, for example.
1. Disconnect the two 17-pin connectors from the control unit and connect
the Break-out Box (A0201/A0202) and the adapter (A020230) between
the car’s wiring harness and the control unit.
2. Start the engine and check (use oscilloscope or similar) that pulses are
received at the Break-out Box, pin F13.
Possible cause of fault: Wiring, connectors or control unit
8
Check of control signal to the injection valve from PMS,
pin M4
This is an output signal from the control unit to the injection valve which
controls fuel metering.
1. Turn on the ignition and measure the power supply to the injection
valve. Desired value: 12–14 V
Possible cause of fault: Wiring, connectors or the injection relay.
38 A01090238-1 / 96-07-01
TROUBLE-SHOOTING
LOCATING FAULTS PMS
2. Check the opening pulse by measuring the voltage across the injection
valves with a test lamp (measure from the rear of one of the connectors
on any injector). At low rpm the lamp should flash; it should shine with
even intensity at higher rpm. If incorrect:
– disconnect the two 17-pin connectors from the control unit. Connect
the Break-out Box (A0201/A0202) and the adapter (A020230) between
the car’s wiring harness and the control unit. Repeat corresponding
measurement between the Break-out Box, pin M4 and F10.
Note
It is possible that the Multi Tester plus/pro reports an error for an injector
when an ignition coil is faulty, this is because the electronic control unit
automatically shuts down the corresponding injector signal to prevent
damage to the catalytic converter.
3. In the case of a suspected discontinuity between PMS, pin M4 and the
injector, make the following measurement:
– turn off the ignition and disconnect the connector from the control
unit. Measure the resistance between the Break-out Box, pin M4 and
the terminal on the injector’s connector (see workshop manual).
Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance across each individual injector with the injector
connector terminal removed (i.e. directly on the injectors).
Desired value: 16 Ω
Possible cause of fault: Injector.
Note
The test is discontinued during fuel cut-off.
Injector failure can also have a mechanical cause (lining, etc.). Such faults
are not registered by the Multi-Tester plus/pro. In such a case, a flow check
must be carried out on each injector.
A01090238-1 / 96-07-01 39
TROUBLE-SHOOTING
PMS LOCATING FAULTS
9
Check of control signal to idle speed correction valve from
PMS, pin M5 and M14
The idle speed correction valve (ISR or ISC) is controlled by an output
signal from the control unit which operates a coil in the correction valve. The
signal has a constant frequency of 400 HZ and the pulse ratio varies between
approx. 25 % and 75 %. When this value increases, rpm increases, for example
when the engine is cold or when the AC compressor is switched on.
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Disconnect the connector from the ISC valve. Measure the resistance of
the cable between the Break-out Box, pin M5 and the connector, pin 4
(see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
3. Measure the resistance of the cable between the Break-out Box, pin M14
and connector, pin 8 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Connect the Break-out Box and the adapter (A020230) between the car’s
wiring harness and the control unit.
5. Measure the resistance between the valve’s terminals.
Desired value: 4 Ω
Possible cause of fault: ISC valve.
6. Connect the ISC valve again. Start the engine and check if pulses appear
on the Break-out Box, pin M5 and M14 (use oscilloscope or similar).
Possible cause of fault: ISC valve or control unit.
10
Check of power supply to the throttle potentiometer from
PMS, pin M6
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) between the
car’s wiring harness and the control unit.
40 A01090238-1 / 96-07-01
TROUBLE-SHOOTING
LOCATING FAULTS PMS
2. Start the engine and measure the voltage between the Break-out Box,
pin M6 and M9. Desired value: 5 V
Possible cause of fault: Wiring, connectors, throttle potentiometer
or control unit.
11
Check of signal from coolant temperature sensor to PMS,
pin M7
This is an input signal to the control unit from the coolant temperature
sensor (type NTC with a negative temperature coefficient).
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin M7 and coolant
temperature sensor, pin 2 (models before 11/94) or pin 1 (models after
12/94, see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
3. Measure the resistance between the Break-out Box, pin M9 and coolant
temperature sensor, pin 1 (models before 11/94) or pin 4 (models after
12/94, see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance between the Break-out Box, pin M7 and M9.
Desired values: engine temperature resistance (Ω Ω)
+20°C 1000
+50°C 850
+70°C 450
+90°C 275
Possible cause of fault: Coolant temperature sensor.
12
Check of signal from ISC-potentiometer to PMS, pin M8
This is an input signal to the control unit from the ISC-potentiometer.
The signal indicates present idle speed level.
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
/ Continued
A01090238-1 / 96-07-01 41
TROUBLE-SHOOTING
PMS LOCATING FAULTS
2. Measure the resistance between the Break-out Box, pin M8 and M9.
Desired value: 1,5 kΩ
Possible cause of fault: Wiring or potentiometer.
3. Connect the Break-out Box and the adapter (A020230) between the car’s
wiring harness and the control unit.
4. Reconnect the connector and measure the voltage between the Break-out
Box, pin M8 and M9. Desired value: 0,3–4,5 V
Possible cause of fault: Wiring or potentiometer.
13
Check of ignition pulse (terminal 1) from PMS, pin M10, M11
This is an output signal from the control unit to the ignition. The control
unit sends ignition pulses to control the ignition coil. There are several
possible causes of an absent signal:
• discontinuity in the wiring or connectors.
• defective or absent main input signal to the system, such as:
– ground connection
– voltage supply
– crankshaft sensor
• faulty control unit, although this is most unlikely as the failure rate for
control units is very low.
1. Turn on the ignition and check if there is battery voltage for the
ignition coil at pin 15 (+).
Possible cause of fault: Ignition switch or cable to ignition coil
(terminal 15).
2. Start or crank the engine and check pulses are being received at the
ignition coil, pin 1 with a test lamp.
Possible cause of fault: Circuit-breaker (possibly ignition amplifier),
ignition coil or wiring on primary side.
3. Turn off the ignition and disconnect the two 17-pin connectors from the
control unit. Connect the Break-out Box (A0201/A0202) and the adapter
(A020230) to the car’s wiring harness only. Do not reconnect the control
unit.
4. Measure the resistance of the cable between the Break-out Box, pin M10,
M11 and ignition coil. Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
If all recorded values were correct: check the crankshaft sensor.
42 A01090238-1 / 96-07-01
TROUBLE-SHOOTING
LOCATING FAULTS PMS
14
Check of control signal to the injection valve from PMS,
pin M13
This is an output signal from the control unit to the injection valve which
controls fuel metering.
1. Turn on the ignition and measure the power supply to the injection
valve. Desired value: 12–14 V
Possible cause of fault: Wiring, connectors or the injection relay.
2. Check the opening pulse by measuring the voltage across the injection
valves with a test lamp (measure from the rear of one of the connectors
on any injector). At low rpm the lamp should flash; it should shine with
even intensity at higher rpm. If incorrect:
– disconnect the two 17-pin connectors from the control unit. Connect
the Break-out Box (A0201/A0202) and the adapter (A020230) between
the car’s wiring harness and the control unit. Repeat corresponding
measurement between the Break-out Box, pin M13 and F10.
3. In the case of a suspected discontinuity between PMS, pin M13 and the
injector, make the following measurement:
– turn off the ignition and disconnect the connector from the control
unit. Measure the resistance between the Break-out Box, pin M13 and
the terminal on the injector’s connector (see workshop manual).
Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance across each individual injector with the injector
connector terminal removed (i.e. directly on the injectors).
Desired value: 16 Ω
Possible cause of fault: Injector.
Note
The test is discontinued during fuel cut-off.
Injector failure can also have a mechanical cause (lining, etc.). Such faults
are not registered by the Multi-Tester plus/pro. In such a case, a flow check
must be carried out on each injector.
It is possible that the Multi Tester plus/pro reports an error for an injector
when an ignition coil is faulty, this is because the electronic control unit
automatically shuts down the corresponding injector signal to prevent
damage to the catalytic converter.
A01090238-1 / 96-07-01 43
TROUBLE-SHOOTING
PMS LOCATING FAULTS
15
Check of signal from throttle potentiometer to PMS, pin M15
This is an input signal from the throttle potentiometer to the control unit.
The output signal varies in response to the throttle position. Two signal
properties are tested; level and continuity.
Signal level fault
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin M15 and
throttle potentiometer, pin 1 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
3. Measure the resistance between the Break-out Box, pin M6 and throttle
potentiometer, pin 3 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance between the Break-out Box, pin M9 and throttle
potentiometer, pin 7 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
5. Measure the resistance between the Break-out Box, pin M15 and pin M9.
Desired value: 2.83 Ω
Possible cause of fault: Throttle potentiometer.
6. Connect the Break-out Box and the adapter (A020230) between the car’s
wiring harness and the control unit.
7. Turn on the ignition and measure the voltage between the Break-out
Box, pin M6 and M9. Desired value: 5 V
Possible cause of fault: Ground connection, throttle potentiometer
or control unit.
Continuity fault
When this fault is reported it is most likely that the potentiometer’s track
is faulty.
1. Replace the potentiometer.
2. Repeat the test with the Multi-Tester plus/pro.
44 A01090238-1 / 96-07-01
TROUBLE-SHOOTING
LOCATING FAULTS PMS
16
Check of signal from air temperature sensor to PMS,
pin M16
This is an input signal to the control unit from the air temperature sensor
(type NTC with a negative temperature coefficient).
1. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin M16 and the air
temperature sensor, pin 2 (models before 11/94) or pin 1 (models after
12/94, see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
3. Measure the resistance between the Break-out Box, pin M9 and the air
temperature sensor, pin 1 (models before 11/94) or pin 4 (models after
12/94, see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance between the Break-out Box, pin M16 and M9.
Desired values: air temperature resistance (kΩΩ)
+ 20°C 2.2
Possible cause of fault: Air temperature sensor.
17
Check of signal from TDC sensor to PMS, pin K1
This is an input signal to the control unit from the TDC sensor. The signal
indicates engine speed and top dead centre.
1. Check the clearance between the sensor and the ring gear (see workshop
manual) and that the cogs are clean.
2. Disconnect the two 17-pin connectors from the control unit. Connect the
Break-out Box (A0201/A0202) and the adapter (A020230) to the car’s
wiring harness only. Do not reconnect the control unit.
3. Measure the resistance of the cable between the Break-out Box, pin K1
and K2, respectively and the TDC sensor.
Desired value in both cases: 0 Ω
Possible cause of fault: Wiring or connectors.
4. Measure the resistance between the Break-out Box, pin K1 and K2.
Desired value: 0 Ω
Possible cause of fault: TDC sensor. / Continued
A01090238-1 / 96-07-01 45
TROUBLE-SHOOTING
PMS LOCATING FAULTS
5. Connect the Break-out Box and the adapter (A020230) between the car’s
wiring harness and the control unit.
6. Start or crank the engine and check that pulses from TDC sensor are
received at Break-out Box, pin K1 and K2, respectively (use oscilloscope
or similar). If the engine does not start, the signal level is lower but will
be displayed on the oscilloscope.
Possible cause of fault: TDC sensor, dirt between cogs or gap
between TDC sensor and flywheel.
46 A01090238-1 / 96-07-01
TROUBLE-SHOOTING
INDEX PMS
Index
Air temperature ...................................................................... 19, 24, 34, 45
Alarm signal ............................................................................................... 33
Battery ..................................................................... 19, 20, 22, 25, 31, 38
Continuous static test ......................................................................... 19, 21
Coolant temperature .............................................................. 19, 23, 32, 41
Crankshaft sensor ...................................................................................... 34
Engine speed signal ................................................................................... 31
Fuel pump relay .................................................................................. 30, 37
Ground ................................................................................... 29, 30, 32, 35
Idle speed correction ............................................................. 31, 32, 33, 40
Ignition coil ................................................................................................. 33
Ignition pulse .............................................................................................. 42
Ignition switch ............................................................................... 27, 29, 35
Injection valve ........................................................................ 31, 33, 38, 43
ISC-potentiometer ......................................................................... 19, 24, 41
Lambda pre-heating ................................................................................... 31
Lambda sensor ............................................................... 19, 23, 30, 36, 37
Power ......................................................................................................... 32
Relay mainfold heating ............................................................................... 31
Revolution counter .............................................................................. 31, 38
Sensor power ............................................................................................. 22
Shift-point retard ........................................................................................ 29
Static test ............................................................................................ 19, 21
System Description ...................................................................................... 3
Throttle potentiometer .............................................. 20, 25, 32, 34, 40, 44
Throttle power feed .................................................................................... 19
Throttle test ......................................................................................... 20, 26
TPM ........................................................................................................... 29
A01090238-1 / 96-07-01 47
TROUBLE-SHOOTING INTERFACE
PMS SIGNAL LOCATIONS
CONTACT F
1. Ground hydraulic unit
2. Terminal 15
3. Shift-point retard
4. TPM
5. P/N or ground
6. Signal from lambda sensor
7. Ground lambda sensor
8. Control signal to fuel pump relay
9. Ground hydraulic unit
10. Constant power supply from battery
11. Signal from CO-Potentiometer
12. AC
13. Engine speed signal to revolution counter
14. V-signal ABS
15. Diagnosis
16. Control signal to lambda pre-heating
17. Control signal to relay mainfold heating
CONTACT M
1. NC
2. NC
3. NC
4. Control signal injector cylinder 1 & 4
5. Control signal idle speed correction
6. Power supply to sensor
7. Signal from coolant temperature sensor
8. Signal from ISC-potentiometer
9. Ground to control unit
10. Control signal to ignition amplifier
cylinder 1 & 4
11. Control signal to ignition amplifier
cylinder 3 & 2
12. Alarm signal
13. Control signal to injector cylinder 3 & 2
14. Control signal to idle correction valve
15. Signal from throttle potentiometer
16. Signal from air temperature sensor
17. Signal from idle switch
KOAX-CONTACT
1. Signal from TDC-sensor
2. Ground to TDC-sensor
48 A01090238-1 / 96-07-01
WIRING DIAGRAM TROUBLE-SHOOTING
PMS PMS
Wiring Diagram
This wiring diagram is an example. Check in the relevant workshop manual
for the diagram of the car model you are working with.
Ignition switch
Crankshaft sensor
ISC potentiometer
Injection valves
Fuel pump
relay
Air temperature
sensor
Coolant temperature
sensor
TN signal
Ignition coil
Idle speed
correction valve