trouble-shooting - simtec 56.5 trouble hooting simtec · astra-f 2.0 x20xev 95– vectra-b 1.8...

TROUBLE-SHOOTING

SIMTEC 56.5

1A 01090254-1

ForewordThe Multi-Tester plus/pro software cassette is the component that givesthe diagnostic equipment its unique test characteristics: All data requiredto make the test system operate are stored on the software cassette.The software cassette can easily be replaced enabling the Multi-Tester plus/proto be rapidly adapted to the trouble-shooting job at hand.These Trouble-Shooting Instructions describe how to use the equipment onfuel injection systems type Simtec 56.5.Multi-Tester plus/pro checks all input and output signals that have bearing onthe 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 thereforebe regarded as binding on 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 fromthe 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 duplicatedin any material form, except for personal use, without the prior written approval ofAUTODIAGNOS. Neither may the contents be passed on to third parties or used in anyother unauthorized manner.

Trouble-Shooting - Simtec 56.5

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SIMTEC 56.5

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CONTENTS

ContentsForeword .......................................................................................................... 1System Description .......................................................................................... 3

General ......................................................................................................... 3Summary – Car Models ............................................................................ 3Sensors, signals and switches .................................................................. 4Control functions ...................................................................................... 4Camshaft sensor ...................................................................................... 5

Users Guide ..................................................................................................... 6Connection of equipment .............................................................................. 6Starting the program ..................................................................................... 7Program structure ....................................................................................... 11Programs and tests .................................................................................... 12

Monitor test ............................................................................................. 13Fault messages .................................................................................. 14To delete recorded faults .................................................................... 15Fault detected ..................................................................................... 16Snapshots (Multi-Tester pro only) ....................................................... 17Running test ....................................................................................... 18

Edit ......................................................................................................... 19Special Tests .......................................................................................... 20

Static test / Continuous static test ....................................................... 23Throttle test ........................................................................................ 24Camshaft sensor test ......................................................................... 25Lambda sensor ................................................................................... 26Battery ................................................................................................ 26Throttle potentiometer ........................................................................ 27Air mass meter ................................................................................... 27Coolant temperature ........................................................................... 28Air temperature ................................................................................... 28Power to crankshaft sensor ................................................................ 29

Trouble-Shooting Procedure ....................................................................... 30Fault Tracing ............................................................................................... 31Locating Faults ........................................................................................... 41

Index ............................................................................................................... 61Interface - Signal Locations ............................................................................ 62Wiring Diagram ............................................................................................... 63

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SYSTEM DESCRIPTION

System Description

GeneralSimtec 56.5 is a fuel injection and ignition system that is used in Opeland Vauxhall cars. The system uses certain sensors which operate in anunusual way. The first is the camshaft sensor, which is described on page5. The second is the lambda sensor which, unlike the lambda sensor inother systems, has a signal that alternates between 0–5 V.Note:It is important that the connection of the equipment is done according toUsers Guide (page 6).

Summary – Car ModelsThe following car models are equipped with Simtec 56.5:Manufacturer Engine size Engine ModelCalibra 2.0 X20XEV 95–Astra-F 1.8 X18XE 95–Astra-F 2.0 X20XEV 95–Vectra-B 1.8 X18XE 95–Vectra-B 2.0 X20XEV 95–Omega 1.8 X18XE 95–Omega 2.0 X20XEV 95–

Please check the workshop manual to verify if the actual car is equippedwith a system described in this manual.

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SYSTEM DESCRIPTION

Sensors, signals and switches• Throttle potentiometer – measures the throttle’s angle.• Coolant temperature sensor.• Air temperature sensor – measures the temperature of the air ingested.• Lambda sensor – measures the oxygen content of the exhaust gases.• Crankshaft sensor – measures the rotation speed and indicates the top

dead center.• Camshaft sensor – measures the camshafts rotation speed and it's position.• Air-mass meter – measures the air volume ingested.• Tachometer/Speedometer.

Control functions• Control of main relay.• Control of fuel pump relay.• Control of injection valve(s).• Control of ignition timing.• Control of tank ventilation.• Control of idle speed.• Control of lambda sensor pre-heating.• Control of EGR – valve (exhaust gas recycling valve).• Control of secondary air injection (cold start)In addition, the system can supply information to other units:• Engine speed• Fuel consumption• Engine load information.

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SYSTEM DESCRIPTION

Camshaft sensorAngle pulse generators are used as camshaft sensors. An angle pulsegenerator consists of two windings (primary and secondary), connectedtogether at one end, and an iron core. The primary winding is suppliedfrom the control box with a 95 kHz signal. The inductive coupling induces avoltage with the same frequency in the secondary winding, but the inducedvoltage has a certain phase shift owing to the time offset at induction.

312

When one of the teeth of the reluctor wheel is located at the sensor, themagnetic field of the sensor is affected and the phase shift is increased.At the next gap, the phase shift is reduced again. The control box sensesthese changes in phase shift as teeth and gaps.

Gap Tooth

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YES

ENTER

NO

HELP

EXIT

F1 F2 F3

YES

ENTER

NO

HELP

EXIT

F1 F2 F3

0

CONNECTION OF EQUIPMENT

Users Guide

1. Preparations

Turn off ignition! Disconnect positive battery terminal!

2. Connect adapter and program cassette

Extension cable

Control system

Adapter

Multi-Tester pro

Program cassette

3. Connect power supply

Power supply

Red Black Multi-Tester pro

Connection of equipment

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STARTING THE PROGRAM

Starting the programGeneralThe program is re-started each time the power supply is interrupted and re-connected. When the supply is interrupted any faults and pre-sets recordedin memory are deleted.At any particular moment, those keys which are not required are disabled.If such a key is pressed, the unit emits a long beep signal.The program starts automatically when the Multi-Tester plus/pro is connectedto the power supply. The unit executes steps 1 to 3 and pauses at step 5.

Working procedure1. All fields in the display are tested

(i.e. are illuminated)(Multi-Tester plus only).If no software cassette is installed orthe cassette is incorrect, only the firstand third row become illuminated.At this point the display’s contrastcan be adjusted. Adjust the potentio-meter to right of the switch inside thecassette opening (using a smallscrewdriver).

2. The Multi-Tester plus/properforms a self-test....

3. ...and identifies the currentversions of the hardware andsoftware.

MULTI-TESTER plus

SELF-TEST OK

MULTITESTERSIMTEC 56.5

VER:XXXXXXXXXXXX

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STARTING THE PROGRAM

4. Snapshots (Multi-Tester pro only)If the instrument contains storedsnapshots, a menu for managing theseis displayed.

5. The adapter connectedThe Multi-Tester plus/pro confirmswhich adapter is connected anddisplays this information.Is the information on row 2 correct?Respond by pressing ENTER.This message is displayed if the adapterwhich is connected to the Multi-Tester plus/pro is of the incorrect type,i.e. not combined with the appropriatesoftware cassette.

If the adapter is not connected to theunit, the message NO ADAPTER CONNECTEDis displayed.

VIEW SNAPSHOTSERASE MAN. SNAP.

ERASE GRAPHS↑↑↑↑↑/↓↓↓↓↓/ENTER

ADAPTER CONNECT.XXXXXXXXXXXXXXXX

↑↑↑↑↑/↓↓↓↓↓/ENTER

WRONG ADAPTERCONNECTED

NO ADAPTERCONNECTED

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QUESTIONS DURING INITIALIZATION

6. Questions during initializationIn order for the Multi-Tester plus/pro to perform the tests correctly it needscertain data on the system. The displayshows either alternatives or questions.

AlternativesUse é/ê to select the correctalternative and then press ENTER.

QuestionsAnswer the questions by pressingeither the YES or NO key.

ASTRA-FVECTRA-BOMEGA-BCALIBRA

TYPE SELECTIONAUTOMATICTRANSMISSION ?

↑↑↑↑↑/↓↓↓↓↓/ENTER

TYPE SELECTIONAIR CONDITIONER?

YES/NO

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CANCEL

7. CancelTo 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

Program structure

SELF-TEST

AUTODIAGNOSMULTI-TESTER

VIEW SNAPSHOTSVIEW GRAPHS

Start menusADAPTER CONNECTED

VER:XXXXXXXXXXXX

Questions whichdepend upon lambdasensor, idle control,number of cylinders, etc.

MONITOR TEST>SPECIAL TEST < RUNNING TEST

↑↑↑↑↑/↓↓↓↓↓/ENTER

EXIT

Choice of test

HELPVIEW SNAPSHOTSVIEW GRAPHS

MONITOR TEST

FAULT DETECTIONIN MONITOR TEST?

YES/NO

YES

RUNNING TEST(in the background)

Condition:Fault present

HELP

EDIT SPECIAL TEST

DELETE RECORDEDFAULTS

RUNNING TEST

Condition:Fault present

FAULT DETECTED

FAULT MESSAGE

HELP MESSAGE

STATUS MESSAGE

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PROGRAMS AND TESTS

Programs and testsThe following types of test are available:Monitor test Directs and displays the control system’s signals without

storing measured values.Running test Records and stores faults which occur under both shorter

and longer test periods.Edit Can be used to disable fault detection on various signals.Special tests A number of tests which are carried out in response to

independent signals.

Monitor testGeneralIn Monitor test, values such as engine speed and coolant temperature aredisplayed.

Monitor test – with fault detectionThis test is used to detect incorrect input and output signals to/from thevarious control systems. An fault is recorded if a signal deviates from itspre-programmed standard value. The fault is recorded until it is deletedmanually or the power supply is interrupted.• Up to five faults can be recorded each time test 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 informationis saved and displayed.

• The same fault cannot be recorded twice in succession.• Order of priority of fault registration:

1. Power supply2. Ground connections to the control system3. Sensor signals which affect the basic functions of the engine4. Other signals

Warning! If the display is to be read whilst driving the test shouldbe performed by two people.

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MONITOR TEST

Monitor test

1. Monitor testSelect MONITOR TEST in the test choicemenu.

2. Fault detection in Monitor testHere you can select whether or notfault detection is run while in Monitortest. If you press YES, Runningsearches for faults while Monitordisplays the values. If you press NO,START ENGINE shows. If you pressENTER, the list of signals is shownwithout the engine being started.

3. Test underwayA small T character flashes on thestatus row which indicates that thetest is underway.

4. Fault detectedIf an fault is detected, the unit emits atone as well as a small F on the statusrow.

5. To inspect faultsIf you press è the unit proceedsdirectly to the faulty signal. A smallF character is displayed before therelevant pin number. If you selectç the unit proceeds to the beginningof the list of signals.You can also press HELP to displaywhich fault has been detected insimple text. If the engine is switchedoff, when Monitor is re-started, youmust begin from stage 1 of this section.

RUNNING TEST>MONITOR TEST <SPECIAL TEST

↑↑↑↑↑/↓↓↓↓↓/ENTER

FAULT DETECTIONIN MONITOR TEST?

YES/NO

#18 POWER 2.30 V#19 GROUND OK#21 HALL PULSEIDLE T

#23 TEMP 2.30 V#24 GROUND OK#25 HALL PULSEIDLE T F

#3 LAMBDA OKF4 GROUND 1.25 V#5 BATT 12.0 VIDLE T F

TOTAL NUMBER OFFAULTS: (1–5)

HELP/EXIT

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FAULT MESSAGES

Fault messagesEach fault has the following information associated with it:• Fault message• Help message• Status message

EXIT EXIT

TOTALNUMBER OFFAULTS:

HELPFAULT MESSAGE

↑↑↑↑↑/↓↓↓↓↓FAULT MESSAGE

First Fifth

NO ENGINE SPEEDSIGNALLH#1

EXIT/HELP

HELPEXIT

CHECK IGNITIONSYSTEM ANDCABLE TO LH#1

EXIT/HELP

HELP

FAULT FOUND AT#1 RPM 0#13 TEMP 2.54 V

EXIT/HELP

EXIT/HELP

Example fault message for an LHcontrol system.

Example help message.

Example status message.

Display engine speed and voltage fromcoolant temperature sensor.

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TO DELETE RECORDED FAULTS

To delete recorded faults

1. StartTo delete faults, start from this point.

2. To delete faultsDepress the EXIT key for at least 5seconds. If EXIT is not pressed within 3seconds the unit returns to the FAULTDETECTED message automatically.

3. Delete faults.All faults and all snapshots are deletedsimultaneously.

4. Exit deleteWhen all faults have been deleted, theinstrument returns to the “Choice oftest” menu.

TOTAL NUMBER OFFAULTS: (1-5)

EXIT/HELP

TO DELETE FAULTSPRESS EXIT

> 5 SEC.

FAULTS WILL BEDELETED5..4..3..2..1

MONITOR TESTRUNNING TEST

↑↑↑↑↑/↓↓↓↓↓/ENTER

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TO DELETE RECORDED FAULTS

Fault detected

FAULT FOUNDTO READ FAULT

MESS. PRESS HELPTO STOP: EXIT

HELP

TOTAL NUMBER OFFAULTS: (1-5)

EXIT / HELP

HELP

EXIT

1st FAULTMESSAGE

EXIT / HELP

↑↑↑↑↑/↓↓↓↓↓

EXIT

5th FAULTMESSAGE

EXIT / HELP

EXIT HELP EXIT HELP EXIT

* TO DELETE FAULTSPRESS EXIT

> 5 SEC

HELPMESSAGE

EXIT / HELP

HELPMESSAGE

EXIT / HELP

EXIT HELP HELP

FAULTS WILLBE DELETED

5..4..3..2..1

STATUSMESSAGE

EXIT / HELP

STATUSMESSAGE

EXIT / HELP

EXIT / HELP EXIT / HELP

MONITOR TESTRUNNING TEST

↑↑↑↑↑/↓↓↓↓↓/ENTER

* Occurs automatically after 3 seconds

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SNAPSHOTS

Snapshots (Multi-Tester pro only)

Automatic snapshotsWhen the Multi-Tester pro finds a fault, all the values in the monitor listare saved automatically as a snapshot. The Multi-Tester pro can store upto five snapshots. The number of snapshots stored is shown at the bottomof the display.

Certain parameters are displayed as mean values. Faults maybe reported on the basis of instantaneous values, with theresult that autosnap may not always display a faulty value evenif the Multi-Tester pro indicates a fault on a particular signal.

Manual snapshotsPress ENTER to create a manual snapshot. Up to five manual snapshots canbe stored. Here too, the number of snapshots stored is shown at the bottomof the display.

Viewing snapshotsTo view snapshots, press EXIT, then HELP. Then move the cursor to VIEWSNAPSHOT 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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RUNNING TEST

Running testGeneralThis test is used to detect incorrect input and output signals to/from thevarious control systems. An fault is recorded if a signal deviates from itspre-programmed standard value. The fault is recorded until it is deletedmanually 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 informationis 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 supply2. Frame connections to the control system3. Sensor signals which affect the basic functions of the engine4. Other signals

Warning! If the display is to be read whilst driving the test shouldbe performed by two people.

An fault can be recorded the moment Running starts. The Multi-Testerplus/pro emits a beep and the letter F is displayed when an fault isdetected. Instructions for retrieving the fault from memory together witha description of fault, help and status messages are described in the “Faultmessages” section.

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EDIT

EditEdit can be used to turn off the error diagnosis for signals which for somereason are not connected to the interface. This may accur if you are testinga different year model of the car than the one that was available whendeveloping 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/proshuts out non-relevant signals.Error diagnosis for other signals can beswitched on and off. Press ENTER tochange the signal’s status. When youpress HELP, more information on theactual signal is displayed.All changes will be erased when theMulti-Tester plus/pro is disconnectedfrom power.

NoteIf error diagnosis is disconnected, thiscan lead to other errors being reported.For example, if error diagnosis for a mainground or power supply is disconnected,then signals that depend on them can bereported as faulty.

EDIT

#XX GROUND ON

#XX GROUND OFF

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SPECIAL TESTS

Special TestsSpecial 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 ismarked 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 togglesthe highlight between the scale factor and the offset bottom left on thedisplay. Depending on which is highlighted, the setting is changed bypressing é/ê. The minimum and maximum values for the scaling are200 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 curvecurrently displayed. When a snapshot has been taken, min/max isreplaced by new values.

Snapshot (Multi Tester pro only)There are two ways of taking a snapshot in graphical mode:• Press F1. Curve drawing stops. Press ENTER to take a snapshot.

To return, press F1 or F2.• Press F2. A new curve is drawn to the end of the X-axis, where it stops.

Press ENTER to take a snapshot. To return, press F1 or F2.

To view snapshots, press EXIT twice, then press HELP. Move the cursorto VIEW GRAPHS with é/ê and press ENTER. The current snapshot andthe 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

The program for the Simtec 56.5 system includes the following special tests:

Static testChecks the signals when the ignition is onbut the engine is not running.

Continuous static testStatic test that is carried out continuously.

Throttle testTests the throttle potentiometer.Checks signal levels and continuity.

Camshaft sensor testTests the camshaft sensor signal.

Lambda sensorDisplays signal voltage from the lambdasensor and the minimum and maximumvalues.

BatteryDisplays the battery voltage and theminimum and maximum values.

Throttle potentiometerDisplays the signal voltage from thethrottle potentiometer and the minimumand maximum values.

>STATIC TEST

>CONT. STAT. TEST

>THROTTLE TEST

>CAMSHAFT TEST

>LAMBDA

>BATTERY

>THROTTLE

Air mass meterDisplays signal voltage from the air massmeter and the minimum and maximumvalues.

Coolant temperatureDisplays the signal voltage from thecoolant temperature sensor and theminimum and maximum values.

>LOAD

>WATERTEMP

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SPECIAL TESTS

Air temperatureDisplays the signal voltage from the airtemperature sensor and the minimumand maximum values.

>AIR TEMP.

Power to crankshaft sensorDisplays the power voltage to thecrankshaft sensor and the minimum andmaximum values.

>POWER CRANKSH.

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SPECIALTESTER

Static testContinuous static testThese tests detect incorrect input andoutput signals from the control unit whenthe ignition is on but the engine is notrunning.A fault is registered if any signal differsfrom the pre-programmed standardvalue. The fault will be held in memoryuntil it is erased manually or until thepower is interrupted.Starting conditions for the test:• The ignition should be on.• The engine should not be started.

If the ignition is off, you will be askedto turn it on. If the engine is startedthe test will not be carried out and theprogram will return to the special testsmenu.

After all the signals are controlled, thetext NO FAULTS FOUND appears on thedisplay or if any faults are located thenFAULTS EXIST will appear.If the continuous static test is selected,then all signals will be tested continu-ously until EXIT is pressed, the ignition isturned off or the engine is started.If faults are found then this will appear onthe display. To view these faults press HELP.

STATIC TEST

Conditions:Ignition is onEngine is not running

Test ofall

signals

FAULT MESSAGE

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SPECIAL TESTS

Throttle testThis test involves a comprehensive checkof the signal levels of the throttle poten-tiometer and the condition of the poten-tiometer pathways. The test can forexample detect signal interruptions thatoriginate from a bad carbon path.Starting conditions for the test:• The ignition has to be turned on.• The engine should not be running.

If the ignition is off, you will be askedto turn it on. If the engine is started,the test will not be carried out and theprogram will return to the special testsmenu.

Firstly, a calibration is carried out for theMulti-Tester plus/pro pre-programmedvalues for full load and idle running. Thisis to guarantee the Multi-Tester plus/profunction as its values can differ fordifferent vehicles. You will be asked togive full throttle and then release theaccelerator completely.Then you will have to press down theaccelerator slowly. A check is now beingcarried out to control that there is nobreak in signal from the throttle poten-tiometer. If the accelerator is depressedtoo quickly during this part of the test,you will be asked to release it and slowlydepress the accelerator again.If faults are found then this will appear onthe display. To view these faults press HELP.

THROTTLE TEST

Conditions:Ignition is onEngine is not running

Calibration offull load and idlerunning values

Test ofcontinuity

FAULT MESSAGE

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SPECIAL TESTS

Camshaft sensor testThis test checks the signals from thecamshaft sensor.Starting conditions for the test:• The engine has to be running. If it

is not, you are prompted to start theengine or crank it with the startermotor for at least ten seconds.

When Multi-Tester plus/pro has detectedthat the engine is running or beingcranked, the time required for thecamshaft sensor, is displayed togetherwith the actual rpm.At the same time the signals from thecamshaft sensor are analysed by Multi-Tester plus/pro to find possible faults.This analys is only done for enginespeeds below 2000 rpm.The test continues until you press EXIT orstop the engine.

CAMSHAFT TEST

Condition:Running engine

#39 IGN XXXX rpm#13 CAMSH. XX.X ms

EXIT

FAULT MESSAGE

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Lambda sensorThis test demonstrates the signal voltageof the lambda sensor.The test displays the actual value togetherwith the minimum and maximum valuesrecorded. This makes it possible to checkthat the sensor is working and swingsbetween extreme positions.Starting condition for this test:• The engine has to be running.

If not, you will be asked to start it.This test will continue until EXIT is pressedor until the engine is turned off.

SPECIAL TESTS

LAMBDA

Condition:Running engine

#10 LAMBDA XXX mVMIN: XXX mVMAX: XXX mV

BatteryThis test demonstrates the voltage levelof the car’s battery.The test displays the actual value togetherwith the minimum and maximum valuesrecorded. This enables the battery voltageduring for example the starting phase to bemeasured.Starting condition for this test:• The ignition has to be turned on.

If not, you will be asked to turn it on.This test will continue until EXIT is pressedor until the engine is turned off.

BATTERY

Condition:Ignition is on

#17 BATT XX.X VMIN: XX.X VMAX: XX.X V

EXIT

EXIT

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SPECIAL TESTS

Throttle potentiometerThis test demonstrates the signal voltageof the throttle potentiometer.The test displays the actual value togetherwith the minimum and maximum valuesrecorded.Starting condition for this test:• The ignition has to be turned on.


THROTTLE POT.


#26 THROTT X.XX VMIN: X.XX VMAX: X.XX V

Air mass meterThis test shows the voltage level of theair mass meter signal.The test displays the actual value togetherwith the minimum and maximum valuesrecorded. This makes it possible to checkthe variations and min/max levels.Starting condition for this test:• The ignition has to be turned on.


LOAD


#33 LOAD X.XX VMIN: X.XX VMAX: X.XX V

EXIT

EXIT

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SPECIAL TESTS

Coolant temperatureThis test demonstrates the signal voltageof the coolant temperature sensor.The test displays the actual value togetherwith the minimum and maximum valuesrecorded.Starting condition for this test:• The ignition has to be turned on.


WATERTEMP


#27 TEMP X.XX VMIN: X.XX VMAX: X.XX V

EXIT

Air temperatureThis test demonstrates the signal voltageof the air temperature sensor.The test displays the actual value togetherwith the minimum and maximum valuesrecorded.Starting condition for this test:• The ignition has to be turned on.


AIR TEMP.


# 8 I-AIR X.XX VMIN: X.XX VMAX: X.XX V

EXIT

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SPECIAL TESTS

Power to crankshaft sensorThis test demonstrates the power voltageand the actual value to the crankshaftsensor together with the minimum andmaximum values recorded.Starting condition for this test:• The ignition has to be turned on.


POWER CRANKSH.


#16 POWER X.XX VMIN: X.XX VMAX: X.XX V

EXIT

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TROUBLE-SHOOTING PROCEDURE

Trouble-Shooting ProcedureGeneralMany faults can be detected by using the Multi-Tester plus/pro (with theappropriate software cassette) only. As an additional aid, each softwarecassette 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 componentswhich are considered potential causes of the fault should be swappedout, each in turn, followed on each occasion with a test drive with theMulti-Tester plus/pro connected.

• NB: the fault rate for control units is relatively low. More likely causesof failure are harness connectors, cabling, sensors or switches.

• Whenever resistance or voltage supply measurements are being taken atthe harness connector by the control unit, the Autodiagnos Break-out Box(A0201/A0202) and associated Break-out Box adapter should be used toavoid destroying the harness connector’s sheathing. This is to ensuregood electrical contact and to avoid damage to or a short circuit acrossthe 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 pinand three columns (the pin number means the number in the control unit’sharness connector). The three columns enumerate the quantities to bechecked by the various tests. In the rightmost column the correspondingsection in the Locating Faults chapter is also included (see figure below).

Pin 2 Ground from chassis

MONITOR

“#2 GROUND” (OK/ERR)SPECIAL

Static test: check ofground level.

RUNNING

Continuous check ofground level.Desired value: 0 V

See chapter 1Locating Faults

In the Locating Faults chapter, the working procedure for locating faults isincluded.

TROUBLE-SHOOTING

SIMTEC 56.5

31A 01090254-1

FAULT TRACING

Fault Tracing

MONITOR“#2 GROUND” (OK/ERR)

SPECIALStatic test: check ofground level.

RUNNINGContinuous check ofground level.Desired value: 0 V


Pin 3 Loadsignal to automatic gear

MONITOR“#3 LOAD” (PULSE/----)

SPECIALNot tested.

RUNNINGNot tested.


Pin 4 Status signal from automatic transmission

MONITOR

“#4 AUTO”(DRIVE/P/N)

SPECIAL

Not tested.RUNNING

Not tested.See chapter

3Locating Faults

Pin 5 Signal from speedometer

MONITOR“#5 VSS” (Hz)

SPECIALNot tested.

RUNNINGNot tested.



Pin 6 Gearchange time signal from automatictransmission

MONITOR“#6 GEAR SH.”(ON/OFF)

SPECIALNot tested.

RUNNINGNot tested.


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SIMTEC 56.5

32 A 01090254-1

FAULT TRACING


MONITOR

“#7 GROUND” (OK/ERR)SPECIAL


RUNNING



Pin 8 Signal from air temperature sensor

MONITOR

“#8 I-AIR” (V)SPECIAL

Static test: check ofsignal level.Air temp.: display ofpower variation.

RUNNING

Continuous check ofsignal level.Desired value at 20°C:1.5 V


Pin 9 Status signal from air conditioning system

MONITOR

“#9 AC SW.” (ON/OFF)SPECIAL

Not tested.RUNNING

Not tested.See chapter 7Locating Faults

Pin 10 Signal from lambda sensor

MONITOR

“#10 LAMBDA” (mV)SPECIAL

Lambda: display ofpower variation.

RUNNING

Check of powervariation. Conditions:– engine at operating

temperature– not idling or under

full load– engine speed

< 3.000 rpmSee chapter

8Locating Faults

TROUBLE-SHOOTING

SIMTEC 56.5

33A 01090254-1

FAULT TRACING


MONITOR

“#11 GROUND”(OK/ERR)

SPECIAL


RUNNING



Pin 13 Signal from camshaft sensor

MONITOR

“#13 CAMSH.”(PULSE/----)

SPECIAL

Static test: pulse check.Camshaft test: check ofthe information contentof the signal.

RUNNING

Continuous pulse check.

Pin 14 Ground to air mass meter

MONITOR


SPECIAL


RUNNING




MONITOR


SPECIAL


RUNNING



Pin 16 Power supply to crankshaft sensor

MONITOR

“#16 POWER” (V)SPECIAL

Static test: check ofvoltage level.Power cranksh.: displayof power variation.

RUNNING

Continuous check ofvoltage level.Desired value: 12 V



TROUBLE-SHOOTING

SIMTEC 56.5

34 A 01090254-1

FAULT TRACING

Pin 17 Power from ignition switch (terminal 15)

MONITOR

“#17 BATT” (V)SPECIAL

Static test: check ofvoltage level.Battery: display ofpower variation.

RUNNING

Continuous check ofvoltage level.Desired value: 12–14 V


MONITOR

“#18 POWER” (ON/OFF)SPECIAL

Static test: check ofvoltage level.Throttle: display ofpower variation.

RUNNING

Continuous check ofvoltage level.Desired value: 5 V



MONITOR


SPECIAL


RUNNING



Pin 20 Engine speed signal to revolution counter

MONITOR“#20 RPM”(PULSE/----)

SPECIALNot tested.

RUNNINGContinuous pulse check.


Pin 21 Fuel consumption signal to boardcomputer

MONITOR

“#21 INFO” (PULSE/----)SPECIAL

Not tested.RUNNING


15Locating Faults

Pin 18 Power supply to throttle potentiometer

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SIMTEC 56.5

35A 01090254-1

FAULT TRACING

Pin 23 Signal from air conditioning compressor

MONITOR

“#23 AC PRESS”(ON/OFF)

SPECIAL

Not tested.RUNNING


16Locating Faults

Pin 24 Signal from crankshaft sensor

MONITOR

“#21 CRANK”(PULSE/----)

SPECIAL

Not tested.RUNNING

Continuous pulse check.See chapter

17Locating Faults

Pin 26 Signal from throttle potentiometer

MONITOR

“#26 THROTT” (V)SPECIAL

Static test: check ofsignal level.Throttle test: check ofsignal level andcontinuity.Throttle: display ofvoltage variation.

RUNNING

Continuous check ofsignal level andcontinuity.Desired value at– idle: 0.1-0.9 V– full load: 2.5-4.5 V


Pin 27 Signal from coolant temperature sensor

MONITOR

“#27 TEMP” (V)SPECIAL

Static test: check ofsignal level.Watertemp: display ofpower variation.

RUNNINGContinuous check ofsignal level.Desired value whenengine at operatingtemperature: 0.8-1.5 V


TROUBLE-SHOOTING

SIMTEC 56.5

36 A 01090254-1

FAULT TRACING


MONITOR


SPECIAL


RUNNING



Pin 31 Oscillation signal to the camshaft sensor

MONITOR

“#31 OSC.CAM”(PLS/----)

SPECIAL

Static test: pulse check.RUNNING


20Locating Faults

Pin 32 Ground to camshaft sensor

MONITOR


SPECIAL


RUNNING



Pin 33 Signal from air mass meter

MONITOR“#33 LOAD” (V)

SPECIALStatic test: check ofsignal level.

RUNNINGCheck of minimum andmaximum values.Desired value at idle:0.4-0.9 V


Pin 34 Control signal to the air conditioning compressorrelay

MONITOR

“#34 AC” (ON/OFF)SPECIAL

Not tested.RUNNING


TROUBLE-SHOOTING

SIMTEC 56.5

37A 01090254-1

FAULT TRACING

Pin 35 Power supply from main relay

MONITOR

“#35 POWER”(ON/OFF)

SPECIAL

Static test: check ofvoltage level.

RUNNING

Continuous check ofvoltage level.Desired value: 12-14 V


Pin 36 Power supply to lambda sensor

MONITOR“#36 POWER”(ON/OFF)

SPECIALStatic test: check ofvoltage level.

RUNNINGContinuous check ofvoltage level.Desired value: 5 V


Pin 38 Control signal to ignition amplifier, cylinder 2 & 3

MONITOR“#38 IGN” (PULSE/----)


RUNNINGContinuous pulse check.


Pin 39 Control signal to ignition amplifier, cylinder 1 & 4

MONITOR

“#39 IGN” (rpm)SPECIAL


RUNNING

Continuous pulse check.See chapter 26Locating Faults

Pin 40 Control signal to injection valve, cylinder 4

MONITOR

“#40 INJ” (ms)SPECIAL

Not tested.RUNNING


TROUBLE-SHOOTING

SIMTEC 56.5

38 A 01090254-1

FAULT TRACING


MONITOR


Not tested.RUNNING



MONITOR


Not tested.RUNNING



MONITOR


Not tested.RUNNING


Pin 44 Power supply from main relayMONITOR

“#44 RELAY”(ON/OFF)

SPECIAL


RUNNING



Pin 45 Control signal to EGR-valve

MONITOR“#45 EGR” (%)


RUNNING


28Locating Faults

Pin 46 Control signal to idle speed correction valve

MONITOR

“#46 ISC” (%)SPECIAL

Static test: pulse check.RUNNING


29Locating Faults

TROUBLE-SHOOTING

SIMTEC 56.5

39A 01090254-1

FAULT TRACING

Pin 47 Control signal to tank ventilation valve

MONITOR

“#47 TANK” (%)SPECIAL


RUNNING


30Locating Faults

Pin 48 Control signal to lambda sensor pre-heater

MONITOR

“#48 O2HEAT” (%)SPECIAL


RUNNING


Pin 49 Control signal to main relay

MONITOR“#49 RELAY” (ON/OFF)

SPECIALStatic test: check ofcontrol signal level.

RUNNINGContinuous check ofcontrol signal level.


Pin 50 Control signal to secondary air injection

MONITOR

“#50 SEC.AIR”(ON/OFF)

SPECIAL


RUNNING


33Locating Faults

Pin 53 Control signal to adjustable manifold valve

MONITOR“#53 VAR.AIR”(ON/OFF)


RUNNINGNot tested.


TROUBLE-SHOOTING

SIMTEC 56.5

40 A 01090254-1

FAULT TRACING

Pin 54 Control signal to fuel pump relay

MONITOR

“#54 RELAY” (ON/OFF)SPECIAL

Static test: check ofcontrol signal level.

RUNNING

Continuous check ofcontrol signal level.


Pin 55 Constant power supply from battery

MONITOR

“#55 BATT” (OK/ERR)SPECIAL


RUNNING



TROUBLE-SHOOTING

SIMTEC 56.5

41A 01090254-1

LOCATING FAULTS

Locating Faults

1Check of ground connection to Simtec, pin 2, 7, 11, 15, 19 and29These contacts are the control unit’s ground connection.1. Disconnect the 55-pin connector from the control unit. Connect the

Break-out Box (A0201/A0202) and the 55-pin adapter (A020204) to thecar’s wiring harness only. Do not reconnect the control unit.

2. Measure the resistance between the Break-out Box, pin 2, 7, 11, 15, 19and 29, respectively and ground. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

2Check of load signal to automatic transmission from Simtec,pin 3This is a signal to the control box of the automatic transmission, whichuses the signal to determine when to change gear.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance between the Break-out Box, pin 3 and theautomatic gearbox. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3Check of status signal from the automatic transmission toSimtec, pin 4This is a signal that provides the control unit with information on when agear is engaged in the drive mode. The control unit responds by openingthe ISC valve slightly to compensate for the stress.1. Disconnect the 55-pin connector from the control unit. Connect the


/Continued

TROUBLE-SHOOTING

SIMTEC 56.5

42 A 01090254-1

LOCATING FAULTS

2. Measure the resistance between the Break-out Box, pin 4 and theautomatic gearbox. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

4Check of signal from the speedometer to Simtec, pin 5This is a signal from the speedometer, which transmits a digital signal tothe control unit.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance between the Break-out Box, pin 5 and thespeedometer. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

5Check of gear change signal from the automatic transmissionto Simtec, pin 6This is a status signal from the automatic gearbox to the control unit.When the automatic gearbox changes gear, the control unit responds byreducing priming to facilitate a smoother gear change.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 6and the automatic gearbox. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

6Check of signal from air temperature sensor to Simtec, pin 8This is an input signal to the control unit from the air temperature sensor(type NTC with a negative temperature coefficient).1. Disconnect the 55-pin connector from the control unit. Connect the


TROUBLE-SHOOTING

SIMTEC 56.5

43A 01090254-1

LOCATING FAULTS

2. Measure the resistance of the cable between the Break-out Box, pin 8 andthe air temperature sensor (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 7and air temperature sensor. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

4. Measure the resistance between the Break-out Box, pin 8 and 7.Desired values: air temp. resistance (kΩ)

+ 10–30°C 2.0–5.0Possible cause of fault: Air temperature sensor.

7Check of status signal from the air conditioning system toSimtec, pin 9This is a status signal from the air conditioning system. When it is active, thecontrol unit will respond by opening the ISC valve slightly to compensate forthe stress.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 9and the air conditioning system. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

8Check of signal from lambda sensor to Simtec, pin 10This is an input signal to the control unit from the lambda sensor. It isonly found on cars fitted with catalytic converters and is used for the fineadjustment 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/prochecks that the lambda sensor signal level lies between 0–5 V:

• Engine temperature must exceed +80°C.• The engine must not be idling – some sensors cool down after long

periods of idling and oscillation ceases.

/Continued

TROUBLE-SHOOTING

SIMTEC 56.5

44 A 01090254-1

LOCATING FAULTS

• The engine must not be at full throttle – the sensor signal thenbecomes constant at approx. 5 V.

• Fuel cut-off should not be activated – the sensor signal then becomesconstant at approx. 0 V.

• Engine speed below 3.000 rpm.1. Check the preheating of the lambda sond as described in Locating Faults

31, page 57.2. Run the engine until it reaches operating temperature and maintain engine

speed at approximately 2.500 rpm. Execute the LAMBDA SENSOR specialtest and confirm that the lambda sensor signals fluctuate between 0-5 V.The signal should oscillate about once a second. Oscillations of longerduration indicate that the sensor may be polluted and should be replaced.

3. Turn off the ignition and disconnect the 55-pin connector from thecontrol unit. Connect the Break-out Box (A0201/A0202) and the 55-pinadapter (A020204) to the car’s wiring harness only. Do not reconnect thecontrol unit.

4. Measure the resistance between the Break-out Box, pin 10 and ground.If the reading is approximately 0 Ω the sensor has short-circuited and isno longer functioning. Repeat the measurement at the sensor connectorto determine whether the short circuit is in the sensor or the cablebetween the sensor and the control unit.

9Check of signal from camshaft sensor to Simtec, pin 13This is an input signal to the control unit from camshaft sensor whichmeasures camshaft rotations.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 13and camshaft sensor, pin 3 (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 32and camshaft sensor, pin 4. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

TROUBLE-SHOOTING

SIMTEC 56.5

45A 01090254-1

LOCATING FAULTS

4. Measure the resistance of the cable between the Break-out Box, pin 31and camshaft sensor, pin 1. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

5. Disconnect the cable from the camshaft sensor. Measure the resistancebetween camshaft sensor, pin 1 and 2. Desired value: 10.7-14.7 ΩPossible cause of fault: Camshaft sensor.

6. Measure the resistance between camshaft sensor, pin 1 and 3.Desired value: 11.2-15.2 ΩPossible cause of fault: Camshaft sensor.

10Check of ground connection to air mass meter from Simtec,pin 141. Disconnect the 55-pin connector from the control unit. Connect the

Break-out Box (A0201/A0202) and the 55-pin adapter (A020204) betweenthe car’s wiring harness and the control unit.

2. Start the engine and measure the voltage between the Break-out Box,pin 14 and ground. Desired value: 0 VPossible cause of fault: Wiring or connectors.

Note:In certain systems the ground point is located in the air mass meter.

11Check of power supply to the crankshaft sensor fromSimtec, pin 161. Disconnect the 55-pin connector from the control unit. Connect the


2. Start the engine and measure the voltage between the Break-out Box,pin 16 and 7. Desired value: 12 VPossible cause of fault: Wiring, connectors, crankshaft sensor or

control unit.

TROUBLE-SHOOTING

SIMTEC 56.5

46 A 01090254-1

LOCATING FAULTS

12Check of power supply from ignition switch (terminal 15) toSimtec, pin 17This 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 between pin 3 on the

ignition amplifier and ground. Desired value: 12-14 VPossible cause of fault: Wiring, connectors or ignition switch.

2. Turn off the ignition. Disconnect the 55-pin connector from the control unit.Connect the Break-out Box (A0201/A0202) and the 55-pin adapter (A020204)between the car’s wiring harness and the control unit.

3. Measure the voltage between the Break-out Box, pin 17 and 7.Desired value: 12-14 VPossible cause of fault:Wiring, connectors, immobilizer or alarm.

NoteThe terminal 15 supply provides the stop signal for the Multi-Tester plus/protest program. This means that an absent signal is interpreted as a stoppedengine. Nevertheless, a faulty signal will be detected at the start of the test.

13Check of power supply to the throttle potentiometer fromSimtec, pin 181. Disconnect the 55-pin connector from the control unit. Connect the


2. Start the engine and measure the voltage between the Break-out Box,pin 18 and 7. Desired value: 5 VPossible cause of fault: Wiring, connectors, throttle potentiometer

or control unit.

TROUBLE-SHOOTING

SIMTEC 56.5

47A 01090254-1

LOCATING FAULTS

14Check of engine speed signal to revolution counter fromSimtec, pin 20This is an output signal from the control unit indicating engine speed forthe car’s tachometer, for example.1. Disconnect the 55-pin connector from the control unit and connect the


2. Start the engine and check (use oscilloscope or similar) that pulses arereceived at the Break-out Box, pin 20.Possible cause of fault: Wiring, connectors or control unit.

15Check of fuel consumption signal to the boardcomputerfrom Simtec, pin 21This is an output signal from the control unit, supplying fuel consumptioninformation to the boardcomputer of the vehicle.1. Disconnect the 55-pin connector from the control unit and connect the


2. Start the engine and check (use oscilloscope or similar) that pulses arereceived at the Break-out Box, pin 21.Possible cause of fault: Wiring, connectors or control unit.

Note: The test is discontinued during fuel cut-off.

16Check of air conditioning compressor signal to Simtec, pin 231. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 23and the air conditioning compressor. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

TROUBLE-SHOOTING

SIMTEC 56.5

48 A 01090254-1

LOCATING FAULTS

17Check of signal from crankshaft sensor to Simtec, pin 24This is an input signal to the control unit from crankshaft sensor whichmeasures crankshaft rotations.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 24and crankshaft sensor, pin 2 (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 16and crankshaft sensor, pin 1. Desired value: 0 ΩPossible cause of fault: Wiring or connectors

4. Measure the resistance of the cable between the Break-out Box, pin 29and crankshaft sensor, pin 3. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

5. Disconnect the cable from the crankshaft sensor. Measure the resistancebetween crankshaft sensor, pin 2 and 3. Desired value: 0.3-0.5 ΩPossible cause of fault: Crankshaft sensor.

6. Measure the resistance between crankshaft sensor, pin 1 and 2.Desired value: 10.3-14.3 ΩPossible cause of fault: Crankshaft sensor.

18Check of signal from throttle potentiometer to Simtec, pin 26This is an input signal from the throttle potentiometer to the control unit.The output signal varies in response to the throttle position. Two signalproperties are tested; level and continuity.

Signal level fault1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 26 andthrottle potentiometer, pin 3 (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

TROUBLE-SHOOTING

SIMTEC 56.5

49A 01090254-1

LOCATING FAULTS

3. Measure the resistance of the cable between the Break-out Box, pin 18and throttle potentiometer, pin 2. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

4. Measure the resistance of the cable between the Break-out Box, pin 7and throttle potentiometer, pin 1. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

5. Measure the resistance between the Break-out Box, pin 26 and pin 7.Desired value: Throttle closed 0.9-1.1 kΩ Throttle opened 2.3-2.4 kΩPossible cause of fault: Throttle potentiometer.

6. Connect the Break-out Box and the 55-pin adapter between the car’swiring harness and the control unit.

7. Turn on the ignition and measure the voltage between the Break-outBox, pin 18 and 7. Desired value: 5 VPossible cause of fault: Ground connection, throttle potentiometer

or control unit.

Continuity faultWhen this fault is reported it is most likely that the potentiometer’s trackis faulty.1. Replace the potentiometer.2. Repeat the test with the Multi-Tester plus/pro.

19Check of signal from coolant temperature sensor to Simtec,pin 27This is an input signal to the control unit from the coolant temperaturesensor (type NTC with a negative temperature coefficient).1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 27 andcoolant temperature sensor (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 7and coolant temperature sensor. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

/Continued

TROUBLE-SHOOTING

SIMTEC 56.5

50 A 01090254-1

LOCATING FAULTS

4. Measure the resistance between the Break-out Box, pin 27 and 7.Desired values: engine temp. resistance

+ 10-30°C 1.5-3.3 kΩ+ 80°C 300-360 Ω

Possible cause of fault: Coolant temperature sensor.

20Check of oscillation signal to the camshaft sensor fromSimtec, pin 311. Disconnect the 55-pin connector from the control unit and connect the


2. Turn on the ignition and check (use oscilloscope or similar) that pulsesare received at the Break-out Box, pin 31. Desired value: 95 kHzPossible cause of fault: Wiring, connectors, camshaft sensor or

control unit.

21Check of ground connection to camshaft sensor fromSimtec, pin 321. Disconnect the 55-pin connector from the control unit. Connect the


2. Start the engine and measure the voltage between the Break-out Box,pin 32 and ground. Desired value: 0 VPossible cause of fault: Wiring or connectors.

22Check of signal from air mass meter to Simtec, pin 33This is an input signal to the control unit from the air mass meter.The signal indicates engine load.1. Disconnect the 55-pin connector and connect the Break-out Box (A0201/

A0202) and the 55-pin adapter (A020204) to the car’s wiring harnessonly. Do not reconnect the control unit.

TROUBLE-SHOOTING

SIMTEC 56.5

51A 01090254-1

LOCATING FAULTS

2. Measure the resistance of the cable between the Break-out Box, pin 33and air flow meter, pin 2. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 15and air flow meter, pin 1. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


5. Start the engine and measure the voltage at air mass meter, pin 3.Desired value: 12 VPossible cause of fault: Wiring or connectors.

6. If all the recorded values are correct, replace the air mass meter andrepeat the test.

/Continued

23Check of control signal to the air conditioning compressorrelay from Simtec, pin 34This is an output signal from the control box to shut down theairconditioning compressor if necessary (powerful acceleration etc.).1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between pin 34 on the Break-out Boxand the compressor relay. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

24Check of power supply from main relay to Simtec, pin 35 and 44When ignition is turned on the main relay is activated by pin 49. It isactivated approximately 1 minute after that ignition has been turned off.1. Measure the voltage at the main relay, pin 4 and ground (see workshop

manual). Desired value: 12-14 VPossible cause of fault: Wiring or connectors.

2. Measure the voltage at the main relay, pin 2 and ground (see workshopmanual). Desired value: 12-14 VPossible cause of fault: Wiring, connectors or ignition switch.

TROUBLE-SHOOTING

SIMTEC 56.5

52 A 01090254-1

LOCATING FAULTS

3. Measure the voltage at the main relay, pin 6 and ground (see workshopmanual). Desired value: 12-14 VPossible cause of fault: Wiring or connectors.


5. Measure the resistance of the cable between the Break-out Box, pin 35/44and main relay, pin 8. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

6. Measure the resistance of the cable between the Break-out Box, pin 49and main relay, pin 6. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


8. Turn on the ignition and measure the voltage between the Break-out Box,pin 49 and ground. Desired value: 0 VPossible cause of fault: Wiring, connectors or control unit.

25Check of power supply to lambda sensor from Simtec, pin 361. Disconnect the 55-pin connector from the control unit. Connect the


2. Turn on the ignition and measure the voltage between the Break-outBox, pin 36 and 7. Desired value: 5 VPossible cause of fault: Wiring, connectors, lambda sensor or control

unit.

TROUBLE-SHOOTING

SIMTEC 56.5

53A 01090254-1

LOCATING FAULTS

26Check of the control signal to the ignition amplifier fromSimtec, pin 38 and 39This is an output signal from the control unit to control ignition. The controlunit emits ignition pulses which control the ignition amplifier. There areseveral possible causes of an absent signal:• A discontinuity in the wiring or connectors.• A defective or absent main input signal to the system such as:

– Crankshaft sensor– Camshaft sensor– Voltage supply– Ground connection

• A faulty control unit, although this is most unlikely as the failure ratefor control units is very low.


2. Measure the resistance of the cable between terminal 15 and the ignitionamplifier, pin 3. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 38/39and ignition amplifier, pin 2/1. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


5. Connect the ignition amplifier contact and check with a test lamp thatpulses are received at pin nr 38/39 when the starter motor is turned over.Possible cause of fault: Ignition amplifier, ignition coil or control unit.

TROUBLE-SHOOTING

SIMTEC 56.5

54 A 01090254-1

LOCATING FAULTS

27Check of control signal to the injection valve from Simtec,pin 40, 41, 42 and 43This is an output signal from the control unit to the injection valve whichcontrols fuel metering.1. Turn on the ignition and measure the power supply to the injection

valve. Desired value: 12-14 VPossible cause of fault: Wiring, connectors or the main relay.

2. Check the opening pulse by measuring the voltage across the injectionvalves with a test lamp (measure from the rear of one of the connectorson any injector). At low rpm the lamp should flash; it should shine witheven intensity at higher rpm.If incorrect:– disconnect the 55-pin connector from the control unit. Connect the

Break-out Box (A0201/A0202) and the 55-pin adapter (A020204)between the car’s wiring harness and the control unit. Repeatcorresponding measurement between the Break-out Box,pin 40/41/42/43 and 7.

3. In the case of a suspected discontinuity between Simtec, pin 40/41/42/43and 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 40/41/42/43 andthe 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: 15 ΩPossible cause of fault: Injector.

NoteThe test is discontinued during fuel cut-off.Injector failure can also have a mechanical cause (lining, etc.). Such faultsare not registered by the Multi-Tester plus/pro. In such a case, a flow checkmust be carried out on each injector.

TROUBLE-SHOOTING

SIMTEC 56.5

55A 01090254-1

LOCATING FAULTS

28Check of control signal to EGR-valve from Simtec, pin 45This is an output signal from the control unit to the EGR-valve that controlsthe exhaust gas recirculation.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Disconnect the cable from the EGR-valve. Measure the resistance of thecable between the Break-out Box, pin 45 and EGR-valve, pin 2 (seeworkshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


4. Turn on the ignition and measure the voltage between connector, pin 1and ground. Desired value: 12 VPossible cause of fault: Wiring or connectors.

29Check of control signal to idle speed correction valve fromSimtec, pin 46The idle speed correction valve (ISR or ISC) is controlled by an output signalfrom the control unit which operates a coil in the correction valve. The signalhas a constant frequency of 160 Hz and the pulse ratio varies between approx.25 % and 75 %. When this value increases, rpm increases, for example whenthe engine is cold or when the AC compressor is switched on.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Disconnect the connector from the ISC valve. Measure the resistance ofthe cable between the Break-out Box, pin 46 and the correspondingterminal at the connector (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 44and the corresponding terminal at the connector. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

/Continued

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SIMTEC 56.5

56 A 01090254-1

LOCATING FAULTS

4. Measure the resistance between the valve’s terminals. Desired value: 10 ΩPossible cause of fault: ISC valve.


6. Connect the ISC valve again. Start the engine and check if pulses appearon the Break-out Box, pin 46 (use oscilloscope or similar).Possible cause of fault: ISC valve or control unit.

30Check of the control signal to tank ventilation valve fromSimtec, pin 47This is an output signal from the control unit. It regulates the valve whichventilates the fuel tank. The value should vary between 1 and 99 % whenaccelerating.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Disconnect the cable from the tank ventilation valve. Measure theresistance of the cable between the Break-out Box, pin 47 and connector(see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


4. Turn on the ignition and measure the voltage between the connector'sother contact and ground at the Break-out Box. Desired value: 12 VPossible cause of fault: Wiring or connectors.

5. Measure the resistance between the valve’s terminals. Desired value: 36 ΩPossible cause of fault: Tank ventilation valve.

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SIMTEC 56.5

57A 01090254-1

LOCATING FAULTS

31Check of control signal to lambda sensor pre-heater fromSimtec, pin 48This is an output signal from the control box to the heating element of thelambda sensor.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Disconnect the cable from the lambda sensor. Measure the resistance ofthe cable between Break-out Box, pin 48 and the connector, pin A.Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


4. Turn on the ignition and measure the voltage between connector, pin Cand the Break-out Box, pin 35. Desired value: 12 VPossible cause of fault: Wiring or connectors.

5. Measure the resistance between the lambda sensors connector, pin Aand C. Desired value: 4.5–5.5 ΩPossible cause of fault: Heating element in lambda sensor.

32Check of control signal to main relay from Simtec, pin 49This is an output signal from the control unit. The signal is grounded toactivate the main relay. There can be several reasons for an absent signalincluding:• Discontinuity in the wiring or connectors.• Defective or absent main input signal to the system, such as:

– Voltage supply– Ground connection

• Faulty control unit, although this is most unlikely as the failure rate forcontrol units is very low.

1. Disconnect the 55-pin connector from the control unit. Connect theBreak-out Box (A0201/A0202) and the 55-pin adapter (A020204) to thecar’s wiring harness only. Do not reconnect the control unit.

/Continued

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SIMTEC 56.5

58 A 01090254-1

LOCATING FAULTS

2. Measure the resistance of the cable between the Break-out Box, pin 49and main relay, pin 6 (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

33Check of control signal to secondary air injection fromSimtec, pin 50This is an output signal from the control box to the secondary air valve andthe secondary air relay, which supplies power to the secondary air pump.The secondary air injection provides the catalytic converter with an extrasupply of oxygen during cold starting so that it heats up quicker.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 50and secondary air pump relay, pin 6. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.

3. Measure the resistance of the cable between the Break-out Box, pin 50and secondary air pump valve, pin 2. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


5. Turn on the ignition and measure the voltage between secondary airpump relay, pin 4 and ground. Desired value: 12 VPossible cause of fault: Wiring or connectors.

6. Disconnect the connector on the secondary air valve. Measure the voltagebetween one pin of the connector and ground. Desired value: 12 VPossible cause of fault: Wiring or connectors.

7. Measure the voltage at the secondary air relay, pin 8 and ground.Desired value: 12 VPossible cause of fault: Wiring, connectors or fuse.

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SIMTEC 56.5

59A 01090254-1

LOCATING FAULTS

34Check of the control signal of the adjustable manifold valvefrom Simtec, pin 53This is an output signal from the control unit. It controls the valve on theadjustable manifold.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Disconnect the cable from the the valve of the adjustable manifold.Measure the resistance of the cable between the Break-out Box, pin 53and connector, pin 1 (see workshop manual). Desired value: 0 ΩPossible cause of fault: Wiring or connector.


4. Turn on the ignition. Measure the voltage at the valve, pin 2.Desired value: 12-14 VPossible cause of fault: Wiring, connector or relay.

35Check of control signal to fuel pump relay from Simtec, pin 54This is a control signal from the control unit to the fuel pump relay. Thesignal is grounded to activate the pump relay after the engine has beenturned over by the starter motor. There are several possible causes for anabsent 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– Camshaft sensor

• Faulty control unit, although this is most unlikely as the failure rate forcontrol units is very low.

1. Disconnect the 55-pin connector from the control unit. Connect theBreak-out Box (A0201/A0202) and the 55-pin adapter (A020204) to thecar’s wiring harness only. Do not reconnect the control unit.

/Continued

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SIMTEC 56.5

60 A 01090254-1

LOCATING FAULTS

2. Measure the resistance of the cable between the Break-out Box, pin 54and fuel pump relay, pin 6. Desired value: 0 ΩPossible cause of fault: Wiring or connectors.


4. Turn on the ignition and measure the voltage between fuel pump relay,pin 4 and ground. Desired value: 12 VPossible cause of fault: Wiring or connectors.

5. Measure the voltage between fuel pump relay, pin 2 and ground.Desired value: 12 VPossible cause of fault: Wiring or connectors.

6. Start the engine (turn over) and measure the voltage between pin 54 andground. Desired value: 0 VPossible cause of fault: A defective or absent main input signal to

the system, control unit.7. Start the engine or turn over and measure the voltage between the fuel

pump relay, pin 8 and ground. Desired value: 12 VPossible cause of fault: Fuel pump relay.

36Check of constant power supply from battery to Simtec, pin 55This connection provides the control unit with a constant power supply fromthe battery to maintain retention of those presets the control unit has “learnt”.1. Disconnect the 55-pin connector from the control unit. Connect the


2. Measure the resistance of the cable between the Break-out Box, pin 55and the battery’s positive pole. Desired value: 0 ΩPossible cause of fault: Wiring, connectors or fuse.

3. Measure the voltage between the battery’s positive pole and ground.Desired value: 12-14 VPossible cause of fault: Battery.

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61A 01090254-1

INDEX

IndexAdjustable manifold valve ........................................................................ 39, 59Air conditioning compressor .................................................................... 35, 47Air conditioning compressor relay ............................................................ 36, 51Air conditioning system ............................................................................ 32, 43Air mass meter ............................................................. 21, 27, 33, 36, 45, 50Air temperature ........................................................................................ 22, 28Air temperature sensor ............................................................................ 32, 42Automatic gear ............................................................................................... 31Automatic transmission ..................................................................... 31, 41, 42Battery ........................................................................................ 21, 26, 40, 60Boardcomputer ........................................................................................ 34, 47Camshaft sensor ........................................................................ 33, 36, 44, 50Camshaft sensor test ............................................................................... 21, 25Chassis ............................................................................... 31, 32, 33, 34, 35Continuous static test .............................................................................. 21, 23Coolant temperature ................................................................... 21, 28, 35, 49Crankshaft sensor ........................................................ 22, 29, 33, 35, 45, 48EGR-valve ............................................................................................... 38, 55Fuel pump relay ....................................................................................... 40, 59Ground ............................................................ 31, 32, 33, 34, 35, 36, 41, 50Idle speed correction valve ...................................................................... 38, 55Ignition amplifier ...................................................................................... 37, 53Ignition switch .......................................................................................... 34, 46Injection valve ................................................................................... 37, 38, 54Lambda sensor ............................................................. 21, 26, 32, 37, 43, 52Lambda sensor pre-heater ...................................................................... 39, 57Main relay ............................................................................ 36, 38, 39, 51, 57Revolution counter ................................................................................... 34, 47Secondary air injection ............................................................................ 39, 58Speedometer ........................................................................................... 31, 42Static test ................................................................................................. 21, 23Tank ventilation valve ............................................................................... 39, 56Throttle potentiometer ................................................... 21, 27, 34, 35, 46, 48Throttle test ............................................................................................. 21, 24

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62 A 01090254-1

INTERFACE - SIGNAL LOCATIONS

Interface - Signal Locations1. Diagnosis2. Ground trom chassis3. Loadsignal to automatic gear*4. Status signal from automatic transmission*5. Signal from speedometer6. Gearchange time signal from automatic

transmission*7. Ground from chassis8. Signal from air temperature sensor9. Status signal from air conditioning system*

10. Signal from lambda sensor11. Ground from chassis12. Signal from knock sensor13. Signal from camshaft sensor14. Ground to air mass meter15. Ground from chassis16. Power supply to crankshaft sensor17. Power from ignition switch (terminal 15)18. Power supply to throttle potentiometer19. Ground from chassis20. Engine speed signal to revolution counter21. Fuel consumption signal to boardcomputer22. Diagnosis23. Signal from air conditioning compressor24. Signal from crankshaft sensor25. Not connected26. Signal from throttle potentiometer27. Signal from coolant temperature sensor28. Not connected29. Ground from chassis30. Signal from knock sensor31. Oscillation signal to the camshaft sensor32. Ground to camshaft sensor33. Signal from air mass meter34. Control signal to the air conditioning compressor

relay*35. Power supply from main relay36. Power supply to lambda sensor37. Not connected38. Control signal to ignition amplifier, cylinder 2 & 339. Control signal to ignition amplifier, cylinder 1 & 440. Control signal to injection valve, cylinder 441. Control signal to injection valve, cylinder 242. Control signal to injection valve, cylinder 143. Control signal to injection valve, cylinder 344. Power supply from main relay

45. Control signal to EGR-valve46. Control signal to idle speed correction valve47. Control signal to tank ventilation valve48. Control signal to lambda sensor pre-heater49. Control signal to main relay50. Control signal to secondary air injection51. Not connected52. Engine control lamp53. Control signal to adjustable manifold valve**54. Control signal to fuel pump relay55. Constant power supply from battery

Wiring* If AC/Automatic** Not OMEGA-B

3736353433323130292827262524232221

19

181716151413121110987654

32

555453525150494847464544434241403938 20

1

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SIMTEC 56.5

63A 01090254-1

+-

1

2

3

6

8

4

2

6

8

15

30

PNR123

IM O ATS

13

3314

48

49

54

36

10

2416

13

12

18

26

27

47

8

6

46

23

341

212052

5

2 7 11 15

22

9

3

4

30

40

41

42

43

31

55

+

+5

+5

+ + +39

38

17 35 44

C

A

BD

3

12

3

12

32

1

12

2 4

SIM

TE

C

19

32

29

8 7

8 58 6

3 0

8 7

8 58 6

3 0 2

4

8 5

3 0

8 6

8 7

8 7A

50

53

45

M

WIRING DIAGRAM

Wiring DiagramThis wiring diagram is an example. Check in the relevant workshop manualfor the diagram of the car you are working with.

Control unit

Air mass meter

Lambda sensor

Crankshaft sensor

Camshaft sensor

Knock sensor

Throttlepotentiometer

Coolanttemp. sensor

Air temp. sensor

Automatic gear box

AC

Speedometer

BatteryIgnitionamplifier

Ignition switch

Main relay

Fuel pumprelay

Fuel pump

Injection valvesSecondaryair pump relay

Secondaryair pumpSecondaryair valve

Variable intakemanifold

EGR-valve

Tank ventilationvalveIdle speedcorrection valve

Dashboard

Diagnosis

trouble-shooting - simtec 56.5 trouble hooting simtec · astra-f 2.0 x20xev 95– vectra-b 1.8...

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