Motronic 4 - 2022

Hong Kong Institute of Vocational Education (Tsing Yi)
Department of Engineering
Technology Laboratory Worksheet
Title of Investigation: Motronic 4.1 System
Objectives: To investigate the various features of the Motronic 4.1 System using a system tester.
Duration: 180 minutes
Investigation rig: Motronic Simulation Board
Tools and Equipment: 1. Board accessories: Power supply

Ignition key
BOSCH KTS 300 System Tester
Multi-function terminal board
2. Vacuum pump
3. Multimeter
A. Introduction
We shall investigate the operating characteristics of the Motronic 4.1 system using the KPS 300
System Tester. Read the introduction to the Motronic system and OBD II at the back of this
worksheet.
B. System set up
In this section students are introduced to the various functions of training board and the operation of
the KPS 300 System tester.
B1. Operating the training board

 Check that the oil tank on the back of the trainer is topped-up to between MAX and MIN.
 Install all the connection bridges on the simulation terminal.
 Connect up the power supply.
 Activate system with ignition key. The system LED should be on.
 The system is now ‘idling’.
 Use the potentiometer to adjust the rpm.
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B2. Setting engine operating condition
Refer to Figure 1 and identify the switches/sensors on the training board.

Switches/sensors on board Variables Range
Potentiometer Engine speed Idle - 3000 rpm

Throttle switch Throttle position Idle - full load
Airflow sensor Air flow Closed to open
Lambda sensor Exhaust oxygen content 0 to 1000 mV
Coolant temperature sensor Coolant temperature -27 to 93 oC
Air temperature sensor Air temperature -27 to 50 oC
Vacuum for fuel regulator Fuel pressure 0 to 500mbar
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Student should set the above sensor inputs to appropriate positions to simulate an engine operating
condition. For example, idle refers to 800 rpm, throttle switch closed, airflow sensor plate fully
closed, Lambda output above 800mV, vacuum in 500 mbar. Coolant temperature depends on warm
up condition.
B3. Multi-function terminal
On the multi-function terminal, individual signal lines to and from the control unit have bridge
connectors. The signal lines are coded with numbers to simplify finding the bridge in wiring
loom/control unit. This pin assignment simplifies diagnosis and fault-finding.
The Motronic 4.1 multifunction terminal has the following pins:
Pin number Component Signal type
17 warning lamp earth clocking, power failure/fault warning

3 control unit earth connection, control unit
18 control unit control unit continuous plus for error memory
1 ignition coil switch signal
13 temperature sensor (coolant) motor/cooling water temperature signal
2 throttle valve switch idle contact
3 throttle valve switch wide open contact
16 control unit earth, control unit
19 control unit earth, control unit
22 temperature sensor (air) intake air temperature signal
6 air quantity meter earth
30 air quantity meter signal loop 1
9 air quantity meter power supply
7 air quantity meter signal loop 2
24 lambda probe lambda probe signal (10 - 1000 mV)
4 diagnostic port stimulation line
12 diagnostic port bi-directional data line
33 idle speed control for regulating idle speed
14 injection valves earth clocking
20 fuel pump relay earth clocking
35 Fuel pump relay voltage
23 rpm sensor rpm signal
25 rpm sensor rpm signal
B4. Fault simulation
The board has a multi-function terminal. With all bridges in place, the system complies with all
specified parameters. If a bridge is replaced with a fault simulating bridge (blind bridge), the ECU
(depending upon seriousness of fault) switches to emergency subroutines and/or switches on
warning lights.
Students can now use the external circuit diagram training board and a multi-meter to locate the
fault and then rectify it by replacing the correct system bridge.
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As soon as the fault is found and rectified, the ignition is switched off once and (turn off any
warning lights and reset the system. However, the error is still registered in system memory. System
memory can only using appropriate equipment (e.g. Bosch KTS 300).
B5. Operating the KPS System Tester
Follow the following steps in using the KPS: (Always turn the KPS on before the engine system
when doing tests.)
 Switch off the board.
 Connect the interface cables (refer to the instructions on the board). The ‘Yellow” cable
connects terminal B. The ‘Green’ cable connects terminal C.
 Press any key to turn the KPS on. Press ‘H’ and then ‘2’ to turn the KPS off.
 The KPS is self-explanatory and user friendly. Follow the instructions on the display.
 Select OPEL and Motronic 4.1 when requested.
Options on the KPS are:

1) Fault memory
Fault memory is initiated on the KPS by switching both the board and KPS on, then restart.
2) Display of real-time engine operating information

Available display on the KPS (in order of appearance):
 Battery voltage
 Engine coolant temperature
 Air temperature
 Engine speed
 Ignition advance
 Air-flow sensor (voltage output according to vane position)
 Lambda output
 Injection pulse duration due to engine speed
 Injection pulse duration due to engine load
 Idle/full-load switch status
3) Actuator tests
Student can hear the following actuators being operated when they are normal:
 Idle speed actuator
 Tank vent valve
 Fuel injectors
C. Investigating procedures
C1. Identify system components

Carefully identify the components on the board and fill in the names on Figure 2.
C2. Real-time engine operating data

Set the engine to idle condition and then to full-load, and record for each condition a full set of
operating data.
Page 4 of 6
C3. Warm-up enrichment
Vary the coolant temperature setting and record the variations in cold-start enrichment with
coolant temperature. Plot the result on graph paper.
C4. Fault simulation

 Clear the memorized fault code.
 Switch off system.
 Let the Instructor replace one or more fault simulation bridges (blind bridges).
 Restart the KPS.
 Locate the fault using the KPS and confirm the faulty components by direct
measurement on the multi-function terminal.
 Replace the blind bridges with normal ones.
 Confirm the faults have been removed on the KPS.
 Clear the faults in memory.
D. Submission of Report
Write a formal report with the following topics:
Introduction, Objective, Equipment, Test/Investigating procedures, Measured results, Analysis of

results, Conclusions/Comments/Observations
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Hong Kong Institute of Vocational Education (Tsing Yi)

Technology Laboratory Worksheet

Title of Investigation: Motronic 4.1 System

Duration: 180 minutes

Investigation rig: Motronic Simulation Board

Tools and Equipment: 1. Board accessories: Power supply

B1. Operating the training board

Refer to Figure 1 and identify the switches/sensors on the training board.

Potentiometer Engine speed Idle - 3000 rpm

B3. Multi-function terminal

The Motronic 4.1 multifunction terminal has the following pins:

Pin number Component Signal type

17 warning lamp earth clocking, power failure/fault warning

B4. Fault simulation

B5. Operating the KPS System Tester

Options on the KPS are:

2) Display of real-time engine operating information

C1. Identify system components

C2. Real-time engine operating data

C4. Fault simulation

Write a formal report with the following topics:

Introduction, Objective, Equipment, Test/Investigating procedures, Measured results, Analysis of

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