OPEL KADETT 1991 Electronic Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Injection Systems
Multi PointSimultaneousInjectors receive pulses from E.C.U. twice per engine cycle.
( Corsa 13 NE, 16NE, Astra 14SE, 16SE, 18XE, 20SHE )
SequentialInjectors are pulsed by E.C.U. once per engine cycle as per spark
plug firing order. ( Astra 20XE )
GroupedInjectors pulsed in groups or banks, once or twice per cycle
depending on system design
Single PointThrottle BodySingle injector mounted on throttle body pulsed as per engine
requirement ( Astra 160 TBI )
Operation
Injectors on the Bosch Motronic engine management systems receive battery voltage and are
triggered by the E.C.U. depending on the signals received from the various sensors attached
to the engine. Fuel pressure is constant (M.P.F.I. – 250 to 300 Kpa).
Injector opening frequency (Hz) and duration (pulse width) determine the amount of fuel
being delivered to the combustion chamber. Variations in pulse width and frequency ensure
that adequate fuel is supplied for efficient engine operation.LONGER PULSE WIDTH= RICHER MIXTURESHORTER PULSE WIDTH= LEANER MIXTURE
Pulse rate and width will increase with increased engine rpm and load.
Duty Cycle
Duty cycle is the combination of pulse width and pulse rate, and is expressed as a percentage
of time “ON” and time “OFF” eg. If an injector was on for 10ms and closed for 90ms, the
duty cycle “ON” is 10% and the duty cycle “OFF” is 90%. The total on and off duty cycle
reading should be 100%.
CrankingInjector duration is longer during cranking (richer mixture) for easier startingand to promote warm-up.
IdlingInjector duration is longer at start-up if engine is cold, and graduallydecreases as engine warms up.
AccelerationInjector duration is longer at initial acceleration to prevent “flat spot”RunningInjection pulse is controlled by the E.C.U. depending on the signals receivedfrom the various engine sensors.

Downloaded from www.Manualslib.com manuals search engine TESTING INFORMATION AND TEST PROCEDURES
Typical Simultaneous Injection Duration
Engine ColdMs
Cranking ------------------------------------------>4
Idle -------------------------------------------3.5 to 4
Engine Warm
Idle---------------------------------------------2.5
1000rpm2.3*
20002.1*
30002.0*
Snap Throttle>7Sequential injection systems will be less than twice the above values due to single pulsingper engine cycle.
NOTES.THE USE OF A 4 GAS ANALYSER CAN GREATLY AID DIAGNOSTICDIRECTION AND TIME.
Comparing mixture content to injector pulse width can identify components and systems to
be tested in a logical sequence.
Example :A rich mixture could indicate high fuel pressure, incorrect manifold pressure,
incorrect coolant temp, etc,etc.
D.N. 12/97* Gradually leans out,depending on load

Downloaded from www.Manualslib.com manuals search engine DUPEC ELECTRONICS (PTY) LTD
DEFITA200
MICROCONTROLLER BASED
FUEL INJECTION AND
SPARK TIMING SYSTEM
AND INTERFACE
SPECIFICATION
TRAINING MANUAL
93/5

Downloaded from www.Manualslib.com manuals search engine CONTENTS
1.0 PRODUCT DESCRIPTION
2.0 FEATURES
3.0 PRODUCT IDENTIFICATION AND APPLICATION
4.0 SPECIFICATION
4.1 Electrical
4.2 Environmental
4.3 Fuel delivery
5.0 CONNECTIONS
6.0 SPARK TIMING
6.1 Distributor bypass operation
6.2 Engine speed and crankshaft
position measurement
6.3 Engine load measurement
6.4 Advance angle look-up
6.5 Ignition firing delay calculation
6.6 Dwell time calculation
6.7 Engine water temperature measurement
7.0 FUEL INJECTION
7.1 Air mass to fuel mass ratio
7.2 Air mass measurement
7.3 Speed density concept
7.4 Fuel metering
7.5 Continuous fuel flow rate
7.6 Injector opening and closing times
7.7 Injection timing
7.8 Injection duration
7.9 Correction factors
7.9.1 Injection hardware deficiencies
7.9.2 Engine operating conditions
7.9.3 Intake air temperature
7.9.4 Engine temperature
7.9.5 Cold starting conditions
7.9.6 Post-start and warm-up conditions
7.9.7 Acceleration conditions
7.9.8 Deceleration lean-out conditions

Downloaded from www.Manualslib.com manuals search engine 7.9.9 Coasting conditions
7.9.10 Flooded engine conditions
7.9.11 Full load operation
8.0 IDLE SPEED
9.0 IMMOBILISER OPERATION
10.0 DEFAULT MODE SELECTION
11.0 DIAGNOSTICS
11.1 Diagnostic codes
11.2 Volt- and ohmmeter
11.2.1 Battery voltage
11.2.2 Ignition voltage
11.2.3 TPS supply voltage
11.2.4 TPS input signal voltage
11.2.5 CO potentiometer supply voltage
11.2.6 MAP sensor supply voltage
11.2.7 MAP sensor signal voltage
11.2.8 Timing map selector
11.2.9 Fuel mixture selector
11.2.10 EWT sensor
11.2.11 MAT sensor
11.3 Fault finding
11.4 D-TEQ200 PC based tester
11.4.1 Description
11.4.2 Installation
11.4.3 Operation
11.5 C-TEQ200 component tester
11.5.1 Description
11.5.2 Operation

Downloaded from www.Manualslib.com manuals search engine 1 PRODUCT DESCRIPTION
The DEFITA200 range of ECU's (Engine Control Units) is
microcontroller based and controls the spark timing, fuel
injection and certain other functions of internal combustion
engines electronically, thus ensuring optimum operating
efficiency.
DEFITA200 is an abbreviation for Dupec Electronic Fuel
Injection and Timing Advance.
2 FEATURES
The DEFITA200 range of ECU's is designed, developed and
manufactured in the Republic of South Africa and offers the
following features:
Standard functions:
- Spark timing up to 7,810 r.p.m. on 4 cylinder engines
- Spark timing based on engine load, temperature
crankshaft position/speed and battery voltage
- Automatic altitude compensation by measurement of
manifold absolute pressure
- Fuel injection based on engine load, speed, tempera-
ture and manifold air temperature
- Coasting fuel cut-off
- Pre-programmed rev. limiting by fuel cut-off
- Active idle speed control

Downloaded from www.Manualslib.com manuals search engine - User selectable spark timing curves for different
fuel octane ratings
- User selectable fuel mixture maps for different
octane ratings
- Automatic default mode selection in the event of
sensor failure allows limp-home operation
- Air-conditioner shutdown control
- Self-diagnostics with fault storage
- Intelligent PC based diagnostics with logging
facility.
- Software immobiliser which prevents hot-wiring
- Repairability. THIS IS NOT A THROW-AWAY UNIT. IT CAN BE REPAIRED AT DUPEC FOR A MINIMAL CHARGE

Downloaded from www.Manualslib.com manuals search engine 3 PRODUCT IDENTIFICATION AND
APPLICATIONThe product is identified by a white label on its lid having the following information. (P/N93593652 supersedes93591117)
DEFITA200
160 TBi
MODEL NO.: A020-C
DMC P/N: 93593652
MADE IN R.S.A.

Downloaded from www.Manualslib.com manuals search engine 4 SPECIFICATION
The following specification is applicable to DEFITA200 P/N:
A020-C ECU's unless otherwise stated:
4.1 Electrical
Operating voltage : 9 to 15 VDC continuous : 6 to 16 VDC limited functions : 24 VDC for 60 seconds maximum
Operating current : Less than 500 mA
Standby current : Less than 12 mA (>1 minute after
ignition off)
Timing accuracy : +/- 0.5 degrees
R.p.m. limit : 6,297
Reference signal : Negative edge from Distributor Y24
at 10ø BTDC
Base timing : 10ø BTDC r.p.m. < 450 or diagnostics initia- lised after starting
Mapped timing : r.p.m. > 450 and diagnostics dis-
abled
Selectable octane maps : 97 RON Factory fitted
: 93 RON
: 87 RON
: 87D RON (For fuel with octane
below 87 RON)
Selectable by interchanging octane plug on harness

Downloaded from www.Manualslib.com manuals search engine Fuel mixture adjustment : - 15% Leaner
: - 10% Leaner
: - 05% Leaner
: + 05% Richer
: + 10% Richer
: + 15% Richer
: + 20% Richer
: + 25% Richer
Selectable by installing optional
mixture selection plug.
Operation only possible in open
throttle position.
Air-conditioner shut-off : Throttle > 88% open OR
: TPS closed and speed < idle r.p.m.
Fuel injection timing : Synchronous with reference signal
Idle CO adjustment : +/- 15% of base fuel map by means
of CO potentiometer with closed
throttle
Coasting cut-out : 1228 r.p.m. - EWT > 78 øC
: 1755 r.p.m. - EWT = 0 øC
Idle speed : 910 r.p.m. - EWT > 78 øC
: 1300 r.p.m. - EWT = 0 øC
: 1050 r.p.m. - A/C ON (EWT > 78 øC)
: 1495 r.p.m. - A/C ON (EWT = 0 øC)
Idle speed control : By means of stepper motor control
of IACV (Idle Air Control Valve)
Wide Open Throttle (WOT) : Throttle > 72% open
Flood compensation : 0.6x base fuel maps in WOT mode
and r.p.m. < 450