Opel 565eng

Trouble-Shooting - SimtecT 56.
5
S
-S ROUBLE HOOTING
IMTEC 56.5
Foreword
The Multi-Tester plus/pro software cassette is the component that gives
the diagnostic equipment its unique test characteristics: All data required
to make the test system operate are stored on the software cassette.
The software cassette can easily be replaced enabling the Multi-Tester plus/pro
to be rapidly adapted to the trouble-shooting job at hand.
These Trouble-Shooting Instructions describe how to use the equipment on
fuel injection systems type Simtec 56.5.
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 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 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 unauthorized manner.
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SIMTEC 56.5 CONTENTS
Contents
Foreword .......................................................................................................... 1
System Description .......................................................................................... 3
General ......................................................................................................... 3
Summary – Car Models ............................................................................ 3
Sensors, signals and switches .................................................................. 4
Control functions ...................................................................................... 4
Camshaft sensor ...................................................................................... 5
Users Guide ..................................................................................................... 6
Connection of equipment .............................................................................. 6
Starting the program ..................................................................................... 7
Program structure ....................................................................................... 11
Programs and tests .................................................................................... 12
Monitor test ............................................................................................. 13
Fault messages .................................................................................. 14
To delete recorded faults .................................................................... 15
Fault detected ..................................................................................... 16
Snapshots (Multi-Tester pro only) ....................................................... 17
Running test ....................................................................................... 18
Edit ......................................................................................................... 19
Special Tests .......................................................................................... 20
Static test / Continuous static test ....................................................... 23
Throttle test ........................................................................................ 24
Camshaft sensor test ......................................................................... 25
Lambda sensor ................................................................................... 26
Battery ................................................................................................ 26
Throttle potentiometer ........................................................................ 27
Air mass meter ................................................................................... 27
Coolant temperature ........................................................................... 28
Air temperature ................................................................................... 28
Power to crankshaft sensor ................................................................ 29
Trouble-Shooting Procedure ....................................................................... 30
Fault Tracing ............................................................................................... 31
Locating Faults ........................................................................................... 41
Index ............................................................................................................... 61
Interface - Signal Locations ............................................................................ 62
Wiring Diagram ............................................................................................... 63
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SYSTEM DESCRIPTION SIMTEC 56.5
System Description
General
Simtec 56.5 is a fuel injection and ignition system that is used in Opel
and Vauxhall cars. The system uses certain sensors which operate in an
unusual way. The first is the camshaft sensor, which is described on page
5. The second is the lambda sensor which, unlike the lambda sensor in
other systems, has a signal that alternates between 0–5 V.
Note:
It is important that the connection of the equipment is done according to
Users Guide (page 6).
Summary – Car Models

The following car models are equipped with Simtec 56.5:
Manufacturer Engine size Engine Model
Calibra 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 equipped
with a system described in this manual.
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SIMTEC 56.5 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 SIMTEC 56.5
Camshaft sensor
Angle pulse generators are used as camshaft sensors. An angle pulse
generator consists of two windings (primary and secondary), connected
together at one end, and an iron core. The primary winding is supplied
from the control box with a 95 kHz signal. The inductive coupling induces a
voltage with the same frequency in the secondary winding, but the induced
voltage has a certain phase shift owing to the time offset at induction.
3
1
2
When one of the teeth of the reluctor wheel is located at the sensor, the
magnetic 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 senses
these changes in phase shift as teeth and gaps.
Gap Tooth
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SIMTEC 56.5 CONNECTION OF EQUIPMENT
Users Guide
Connection of equipment
1. Preparations
Turn off ignition! Disconnect positive battery terminal!

0
2. Connect adapter and program cassette
Extension cable
Control system
F1 F2 F3
Multi-Tester pro
YES NO
HELP
EXIT ENTER
Adapter Program cassette
3. Connect power supply
Power supply
Red Black Multi-Tester pro

F1 F2 F3
YES NO
HELP
EXIT ENTER
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STARTING THE PROGRAM SIMTEC 56.5
Starting the program

General
The program is re-started each time the power supply is interrupted and
re-connected. When the supply is interrupted any faults and pre-sets recorded
in 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 connected
to the power supply. The unit executes steps 1 to 3 and pauses at step 5.
Working procedure
1. All fields in the display are tested
(i.e. are illuminated)
MULTI-TESTER plus
(Multi-Tester plus only).
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 potentio-
meter to right of the switch inside the
cassette opening (using a small
screwdriver).
2. The Multi-Tester plus/pro SELF-TEST OK

performs a self-test....
3. ...and identifies the current MULTITESTER

versions of the hardware and SIMTEC 56.5
software.
VER:XXXXXXXXXXXX
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SIMTEC 56.5 STARTING THE PROGRAM
VIEW SNAPSHOTS 4. Snapshots (Multi-Tester pro only)

ERASE MAN. SNAP. If the instrument contains stored
ERASE GRAPHS snapshots, a menu for managing these
↑ /↓/ENTER is displayed.
ADAPTER CONNECT. 5. The adapter connected

XXXXXXXXXXXXXXXX The Multi-Tester plus/pro confirms
which adapter is connected and
↑ /↓ /ENTER displays this information.
Is the information on row 2 correct?
WRONG ADAPTER Respond by pressing ENTER.
CONNECTED This message is displayed if the adapter
which is connected to the Multi-
Tester plus/pro is of the incorrect type,
i.e. not combined with the appropriate
software cassette.
NO ADAPTER If the adapter is not connected to the

CONNECTED unit, the message NO ADAPTER CONNECTED
is displayed.
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QUESTIONS DURING INITIALIZATION SIMTEC 56.5
6. Questions during initialization ASTRA-F

In order for the Multi-Tester plus/pro VECTRA-B
to perform the tests correctly it needs OMEGA-B
certain data on the system. The display CALIBRA
shows either alternatives or questions.
TYPE SELECTION
Alternatives AUTOMATIC
Use é/ê to select the correct TRANSMISSION ?
alternative and then press ENTER. ↑ /↓ /ENTER
Questions TYPE SELECTION
Answer the questions by pressing AIR CONDITIONER?
either the YES or NO key.
YES/NO
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SIMTEC 56.5 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 SIMTEC 56.5
Program structure
SELF-TEST
AUTODIAGNOS
MULTI-TESTER
VIEW SNAPSHOTS
VIEW GRAPHS
Start menus
ADAPTER CONNECTED
VER:XXXXXXXXXXXX
Questions which
depend upon lambda
sensor, idle control,
number of cylinders, etc.
VIEW SNAPSHOTS HELP MONITOR TEST EXIT

VIEW GRAPHS >SPECIAL TEST <
RUNNING TEST
↑ /↓
↓ /ENTER Choice of test
MONITOR TEST EDIT SPECIAL TEST RUNNING TEST
FAULT DETECTION
IN MONITOR TEST?
Condition:
YES/NO Fault present
YES
RUNNING TEST
FAULT DETECTED
(in the background)
HELP
Condition:
Fault present FAULT MESSAGE
DELETE RECORDED
FAULTS HELP MESSAGE
STATUS MESSAGE
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SIMTEC 56.5 PROGRAMS AND TESTS
Programs and tests

The 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 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 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 information
is saved and displayed.
• The same fault cannot be recorded twice in succession.
• Order of priority of fault registration:
1. Power supply
2. Ground 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 SIMTEC 56.5
Monitor test
1. Monitor test RUNNING TEST

Select MONITOR TEST in the test choice >MONITOR TEST <
menu. SPECIAL TEST
↑ /↓ /ENTER
2. Fault detection in Monitor test FAULT DETECTION

Here you can select whether or not IN MONITOR TEST?
fault detection is run while in Monitor
test. If you press YES, Running YES/NO
searches for faults while Monitor
displays the values. If you press NO,
START ENGINE shows. If you press
ENTER, the list of signals is shown
without the engine being started.
3. Test underway #18 POWER 2.30 V
A small T character flashes on the #19 GROUND OK
status row which indicates that the #21 HALL PULSE
test is underway. IDLE T
4. Fault detected
If an fault is detected, the unit emits a #23 TEMP 2.30 V
tone as well as a small F on the status #24 GROUND OK
row. #25 HALL PULSE
IDLE T F
5. To inspect faults
If you press è the unit proceeds
#3 LAMBDA OK
directly to the faulty signal. A small
F4 GROUND 1.25 V
F character is displayed before the
#5 BATT 12.0 V
relevant pin number. If you select
IDLE T F
ç the unit proceeds to the beginning
of the list of signals.
TOTAL NUMBER OF
You can also press HELP to display FAULTS: (1–5)
which fault has been detected in
simple text. If the engine is switched HELP/EXIT
off, when Monitor is re-started, you
must begin from stage 1 of this section.
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SIMTEC 56.5 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
NO ENGINE SPEED Example fault message for an LH

SIGNAL control system.
LH#1
EXIT/HELP
EXIT
HELP
CHECK IGNITION Example help message.

SYSTEM AND
CABLE TO LH#1
EXIT/HELP
HELP
FAULT FOUND AT Example status message.

#1 RPM 0 Display engine speed and voltage from
#13 TEMP 2.54 V coolant temperature sensor.
EXIT/HELP
EXIT/HELP
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TO DELETE RECORDED FAULTS SIMTEC 56.5
To delete recorded faults

1. Start TOTAL NUMBER OF
To delete faults, start from this point. FAULTS: (1-5)
EXIT/HELP
2. To delete faults TO DELETE FAULTS

Depress the EXIT key for at least 5 PRESS EXIT
seconds. If EXIT is not pressed within 3 > 5 SEC.
seconds the unit returns to the FAULT
DETECTED message automatically.
3. Delete faults. FAULTS WILL BE

All faults and all snapshots are deleted DELETED
simultaneously. 5..4..3..2..1
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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SIMTEC 56.5 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
EXIT HELP EXIT HELP EXIT
* TO DELETE FAULTS HELP HELP

PRESS EXIT MESSAGE MESSAGE
> 5 SEC
EXIT / HELP EXIT / HELP
EXIT HELP HELP
FAULTS WILL STATUS STATUS

BE DELETED MESSAGE MESSAGE
5..4..3..2..1
MONITOR TEST
RUNNING TEST
↑ /↓
↓ /ENTER
* Occurs automatically after 3 seconds
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SNAPSHOTS SIMTEC 56.5
Snapshots (Multi-Tester pro only)
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.
Certain parameters are displayed as mean values. Faults may

be reported on the basis of instantaneous values, with the
result that autosnap may not always display a faulty value even
if the Multi-Tester pro indicates a fault on a particular signal.
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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SIMTEC 56.5 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.
An fault can be recorded the moment Running starts. The Multi-Tester

plus/pro emits a beep and the letter F is displayed when an fault is
detected. Instructions for retrieving the fault from memory together with
a description of fault, help and status messages are described in the “Fault
messages” section.
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EDIT SIMTEC 56.5
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 EDIT
shuts out non-relevant signals.
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 #XX GROUND ON
actual signal is displayed.
All changes will be erased when the
Multi-Tester plus/pro is disconnected
from power.
#XX GROUND OFF
Note
If error diagnosis is disconnected, this
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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SIMTEC 56.5 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.
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 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 SIMTEC 56.5
The program for the Simtec 56.5 system includes the following special tests:
Static test
Checks the signals when the ignition is on >STATIC TEST
but the engine is not running.
Continuous static test

Static test that is carried out continuously. >CONT. STAT. TEST
Throttle test
Tests the throttle potentiometer. >THROTTLE TEST
Checks signal levels and continuity.
Camshaft sensor test

Tests the camshaft sensor signal. >CAMSHAFT TEST
Lambda sensor
Displays signal voltage from the lambda >LAMBDA
sensor and the minimum and maximum
values.
Battery
Displays the battery voltage and the >BATTERY
minimum and maximum values.
Throttle potentiometer
Displays the signal voltage from the >THROTTLE
throttle potentiometer and the minimum
and maximum values.
Air mass meter
Displays signal voltage from the air mass
>LOAD
meter and the minimum and maximum
values.
Coolant temperature
Displays the signal voltage from the
coolant temperature sensor and the >WATERTEMP
minimum and maximum values.
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Air temperature
>AIR TEMP. Displays the signal voltage from the air
temperature sensor and the minimum
and maximum values.
Power to crankshaft sensor

>POWER CRANKSH. Displays the power voltage to the
crankshaft sensor and the minimum and
maximum values.
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SPECIALTESTER SIMTEC 56.5
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:
Ignition is on
A fault is registered if any signal differs
Engine is not running
from the pre-programmed standard
value. The fault will be held in memory
until it is erased manually or until the
Test of
power is interrupted.
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
display 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
turned 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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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.
Calibration of If the ignition is off, you will be asked
full load and idle to turn it on. If the engine is started,
running values the test will not be carried out and the
program will return to the special tests
menu.
Firstly, a calibration is carried out for the
Test of Multi-Tester plus/pro pre-programmed
continuity values for full load and idle running. This
is 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
FAULT MESSAGE accelerator completely.
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.
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Camshaft sensor test

This test checks the signals from the CAMSHAFT TEST
camshaft sensor.
Starting conditions for the test:
• The engine has to be running. If it
is not, you are prompted to start the
engine or crank it with the starter Condition:
motor for at least ten seconds. Running engine
When Multi-Tester plus/pro has detected
that the engine is running or being
cranked, the time required for the #39 IGN XXXX rpm
camshaft sensor, is displayed together #13 CAMSH. XX.X ms
with the actual rpm.
At the same time the signals from the EXIT
camshaft sensor are analysed by Multi-
Tester plus/pro to find possible faults.
This analys is only done for engine
speeds below 2000 rpm. FAULT MESSAGE
The test continues until you press EXIT or
stop the engine.
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Lambda sensor
LAMBDA This test demonstrates the signal voltage
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.
Starting condition for this test:
• The engine has to be running.
#10 LAMBDA XXX mV If not, you will be asked to start it.
MIN: XXX mV This test will continue until EXIT is pressed
MAX: XXX mV or until the engine is turned off.
EXIT
Battery
This test demonstrates the voltage level
BATTERY
of the car’s battery.
recorded. This enables the battery voltage
Condition:
during for example the starting phase to be
Ignition is on
measured.
#17 BATT XX.X V If not, you will be asked to turn it on.
MIN: XX.X V This test will continue until EXIT is pressed
MAX: XX.X V or until the engine is turned off.
EXIT
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Throttle potentiometer
This test demonstrates the signal voltage THROTTLE POT.
of the throttle potentiometer.
recorded. Condition:
Starting condition for this test: Ignition is on
If not, you will be asked to turn it on.
This test will continue until EXIT is pressed
or until the engine is turned off. #26 THROTT X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
Air mass meter

This test shows the voltage level of the LOAD
air mass meter signal.
recorded. This makes it possible to check Condition:
the variations and min/max levels. Ignition is on
#33 LOAD X.XX V
MIN: X.XX V
or until the engine is turned off.
MAX: X.XX V
EXIT
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Coolant temperature
WATERTEMP This test demonstrates the signal voltage
of the coolant temperature sensor.
Condition: recorded.
Ignition is on Starting condition for this test:
#27 TEMP X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
Air temperature
AIR TEMP. This test demonstrates the signal voltage
of the air temperature sensor.
Condition: recorded.
Ignition is on Starting condition for this test:
# 8 I-AIR X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
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Power to crankshaft sensor

This test demonstrates the power voltage POWER CRANKSH.
and the actual value to the crankshaft
sensor together with the minimum and
maximum values recorded.
Condition:
• The ignition has to be turned on. Ignition is on
#16 POWER X.XX V
MIN: X.XX V
MAX: X.XX V
EXIT
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SIMTEC 56.5 TROUBLE-SHOOTING PROCEDURE
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).
Pin 2 Ground from chassis

MONITOR SPECIAL RUNNING
“#2 GROUND” (OK/ERR) Static test: check of Continuous check of
ground level. ground level.
Desired value: 0 V
See chapter
Locating Faults ➧1
In the Locating Faults chapter, the working procedure for locating faults is
included.
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FAULT TRACING SIMTEC 56.5
Fault Tracing
Desired value: 0 V
See chapter
Pin 3 Loadsignal to automatic gear
“#3 LOAD” (PULSE/----) Not tested. Not tested.
See chapter
Pin 4 Status signal from automatic transmission
“#4 AUTO” Not tested. Not tested.
(DRIVE/P/N) See chapter
Pin 5 Signal from speedometer
“#5 VSS” (Hz) Not tested. Not tested.
See chapter
Pin 6 Gearchange time signal from automatic
transmission
“#6 GEAR SH.” Not tested. Not tested.
(ON/OFF) See chapter
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SIMTEC 56.5 FAULT TRACING

Desired value: 0 V
See chapter
Pin 8 Signal from air temperature sensor
“#8 I-AIR” (V) Static test: check of Continuous check of
signal level. signal level.
Air temp.: display of Desired value at 20°C:
power variation. 1.5 V
See chapter
Pin 9 Status signal from air conditioning system
“#9 AC SW.” (ON/OFF) Not tested. Not tested.
See chapter
Pin 10 Signal from lambda sensor
“#10 LAMBDA” (mV) Lambda: display of Check of power
power variation. variation. Conditions:
– engine at operating
temperature
– not idling or under
full load
– engine speed
< 3.000 rpm
See chapter
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“#11 GROUND” Static test: check of Continuous check of
(OK/ERR) ground level. ground level.
Desired value: 0 V
See chapter
Pin 13 Signal from camshaft sensor
“#13 CAMSH.” Static test: pulse check. Continuous pulse check.
(PULSE/----) Camshaft test: check of
the information content See chapter
of the signal. Locating Faults ➧9
Pin 14 Ground to air mass meter
Desired value: 0 V
See chapter
Locating Faults ➧ 10
Desired value: 0 V
See chapter
Pin 16 Power supply to crankshaft sensor
“#16 POWER” (V) Static test: check of Continuous check of
voltage level. voltage level.
Power cranksh.: display Desired value: 12 V
of power variation. See chapter
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Pin 17 Power from ignition switch (terminal 15)

“#17 BATT” (V) Static test: check of Continuous check of
Battery: display of Desired value: 12–14 V
power variation. See chapter
Pin 18 Power supply to throttle potentiometer
“#18 POWER” (ON/OFF) Static test: check of Continuous check of
Throttle: display of Desired value: 5 V
power variation. See chapter
Desired value: 0 V
See chapter
Pin 20 Engine speed signal to revolution counter
“#20 RPM” Not tested. Continuous pulse check.
(PULSE/----) See chapter
Pin 21 Fuel consumption signal to boardcomputer
“#21 INFO” (PULSE/----) Not tested. Not tested.
See chapter
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Pin 23 Signal from air conditioning compressor

“#23 AC PRESS” Not tested. Not tested.
(ON/OFF) See chapter
Pin 24 Signal from crankshaft sensor
“#21 CRANK” Not tested. Continuous pulse check.
(PULSE/----) See chapter
Pin 26 Signal from throttle potentiometer
“#26 THROTT” (V) Static test: check of Continuous check of
signal level. signal level and
Throttle test: check of continuity.
signal level and Desired value at
continuity. – idle: 0.1-0.9 V
– full load: 2.5-4.5 V
Throttle: display of
See chapter
voltage variation.
Pin 27 Signal from coolant temperature sensor
“#27 TEMP” (V) Static test: check of Continuous check of
signal level. signal level.
Watertemp: display of Desired value when
power variation. engine at operating
temperature: 0.8-1.5 V
See chapter
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Desired value: 0 V
See chapter
Pin 31 Oscillation signal to the camshaft sensor
“#31 OSC.CAM” Static test: pulse check. Continuous pulse check.
(PLS/----) See chapter
Pin 32 Ground to camshaft sensor
Desired value: 0 V
See chapter
Pin 33 Signal from air mass meter
“#33 LOAD” (V) Static test: check of Check of minimum and
signal level. maximum values.
Desired value at idle:
0.4-0.9 V
See chapter
Pin 34 Control signal to the air conditioning compressor
relay
“#34 AC” (ON/OFF) Not tested. Not tested.
See chapter
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Pin 35 Power supply from main relay

“#35 POWER” Static test: check of Continuous check of
(ON/OFF) voltage level. voltage level.
Desired value: 12-14 V
See chapter
Pin 36 Power supply to lambda sensor
“#36 POWER” Static test: check of Continuous check of
Desired value: 5 V
See chapter
Pin 38 Control signal to ignition amplifier, cylinder 2 & 3
“#38 IGN” (PULSE/----) Static test: check of Continuous pulse check.
voltage level. See chapter
Pin 39 Control signal to ignition amplifier, cylinder 1 & 4
“#39 IGN” (rpm) Static test: check of Continuous pulse check.
Pin 40 Control signal to injection valve, cylinder 4
“#40 INJ” (ms) Not tested. Continuous pulse check.
See chapter
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See chapter
See chapter
See chapter
Pin 44 Power supply from main relay
“#44 RELAY” Static test: check of Continuous check of
See chapter
Pin 45 Control signal to EGR-valve
“#45 EGR” (%) Static test: check of Not tested.
See chapter
voltage level.
Pin 46 Control signal to idle speed correction valve
“#46 ISC” (%) Static test: pulse check. Continuous pulse check.
See chapter
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Pin 47 Control signal to tank ventilation valve

“#47 TANK” (%) Static test: check of Not tested.
Pin 48 Control signal to lambda sensor pre-heater
“#48 O2HEAT” (%) Static test: check of Not tested.
Pin 49 Control signal to main relay
“#49 RELAY” (ON/OFF) Static test: check of Continuous check of
control signal level. control signal level.
See chapter
Pin 50 Control signal to secondary air injection
“#50 SEC.AIR” Static test: check of Not tested.
(ON/OFF) voltage level. See chapter
Pin 53 Control signal to adjustable manifold valve
“#53 VAR.AIR” Static test: check of Not tested.
(ON/OFF) voltage level. See chapter
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Pin 54 Control signal to fuel pump relay

“#54 RELAY” (ON/OFF) Static test: check of Continuous check of
control signal level. control signal level.
See chapter
Pin 55 Constant power supply from battery
“#55 BATT” (OK/ERR) Static test: check of Continuous check of
See chapter
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LOCATING FAULTS SIMTEC 56.5
Locating Faults
1
Check of ground connection to Simtec, pin 2, 7, 11, 15, 19 and
29
These 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 the
car’s wiring harness only. Do not reconnect the control unit.
2. Measure the resistance between the Break-out Box, pin 2, 7, 11, 15, 19
and 29, respectively and ground. Desired value: 0 Ω
Possible cause of fault: Wiring or connectors.
2
Check of load signal to automatic transmission from Simtec,
pin 3
This is a signal to the control box of the automatic transmission, which
uses the signal to determine when to change gear.
2. Measure the resistance between the Break-out Box, pin 3 and the
automatic gearbox. Desired value: 0 Ω
3
Check of status signal from the automatic transmission to
Simtec, pin 4
This is a signal that provides the control unit with information on when a
gear is engaged in the drive mode. The control unit responds by opening
the ISC valve slightly to compensate for the stress.
/Continued
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SIMTEC 56.5 LOCATING FAULTS
automatic gearbox. Desired value: 0 Ω
4
Check of signal from the speedometer to Simtec, pin 5
This is a signal from the speedometer, which transmits a digital signal to
the control unit.
speedometer. Desired value: 0 Ω
5
Check of gear change signal from the automatic transmission
to Simtec, pin 6
This is a status signal from the automatic gearbox to the control unit.
When the automatic gearbox changes gear, the control unit responds by
reducing priming to facilitate a smoother gear change.
2. Measure the resistance of the cable between the Break-out Box, pin 6
and the automatic gearbox. Desired value: 0 Ω
6
Check of signal from air temperature sensor to Simtec, pin 8
This is an input signal to the control unit from the air temperature sensor
(type NTC with a negative temperature coefficient).
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2. Measure the resistance of the cable between the Break-out Box, pin 8 and
the air temperature sensor (see workshop manual). Desired value: 0 Ω
and air temperature sensor. Desired value: 0 Ω
4. Measure the resistance between the Break-out Box, pin 8 and 7.
Desired values: air temp. resistance (kΩ)
+ 10–30°C 2.0–5.0
Possible cause of fault: Air temperature sensor.
7
Check of status signal from the air conditioning system to
Simtec, pin 9
This is a status signal from the air conditioning system. When it is active, the
control unit will respond by opening the ISC valve slightly to compensate for
the stress.
and the air conditioning system. Desired value: 0 Ω
8
Check of signal from lambda sensor to Simtec, pin 10
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 0–5 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
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• The engine must not be at full throttle – the sensor signal then
becomes constant at approx. 5 V.
• Fuel cut-off should not be activated – the sensor signal then becomes
constant 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 special
test and confirm that the lambda sensor signals fluctuate between 0-5 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 55-pin connector from the
control unit. Connect the Break-out Box (A0201/A0202) and the 55-pin
adapter (A020204) to the car’s wiring harness only. Do not reconnect the
control 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 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.
9
Check of signal from camshaft sensor to Simtec, pin 13
This is an input signal to the control unit from camshaft sensor which
measures camshaft rotations.
and camshaft sensor, pin 3 (see workshop manual). Desired value: 0 Ω
and camshaft sensor, pin 4. Desired value: 0 Ω
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and camshaft sensor, pin 1. Desired value: 0 Ω
5. Disconnect the cable from the camshaft sensor. Measure the resistance
between camshaft sensor, pin 1 and 2. Desired value: 10.7-14.7 Ω
Possible cause of fault: Camshaft sensor.
6. Measure the resistance between camshaft sensor, pin 1 and 3.
Desired value: 11.2-15.2 Ω
Possible cause of fault: Camshaft sensor.
10
Check of ground connection to air mass meter from Simtec,
pin 14
Break-out Box (A0201/A0202) and the 55-pin adapter (A020204) between
the 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 V
Note:
In certain systems the ground point is located in the air mass meter.
11
Check of power supply to the crankshaft sensor from
Simtec, pin 16
pin 16 and 7. Desired value: 12 V
Possible cause of fault: Wiring, connectors, crankshaft sensor or
control unit.
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12
Check of power supply from ignition switch (terminal 15) to
Simtec, pin 17
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 between pin 3 on the
ignition amplifier and ground. Desired value: 12-14 V
Possible 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.
Possible cause of fault:Wiring, connectors, immobilizer or alarm.
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.
13
Check of power supply to the throttle potentiometer from
Simtec, pin 18
pin 18 and 7. Desired value: 5 V
Possible cause of fault: Wiring, connectors, throttle potentiometer
or control unit.
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14
Check of engine speed signal to revolution counter from
Simtec, pin 20
This is an output signal from the control unit indicating engine speed for
the 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 are
received at the Break-out Box, pin 20.
Possible cause of fault: Wiring, connectors or control unit.
15
Check of fuel consumption signal to the boardcomputer
from Simtec, pin 21
This is an output signal from the control unit, supplying fuel consumption
information to the boardcomputer of the vehicle.
2. Start the engine and check (use oscilloscope or similar) that pulses are
received at the Break-out Box, pin 21.
Note: The test is discontinued during fuel cut-off.
16
Check of air conditioning compressor signal to Simtec, pin 23
and the air conditioning compressor. Desired value: 0 Ω
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17
Check of signal from crankshaft sensor to Simtec, pin 24
This is an input signal to the control unit from crankshaft sensor which
measures crankshaft rotations.
and crankshaft sensor, pin 2 (see workshop manual). Desired value: 0 Ω
and crankshaft sensor, pin 1. Desired value: 0 Ω
Possible cause of fault: Wiring or connectors
and crankshaft sensor, pin 3. Desired value: 0 Ω
5. Disconnect the cable from the crankshaft sensor. Measure the resistance
between crankshaft sensor, pin 2 and 3. Desired value: 0.3-0.5 Ω
Possible cause of fault: Crankshaft sensor.
6. Measure the resistance between crankshaft sensor, pin 1 and 2.
Desired value: 10.3-14.3 Ω
Possible cause of fault: Crankshaft sensor.
18
Check of signal from throttle potentiometer to Simtec, pin 26
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
throttle potentiometer, pin 3 (see workshop manual). Desired value: 0 Ω
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and throttle potentiometer, pin 2. Desired value: 0 Ω
and throttle potentiometer, pin 1. Desired value: 0 Ω
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 kΩ
Possible cause of fault: Throttle potentiometer.
6. Connect the Break-out Box and the 55-pin adapter 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 18 and 7. 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.
19
Check of signal from coolant temperature sensor to Simtec,
pin 27
This is an input signal to the control unit from the coolant temperature
sensor (type NTC with a negative temperature coefficient).
coolant temperature sensor (see workshop manual). Desired value: 0 Ω
and coolant temperature sensor. Desired value: 0 Ω
/Continued
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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.
20
Check of oscillation signal to the camshaft sensor from
Simtec, pin 31
2. Turn on the ignition and check (use oscilloscope or similar) that pulses
are received at the Break-out Box, pin 31. Desired value: 95 kHz
Possible cause of fault: Wiring, connectors, camshaft sensor or
control unit.
21
Check of ground connection to camshaft sensor from
Simtec, pin 32
22
Check of signal from air mass meter to Simtec, pin 33
This 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 harness
only. Do not reconnect the control unit.
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and air flow meter, pin 2. Desired value: 0 Ω
and air flow meter, pin 1. Desired value: 0 Ω
5. Start the engine and measure the voltage at air mass meter, pin 3.
Desired value: 12 V
6. If all the recorded values are correct, replace the air mass meter and
repeat the test.
23
Check of control signal to the air conditioning compressor
relay from Simtec, pin 34
This is an output signal from the control box to shut down the
airconditioning compressor if necessary (powerful acceleration etc.).
2. Measure the resistance of the cable between pin 34 on the Break-out Box
and the compressor relay. Desired value: 0 Ω
24
Check of power supply from main relay to Simtec, pin 35 and 44
When ignition is turned on the main relay is activated by pin 49. It is
activated 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 V
Possible cause of fault: Wiring, connectors or ignition switch.
/Continued
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control unit.
5. Measure the resistance of the cable between the Break-out Box, pin 35/44
and main relay, pin 8. Desired value: 0 Ω
and main relay, pin 6. Desired value: 0 Ω
8. Turn on the ignition and measure the voltage between the Break-out Box,
25
Check of power supply to lambda sensor from Simtec, pin 36
2. Turn on the ignition and measure the voltage between the Break-out
Box, pin 36 and 7. Desired value: 5 V
Possible cause of fault: Wiring, connectors, lambda sensor or control
unit.
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26
Check of the control signal to the ignition amplifier from
Simtec, pin 38 and 39
This is an output signal from the control unit to control ignition. The control
unit emits ignition pulses which control the ignition amplifier. There are
several 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 rate
for control units is very low.
control unit.
2. Measure the resistance of the cable between terminal 15 and the ignition
amplifier, pin 3. Desired value: 0 Ω
3. Measure the resistance of the cable between the Break-out Box, pin 38/39
and ignition amplifier, pin 2/1. Desired value: 0 Ω
5. Connect the ignition amplifier contact and check with a test lamp that
pulses 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.
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27
Check of control signal to the injection valve from Simtec,
pin 40, 41, 42 and 43
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 main 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 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. Repeat
corresponding measurement between the Break-out Box,
pin 40/41/42/43 and 7.
3. In the case of a suspected discontinuity between Simtec, pin 40/41/42/43
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 40/41/42/43 and
the terminal on the injector’s connector (see workshop manual).
Desired value: 0 Ω
4. Measure the resistance across each individual injector with the injector
connector terminal removed (i.e. directly on the injectors).
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.
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28
Check of control signal to EGR-valve from Simtec, pin 45
This is an output signal from the control unit to the EGR-valve that controls
the exhaust gas recirculation.
2. Disconnect the cable from the EGR-valve. Measure the resistance of the
cable between the Break-out Box, pin 45 and EGR-valve, pin 2 (see
workshop manual). Desired value: 0 Ω
4. Turn on the ignition and measure the voltage between connector, pin 1
and ground. Desired value: 12 V
29
Check of control signal to idle speed correction valve from
Simtec, pin 46
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 160 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.
2. Disconnect the connector from the ISC valve. Measure the resistance of
the cable between the Break-out Box, pin 46 and the corresponding
terminal at the connector (see workshop manual). Desired value: 0 Ω
and the corresponding terminal at the connector. Desired value: 0 Ω
/Continued
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4. Measure the resistance between the valve’s terminals. Desired value: 10 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 46 (use oscilloscope or similar).
Possible cause of fault: ISC valve or control unit.
30
Check of the control signal to tank ventilation valve from
Simtec, pin 47
This is an output signal from the control unit. It regulates the valve which
ventilates the fuel tank. The value should vary between 1 and 99 % when
accelerating.
2. Disconnect the cable from the tank ventilation valve. Measure the
resistance of the cable between the Break-out Box, pin 47 and connector
(see workshop manual). Desired value: 0 Ω
4. Turn on the ignition and measure the voltage between the connector's
other contact and ground at the Break-out Box. Desired value: 12 V
5. Measure the resistance between the valve’s terminals. Desired value: 36 Ω
Possible cause of fault: Tank ventilation valve.
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31
Check of control signal to lambda sensor pre-heater from
Simtec, pin 48
This is an output signal from the control box to the heating element of the
lambda sensor.
2. Disconnect the cable from the lambda sensor. Measure the resistance of
the cable between Break-out Box, pin 48 and the connector, pin A.
4. Turn on the ignition and measure the voltage between connector, pin C
and the Break-out Box, pin 35. Desired value: 12 V
5. Measure the resistance between the lambda sensors connector, pin A
and C. Desired value: 4.5–5.5 Ω
Possible cause of fault: Heating element in lambda sensor.
32
Check of control signal to main relay from Simtec, pin 49
This is an output signal from the control unit. The signal is grounded to
activate the main relay. There can be several reasons for an absent signal
including:
• Discontinuity in the wiring or connectors.
• Defective or absent main input signal to the system, such as:
– Voltage supply
• Faulty control unit, although this is most unlikely as the failure rate for
control units is very low.
/Continued
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and main relay, pin 6 (see workshop manual). Desired value: 0 Ω
33
Check of control signal to secondary air injection from
Simtec, pin 50
This is an output signal from the control box to the secondary air valve and
the secondary air relay, which supplies power to the secondary air pump.
The secondary air injection provides the catalytic converter with an extra
supply of oxygen during cold starting so that it heats up quicker.
and secondary air pump relay, pin 6. Desired value: 0 Ω
and secondary air pump valve, pin 2. Desired value: 0 Ω
5. Turn on the ignition and measure the voltage between secondary air
pump relay, pin 4 and ground. Desired value: 12 V
6. Disconnect the connector on the secondary air valve. Measure the voltage
between one pin of the connector and ground. Desired value: 12 V
7. Measure the voltage at the secondary air relay, pin 8 and ground.
Desired value: 12 V
Possible cause of fault: Wiring, connectors or fuse.
58 A 01090254-1
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34
Check of the control signal of the adjustable manifold valve
from Simtec, pin 53
This is an output signal from the control unit. It controls the valve on the
adjustable manifold.
2. Disconnect the cable from the the valve of the adjustable manifold.
Measure the resistance of the cable between the Break-out Box, pin 53
and connector, pin 1 (see workshop manual). Desired value: 0 Ω
Possible cause of fault: Wiring or connector.
4. Turn on the ignition. Measure the voltage at the valve, pin 2.
Possible cause of fault: Wiring, connector or relay.
35
Check of control signal to fuel pump relay from Simtec, pin 54
This is a control signal from the control unit to the fuel pump relay. 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:
– Power supply
– Crankshaft sensor
– Camshaft sensor
• Faulty control unit, although this is most unlikely as the failure rate for
control units is very low.
/Continued
A 01090254-1 59
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and fuel pump relay, pin 6. Desired value: 0 Ω
4. Turn on the ignition and measure the voltage between fuel pump relay,
5. Measure the voltage between fuel pump relay, pin 2 and ground.
Desired value: 12 V
6. Start the engine (turn over) and measure the voltage between pin 54 and
ground. Desired value: 0 V
Possible 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 V
Possible cause of fault: Fuel pump relay.
36
Check of constant power supply from battery to Simtec, pin 55
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”.
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.
Possible cause of fault: Battery.
60 A 01090254-1
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INDEX SIMTEC 56.5
Index
Adjustable manifold valve ........................................................................ 39, 59
Air conditioning compressor .................................................................... 35, 47
Air conditioning compressor relay ............................................................ 36, 51
Air conditioning system ............................................................................ 32, 43
Air mass meter ............................................................. 21, 27, 33, 36, 45, 50
Air temperature ........................................................................................ 22, 28
Air temperature sensor ............................................................................ 32, 42
Automatic gear ............................................................................................... 31
Automatic transmission ..................................................................... 31, 41, 42
Battery ........................................................................................ 21, 26, 40, 60
Boardcomputer ........................................................................................ 34, 47
Camshaft sensor ........................................................................ 33, 36, 44, 50
Camshaft sensor test ............................................................................... 21, 25
Chassis ............................................................................... 31, 32, 33, 34, 35
Continuous static test .............................................................................. 21, 23
Coolant temperature ................................................................... 21, 28, 35, 49
Crankshaft sensor ........................................................ 22, 29, 33, 35, 45, 48
EGR-valve ............................................................................................... 38, 55
Fuel pump relay ....................................................................................... 40, 59
Ground ............................................................ 31, 32, 33, 34, 35, 36, 41, 50
Idle speed correction valve ...................................................................... 38, 55
Ignition amplifier ...................................................................................... 37, 53
Ignition switch .......................................................................................... 34, 46
Injection valve ................................................................................... 37, 38, 54
Lambda sensor ............................................................. 21, 26, 32, 37, 43, 52
Lambda sensor pre-heater ...................................................................... 39, 57
Main relay ............................................................................ 36, 38, 39, 51, 57
Revolution counter ................................................................................... 34, 47
Secondary air injection ............................................................................ 39, 58
Speedometer ........................................................................................... 31, 42
Static test ................................................................................................. 21, 23
Tank ventilation valve ............................................................................... 39, 56
Throttle potentiometer ................................................... 21, 27, 34, 35, 46, 48
Throttle test ............................................................................................. 21, 24
A 01090254-1 61
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SIMTEC 56.5 INTERFACE - SIGNAL LOCATIONS
Interface - Signal Locations

1. Diagnosis 45. Control signal to EGR-valve
2. Ground trom chassis 46. Control signal to idle speed correction valve
3. Loadsignal to automatic gear* 47. Control signal to tank ventilation valve
4. Status signal from automatic transmission* 48. Control signal to lambda sensor pre-heater
5. Signal from speedometer 49. Control signal to main relay
6. Gearchange time signal from automatic 50. Control signal to secondary air injection
transmission* 51. Not connected
7. Ground from chassis 52. Engine control lamp
8. Signal from air temperature sensor 53. Control signal to adjustable manifold valve**
9. Status signal from air conditioning system* 54. Control signal to fuel pump relay
10. Signal from lambda sensor 55. Constant power supply from battery
11. Ground from chassis
12. Signal from knock sensor * If AC/Automatic
13. Signal from camshaft sensor ** Not OMEGA-B Wiring
14. Ground to air mass meter
15. Ground from chassis
16. Power supply to crankshaft sensor
17. Power from ignition switch (terminal 15)
18. Power supply to throttle potentiometer 19
19. Ground from chassis 55 37
20. Engine speed signal to revolution counter 18
54 36
21. Fuel consumption signal to boardcomputer 17
22. Diagnosis 53 35
23. Signal from air conditioning compressor 16
52 34
24. Signal from crankshaft sensor 15
25. Not connected 51 33
14
26. Signal from throttle potentiometer 50 32
27. Signal from coolant temperature sensor 13
49 31
28. Not connected 12
29. Ground from chassis 48 30
30. Signal from knock sensor 11
47 29
31. Oscillation signal to the camshaft sensor 10
32. Ground to camshaft sensor 46 28
9
33. Signal from air mass meter 45 27
34. Control signal to the air conditioning compressor 8
44 26
relay* 7
35. Power supply from main relay 43 25
36. Power supply to lambda sensor
6
42 24
37. Not connected 5
38. Control signal to ignition amplifier, cylinder 2 & 3 41 23
4
39. Control signal to ignition amplifier, cylinder 1 & 4 40 22
40. Control signal to injection valve, cylinder 4 3
39 21
41. Control signal to injection valve, cylinder 2 2
42. Control signal to injection valve, cylinder 1 38 20
1
43. Control signal to injection valve, cylinder 3
44. Power supply from main relay
62 A 01090254-1
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WIRING DIAGRAM SIMTEC 56.5
Wiring Diagram
This wiring diagram is an example. Check in the relevant workshop manual
for the diagram of the car you are working with.
Control unit
IM O ATS
Ignition Battery
amplifier - +
55 17 35 44
3
+ + + +
1
39
33
2
14 38
3241 15
Ignition switch
Air mass meter 30
86 4
C 6 85
A
48
49
8 87 30 2 Main relay
B
+5
Lambda sensor D
36
10 54
6 85
86 4
Fuel pump
29
8 87 30 2
relay
40
3 41
2
Crankshaft sensor 1
24
16
42
43 Fuel pump
SIM TEC
3
Injection valves 85
32
Camshaft sensor 1
13 30
86
87 Secondary
2
31 8 7A
air pump relay
M
1
2
12 Secondary
30
Knock sensor air pump
50
Throttle 2 18 +5 Secondary
potentiometer
3
1
26
air valve
53
Variable intake
Coolant 27 manifold
temp. sensor 45
EGR-valve
8
Air temp. sensor
47
Tank ventilation
P
N
6
valve
Automatic gear box R
1 3
2
3
4
46
Idle speed
correction valve
23 21
20 Dashboard
AC 9 52
34
1
Speedometer 5 22 Diagnosis
2 7 11 15 19
A 01090254-1 63

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Trouble-Shooting - SimtecT 56.

Summary – Car Models

Sensors, signals and switches

Turn off ignition! Disconnect positive battery terminal!

2. Connect adapter and program cassette

Adapter Program cassette

3. Connect power supply

Red Black Multi-Tester pro

Starting the program

2. The Multi-Tester plus/pro SELF-TEST OK

3. ...and identifies the current MULTITESTER

VIEW SNAPSHOTS 4. Snapshots (Multi-Tester pro only)

ADAPTER CONNECT. 5. The adapter connected

NO ADAPTER If the adapter is not connected to the

6. Questions during initialization ASTRA-F

VIEW SNAPSHOTS HELP MONITOR TEST EXIT

MONITOR TEST EDIT SPECIAL TEST RUNNING TEST

Programs and tests

1. Monitor test RUNNING TEST

2. Fault detection in Monitor test FAULT DETECTION

NO ENGINE SPEED Example fault message for an LH

CHECK IGNITION Example help message.

FAULT FOUND AT Example status message.

To delete recorded faults

2. To delete faults TO DELETE FAULTS

3. Delete faults. FAULTS WILL BE

4. Exit delete MONITOR TEST

EXIT HELP EXIT HELP EXIT

* TO DELETE FAULTS HELP HELP

EXIT HELP HELP

FAULTS WILL STATUS STATUS

EXIT / HELP EXIT / HELP

* Occurs automatically after 3 seconds

Snapshots (Multi-Tester pro only)

Certain parameters are displayed as mean values. Faults may

An fault can be recorded the moment Running starts. The Multi-Tester

Snapshot (Multi Tester pro only)

Continuous static test

Camshaft sensor test

Power to crankshaft sensor

Camshaft sensor test

Air mass meter

Power to crankshaft sensor

Pin 2 Ground from chassis

Pin 7 Ground from chassis

Pin 11 Ground from chassis

Pin 17 Power from ignition switch (terminal 15)

Pin 23 Signal from air conditioning compressor

Pin 29 Ground from chassis

Pin 35 Power supply from main relay

Pin 41 Control signal to injection valve, cylinder 2

Pin 47 Control signal to tank ventilation valve

Pin 54 Control signal to fuel pump relay

4. Measure the resistance between the Break-out Box, pin 27 and 7.

4. Measure the resistance between the valve’s terminals. Desired value: 10 Ω

Interface - Signal Locations

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