Bosch Motronic 1.

5 Copyright Equiptech
Motronic 1.5 operation

Motronic 1.5 is an enhancement of the Motronic 4.1 EMS fitted to earlier Vauxhall and Opel vehicles. It was first fitted in the 1990
model year (late 1989) and is a fully integrated system that controls primary ignition, fuelling and idle control from within the
same ECU. Both 4 and 6 cylinder engines use M1.5, with little difference between applications - other than that the six cylinder
fuel pump is contained within the fuel tank. Also, the six cylinder 24 valve engine utilise a knock control facility.

The Motronic ignition point and injection duration are jointly processed by the ECU so that the best moment for ignition and
fuelling are determined for every operating condition. The injection function of the Motronic system is based on the well tried 'L'
jetronic system, although a number of refinements have improved operation. A 55 pin connector and multi-plug connects the
ECU to the battery, sensors and actuators.

This system description and tests are based upon the Cavalier and Carlton vehicles equipped with Motronic 1.5. Most other
vehicles are very similar with differences being mainly concerned with equipment levels (ie AT and A/C etc and their associated
connections to the ECU) and the various ECU connections to earth. Not all vehicles use coding earth connections.

Basic ECU operation

A permanent voltage supply is made from the vehicle battery to pin 18 of the ECU. This allows the self-diagnostic function to
retain data of an intermittent nature. Once the ignition is switched on, a voltage supply to the ignition coil and to ECU pin 27 is
made from the ignition switch. This causes the ECU to connect pin 36 to earth, so actuating the main fuel injection relay. A relay
switched voltage supply is thus made to ECU pin 37, from terminal 87 of the main fuel injection relay.

The majority of sensors (other than those that generate a voltage such the CAS, KS and OS), are now provided with a 5.0 volt
reference supply from a relevant pin on the ECU. When the engine is cranked or run, a speed signal from the CAS causes the
ECU to earth pin 3 so that the fuel pump will run. Ignition and injection functions are also activated. All actuators (Injectors, ISCV,
FTVV etc), are supplied with nbv from the main relay and the ECU completes the circuit by pulsing the relevant actuator wire to
earth.

Reference voltage and ECU earths

Voltage supply from the ECU to many of the engine sensors is at a 5.0 volt reference level. This ensures a stable working
voltage unaffected by variations in system voltage.

The ECU main earth is made through pin number 19. Other ECU earths are use to complete actuator and sensor circuits.

The earth return connection for most engine sensors is made through an ECU pin that is not directly connected to earth. The
ECU internally connects that pin to earth via one of the ECU pins that are directly connected to earth.

In vehicles with MT, pin 42 is directly connected to earth. In vehicles with AT, pin 42 is connected to the P/N circuit. When the AT
selector is in P/N mode the voltage is connected to earth and when the AT selector is in driving mode the voltage is at nbv level.

ECU coding wires (where fitted)

Some vehicles equipped with Motronic 1.5 has ECU pins 20 and 21 allocated as coding earths. The open circuit voltage at these
pins is at the 5.0 volt reference level. Connection of the pin to earth indicates to the ECU that the vehicle is equipped with certain
equipment. The non cat vehicle will have pin 20 connected to earth and the catalyst equipped vehicle will have pin 20 open
circuit. The vehicle with AT will have pin 21 connected to earth and the vehicle with MT will have pin 21 open circuit.

Signal processing
Basic ignition timing is stored in a two dimensional map and the engine load and speed signals determines the ignition timing.
The main engine load sensor is the AFS and engine speed is determined from the CAS signal.

Correction factors are then applied for starting, idle, deceleration and part and full-load operation. The main correction factor is
engine temperature (CTS). Minor correction to timing and AFR are made with reference to the ATS and TPS signals.

The basic AFR is also stored in a two dimensional map and the engine load and speed signals determines the basic injection
pulse value. Motronic calculates the AFR from the AFS signal and the speed of the engine (CAS).

The AFR and the pulse duration are then corrected on reference to ATS, CTS, battery voltage and position of the TPS. Other
controlling factors are determined by operating conditions such as cold start and warm-up, idle condition, acceleration and
deceleration.

Motronic accesses a different map for idle running conditions and this map is implemented whenever the engine speed is at idle.
Idle speed during warm-up and normal hot running conditions are maintained by the ISCV. However, Motronic makes small
adjustments to the idle speed by advancing or retarding the timing, and this results in an ignition timing that is forever changing
during engine idle.

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Motronic 1.5 also has a number of other duties to perform. These include cutting off the A/C compressor at engine speeds over
6000 rpm and controlling the inlet manifold change-over valve to maximise engine torque at low speeds (under 4000 rpm) and
maximise power at high speeds.

Self Diagnostic function

The Motronic 1.5 system has a self-test capability that regularly examines the signals from engine sensors and internally logs a
code in the event of a fault being present. This code can be extracted from the Motronic Serial Port by a suitable Fault Code
Reader. When the ECU detects that a fault is present, it earths pin 22 and the warning lamp on the dash will light. The lamp will
stay lit until the fault is no longer present. If the fault clears, the code will remain logged until wiped clean with a suitable FCR, or
until the engine has been started for more than 20 times when the fault code is self initialising. An ECU that retains codes for
faults of an intermittent nature is a valuable aid to fault diagnosis.

In addition to the self-test capability, Motronic 1.5 has full limp home facilities. In the event of a serious fault in one or more of the
sensors, the EMS will substitute a fixed default value in place of the defective sensor.

This means that the engine may actually run quite well with failure of one or more minor sensors. Since the substituted values
are those of a hot engine, cold starting and running during the warm-up period may be less than satisfactory. Also, failure of a
major sensor, ie the AFS, will tend to make driving conditions less easy.

Signal shielding
To reduce RFI, a number of sensors (ie CAS, KS and OS) use a shielded cable. The shielded cable is connected to the main
ECU earth wire at terminal 19 to reduce interference to a minimum.

CAS
The primary signal to initiate both ignition and fuelling emanates from a CAS mounted in proximity to the crankshaft. The CAS
may be mounted in one of two positions depending on engine. On some engines the CAS is plugged into the block and on other
engines the CAS is mounted externally behind the flywheel pulley.
CAS on block
Most 4 cylinder 2.0 engines
CAS on pulley
C16SEI
C24NE
Most 6 cylinder engines

The CAS consists of an inductive magnet that radiates a magnetic field and a toothed disk. The disk is attached to the crankshaft
or front pulley and theoretically comprises 60 teeth set at 3° intervals around its circumference; each tooth being 3° wide. At a
position some distance BTDC, two teeth are omitted as a reference to TDC and so a total of 58 teeth remain on the disk. As the
crankshaft spins, and the teeth are rotated in the magnetic field, an AC voltage signal is generated and delivered to the ECU to
indicate speed of crankshaft rotation. In addition, as the engine spins, the missing teeth generate a variation of the signal that
serves as a reference to TDC to indicate crankshaft position.

The peak to peak voltage of the speed signal (when viewed upon an oscilloscope) can vary from 5 volts at idle to over 100 volts
at 6000 rpm. Because computers prefer their data as on/ off signals, the ECU utilises an analogue to digital converter (ADC) to
transform the AC pulse into a digital signal.

Ignition
Data on load (AFS), engine speed (CAS), engine temperature (CTS) and throttle position (TS) are collected by the ECU, which
then refers to a three dimensional digital map stored within its microprocessor. This map contains an advance angle for each
operating condition, and thus the best ignition advance angle for a particular operating condition can be determined.

Amplifier
The Motronic amplifier contains the circuitry for switching the coil negative terminal at the correct moment to instigate ignition.
The signal received by the amplifier from the trigger is of an insufficient level to complete the necessary coil switching. The signal
is thus amplified to a level capable of switching the coil negative terminal. The amplifier circuitry is contained within the ECU
itself and the microprocessor holds a map containing the correct ignition dwell period for each condition of engine speed and
battery voltage. One disadvantage of an internal amplifier, is that if the amplifier fails, the whole ECU must be renewed.

Dwell operation in Motronic is based upon the principle of the 'constant energy current limiting' system. This means that the dwell
period remains constant at around 4.0 to 5.0 ms, at virtually all engine running speeds. However, the dwell duty cycle, when
measured in percent or degrees, will vary as the engine speed varies. A current limiting hump is not visible when viewing an
oscilloscope waveform.

Ignition coil
The ignition coil utilises low primary resistance in order to increase primary current and primary energy. The amplifier limits the
primary current to around 8 amps and this permits a reserve of energy to maintain the required spark burn time (duration).

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Distributor
In the Motronic system, the distributor only contains secondary HT components (distributor cap, rotor and HT leads) and serves
to distribute the HT current from the coil secondary terminal to each spark plug in firing order.

Knock sensor (6 cylinder, 24 valve engines only)

The optimal ignition timing (at engine speeds greater than idle) for a given high compression engine is quite close to the point of
onset of knock. However, running so close to the point of knock occurrence, means that knock will certainly occur on one or
more cylinders at certain times during the engine operating cycle.

Since knock may occur at a different moment in each individual cylinder, Motronic 1.5 employs the Knock Control unit - KCU (in
the ECU) to pinpoint the actual cylinder or cylinders that are knocking. The Knock Sensor is mounted on the engine block and
consists of a piezoceramic measuring element that responds to engine noise oscillations. This signal is converted to a voltage
signal by the Knock Sensor and returned to the KCU for evaluation and action. The knocking frequency is in the 15kHz
frequency band.

The KCU will analyse the noise from each individual cylinder and set a reference noise level for that cylinder based upon the
average of the last 16 phases. If the noise level exceeds the reference level by a certain amount, the KCU identifies the
presence of engine knock.

Initially, timing will occur at its optimal ignition point. Once knock is identified, the Knock Control microprocessor retards the
ignition timing for that cylinder or cylinders by 3°. Approximately 2 seconds after knocking ceases (20 to 120 knock- free
combustion cycles), the timing is advanced in 0.75° increments until the reference timing value is achieved or knock occurs
again, when the processor will retard the timing once more. This procedure continually occurs so that all cylinders will
consistently run at their optimum timing.

If a fault exists in the Knock Control processor, Knock control sensor or wiring, an appropriate code will be logged in the
self-diagnostic unit and the ignition timing retarded by 10.5° by the LOS program.

Cylinder Identification sensor (6 cylinder, 24 valve engines only)

In earlier Motronic systems the ECU does not recognise number one cylinder or indeed even the firing order. This is because it is
actually unnecessary. When the crankshaft or distributor provides a timing signal, the correct cylinder is identified by the
mechanical position of the crankshaft, camshaft, valves and ignition rotor.

Since knock sensing occurs on an individual cylinder basis in Motronic 1.5, the ECU must be informed on which stroke a cylinder
is actually on. This is achieved by a cylinder identification sensor attached to the distributor and which works on the Hall-Effect
principle. The sensor identifies number one cylinder, and returns a signal to the ECU from which the identification of all the other
cylinders can be calculated. The CID sensor is not connected to injector operation as in Motronic 2.5.

Octane coding
It is not possible to adjust the ignition timing on the Motronic 1.5 system. However, an octane coding plug is provided to enable
the ECU to adopt different characteristics to suit various operating conditions.

The ECU has been built with several different programs to cater for various circumstances, and selecting an alternative Octane
Plug or setting will trigger a different program. The most obvious change is from leaded to unleaded fuel - or vice versa, when the
ECU may alter the ignition timing and fuel map to cater for the changed conditions.

Simply turning the standard 95/98 Octane Plug to its alternative position will fulfill the alternative condition. Other conditions may
be fulfilled by fitting an alternative octane plugs - such as the 95/91. A number of other octane plugs are also available and
depending upon the Octane Plug chosen, will cause fuel enrichment during acceleration, overall fuel enrichment throughout the
engine speed range, timing retard or an increase in idle speed. However, fitting alternative plugs should be approached with
caution as the effects may be detrimental to good running and economy.

Fuel injection
The Motronic ECU contains a fuel map with an injector opening time for basic conditions of speed and load. Information is then
gathered from engine sensors such as the AFS, CAS, CTS, and TS. As a result of this information, the ECU will look up the
correct injector pulse duration right across the engine rpm, load and temperature range.

The Motronic 1.5 system is a multi-point injection system and pulses all injectors at the same time - ie simultaneously and once
per engine revolution. This means that half of the fuel for the next power stroke is injected at each opening of the injector and
fuel lies briefly on the back of an inlet valve until that valve opens. The injector thus opens twice for every engine cycle. During
engine start from cold, the pulse duration is increased to provide a richer air/fuel mixture. During engine cranking (hot or cold),
the number of pulses (frequency) is increased from once per revolution to twice per revolution. After 20 seconds of cranking, the
pulse reverts to one pulse per revolution.

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Although all 4 injectors are pulsed simultaneously, the injectors are arranged in two banks with injectors 1 and 2 comprising one
bank and injectors 3 and 4 making up the other bank. Each bank is connected to the ECU via a separate ECU pin).

The fuel injector is a magnetically operated solenoid valve that is actuated by the ECU. Voltage to the injectors is applied from
the main relay and the earth path is completed by the ECU for a period of time (called pulse duration) of between 1.5 and 10
milliseconds. The pulse duration is very much dependant upon engine temperature, load, speed and operating conditions. When
the magnetic solenoid closes, a back EMF voltage of up to 60 volts is induced.

The fuel injectors are mounted in the inlet stubs to the engine inlet valves so that a finely atomised fuel spray is directed onto the
back of each valve. Since the injectors are all pulsed simultaneously, fuel will briefly rest upon the back of a valve before being
drawn into a cylinder.

AFS
The AFS is located between the air filter and the throttle body. As air flows through the sensor it deflects a vane (flap). The
greater the volume of air, the more will the flap be deflected. The vane is connected to a wiper arm which wipes a potentiometer
resistance track and so varies the resistance of the track. This allows a variable voltage signal to be returned to the ECU.

Three wires are used by the circuitry of this sensor and it is often referred to as a three wire sensor. A 5 volt reference voltage is
applied to the resistance track with the other end connected to the AFS earth return. The third wire is connected to the wiper
arm.

From the voltage returned, the ECU is able to calculate the volume of air (load) entering the engine and this is used to calculate
the main fuel injection duration. To smooth out inlet pulses, a damper is connected to the AFS vane. The AFS exerts a major
influence on the amount of fuel injected.

ATS
The ATS is mounted in the AFS inlet tract and measures the air temperature before it enters the inlet manifold. Because the
density of air varies in inverse proportion to the temperature, the ATS signal allows more accurate assessment of the volume of
air entering the engine. However, the ATS has only a minor correcting effect on ECU output.

The open circuit supply to the sensor is at a 5.0 volt reference level and the earth path is through the AFS earth return. The ATS
operates on the NTC principle. A variable voltage signal is returned to the ECU based upon the air temperature. This signal is
approximately 2.0 to 3.0 volts at an ambient temperature of 20°C and reduces to about 1.5 volt as the temperature rises to
around 40°C.

CO pot
The CO pot mixture adjuster is a three wire potentiometer that allows small changes to be made to the idle CO. A 5.0 volt
reference voltage is applied to the sensor and connected to the AFS earth return circuit. The third wire is the CO pot signal.

As the CO pot adjustment screw is turned the change in resistance returns a voltage signal to the ECU that will result in a
change in CO. The CO pot adjustment only affects idle CO. Datum position is usually 2.50 volts. On catalyst equipped models,
the CO pot has no effect and the CO is thus non-adjustable.

CTS
The CTS is immersed in the coolant system and contains a variable resistance that operates on the NTC principle. When the
engine is cold, the resistance is quite high. Once the engine is started and begins to warm-up, the coolant becomes hotter and
this causes a change in the CTS resistance. As the CTS becomes hotter, the resistance of the CTS reduces (NTC principle) and
this returns a variable voltage signal to the ECU based upon the coolant temperature.

The open circuit supply to the sensor is at a 5.0 volt reference level and this voltage reduces to a value that depends upon the
resistance of the CTS resistance. Normal operating temperature is usually from 80° to 100° C. The ECU uses the CTS signal as
a main correction factor when calculating ignition timing and injection duration.

TPS
A TPS is provided to inform the ECU of idle position, deceleration, rate of acceleration and full-load (WOT) conditions. The TPS
is a potentiometer with three wires. A 5 volt reference voltage is supplied to a resistance track with the other end connected to
earth. The third wire is connected to an arm which wipes along the resistance track and so varies the resistance and voltage of
the signal returned to the ECU.

From the voltage returned, the ECU is able to calculate idle position (approximately 0.6 volts), full-load (approximately 4.5 volts)
and also how quickly the throttle is opened. During full-load operation, the ECU provides additional enrichment. During closed
throttle operation above a certain rpm (deceleration), the ECU will cut-off fuel injection. Injection will be reintroduced once the
rpm returns to idle or the throttle is opened.

The TPS direction of rotation for all vehicles except the C30SE is clockwise. However, the C30SE utilises an TPS that rotates

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anti-clockwise. Although the same TPS is used in all engines, terminals 1 and 2 in the wiring harness are swapped.

ISCV
The ISCV is a solenoid controlled actuator that the ECU uses to automatically control idle speed during normal idle and during
engine warm-up. The ISCV is located in a hose that connects the inlet manifold to the air filter side of the throttle plate.

When an electrical load, such as headlights or heater fan etc are switched on, the idle speed would tend to drop. The ECU will
sense the load and rotate the ISCV against spring tension to increase the air flow through the valve and thus increase the idle
speed. When the load is removed, the ECU will pulse the valve so that the air flow is reduced. Normal idle speed should be
maintained under all cold and hot operating conditions. If the ISCV fails it will fail in a fail-safe position with the aperture almost
closed. This will provide a basic idle speed.

Relays
The Motronic electrical system is controlled by a single system relay with dual contacts. A permanent voltage supply is made to
relay terminals 30 and 86 from the battery positive terminal. When the ignition is switched on, the ECU earths terminal 85
through ECU terminal number 36 which energises the first relay winding. This causes the first relay contacts to close and
terminal 30 is connected to the output circuit at terminal 87. A voltage supply is thus output at terminal 87. Terminal 87 supplies
voltage to the injectors, ECU terminal 37, ISCV and the FTVV when fitted. In addition voltage is supplied to the second relay
contact.

When the ignition is switched on. the ECU briefly earths relay contact 85b at ECU terminal 3. This energises the second relay
winding, which closes the second relay contact and connects voltage from terminal 30 to terminal 87b, thereby providing voltage
to the fuel pump circuit. After approximately one second, the ECU opens the circuit and the pump stops. This brief running of the
fuel pump allows pressure to build within the fuel pressure lines, and provides for an easier start.

The second circuit will then remain open until the engine is cranked or run. Once the ECU receives a speed signal from the CAS,
the second winding will again be energised by the ECU, and the fuel pump will run until the engine is stopped.

Fuel pressure system

A roller type fuel pump, driven by a permanent magnet electric motor mounted close to the fuel tank (inside the fuel tank for 6
cylinder models), draws fuel from the tank and pumps it to the fuel rail via a fuel filter. The pump is of the 'wet' variety in that fuel
actually flows through the pump and the electric motor. There is no actual fire risk because the fuel drawn through the pump is
not in a combustible condition.

Mounted upon the armature shaft is an eccentric rotor holding a number of pockets arranged around the circumference - each
pocket containing a metal roller. As the pump is actuated, the rollers are flung outwards by centrifugal force to act as seals. The
fuel between the rollers is forced to the pump pressure outlet.

Fuel pressure in the fuel rail is maintained at a constant 2.5 bar by a fuel pressure regulator. The fuel pump normally provides
much more fuel than is required, and surplus fuel is thus returned to the fuel tank via a return pipe. In fact, a maximum fuel
pressure in excess of 5 bar is possible in this system. To prevent pressure loss in the supply system, a non-return valve is
provided in the fuel pump outlet. When the ignition is switched off, and the fuel pump ceases operation, pressure is thus
maintained for some time.

Fuel pressure regulator

The pressure regulator is fitted on the outlet side of the fuel rail and maintains an even pressure of 2.5 bar in the fuel rail. The
pressure regulator consists of two chambers separated by a diaphragm. The upper chamber contains a spring which exerts
pressure upon the lower chamber and closes off the outlet diaphragm. Pressurised fuel flows into the lower chamber and this
exerts pressure upon the diaphragm. Once the pressure exceeds 2.5 bar, the outlet diaphragm is opened and excess fuel flows
back to the fuel tank via a return line.

A vacuum hose connects the upper chamber to the inlet manifold so that variations in inlet manifold pressure will not affect the
amount of fuel injected. This means that the pressure in the rail is always at a constant pressure above the pressure in the inlet
manifold. The quantity of injected fuel thus depends solely on injector opening time, as determined by the ECU, and not on a
variable fuel pressure.

At idle speed with the vacuum pipe disconnected, or with the engine stopped and the pump running, or at WOT the system fuel
pressure will be approximately 2.5 bar. At idle speed (vacuum pipe connected), the fuel pressure will be approximately 0.5 bar
under the system pressure.

Catalytic Converter and emission control

Versions with a Catalytic Converter will also be fitted with an oxygen sensor so that closed loop control of emissions can be
implemented. The OS is heated so that it will reach optimum operating temperature as quickly as possible after the engine is
started. The OS heater supply is made from the fuel injection relay terminal number 87b. This ensures that the heater will only
operate whilst the engine is running.

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An FTVV and activated carbon canister are also be employed to aid evaporative emission control. The carbon canister stores
fuel vapours until the FTVV is opened by the EMS under certain operating conditions. Once the FTVV is actuated by the EMS,
fuel vapours are drawn into the inlet manifold to be burnt by the engine during normal combustion.

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