INHALTSVERZEICHNIS_____________________________________________IHM SD

Introduction ........................................................................................................................... 2
Drive 4 WD ......................................................................................................................... 4
Transmission ................................................................................................................................. 5
Hanging up ....................................................................................................................... 6
Brakes ................................................................................................................................ 8
Power steering ......................................................................................................................... 9
Rderund vehicle drive (general references) ......................................................................... 10
Drive system Viscomatic clutch ........................................................................... 11
Hydraulic control circuit ............................................................................................................ 17
Hydraulic control circuit ............................................................................................................ 17
Electronic Kontrollanlage ................................................................................................. 22
Funktionsiogik of the system .................................................................................................. 25
Components of the system .................................................................................................... 35
Diagnostics of the system ........................................................................................................ 42
Abs system, version for four drive wheels ................................................................... 43
General description ...................................................................................................... 44
Interference logic for the version 4 WD ........................................................................................ 45
Localization components of the system ............................................................................. 48
Description of function .......................................................................................................... 52
Selbstdiagnose ...................................................................................................................... 53
Electronic engine management Motronic M 3,7 ........................................................ 54
MotronicM3.7 ....................................................................................................................... 58
Operation diagramme ................................................................................................................... 62
Electronic steering box .............................................................................................. 64
Components ........................................................................................................................ 65
Selbstdiagnose ...................................................................................................................... 69
Fuel system circle ................................................................................................... 70
On-board board .............................................................................................................................. 74
Notes/notes ........................................................................................................... 77
1Bi B_________________________________________________EINLEITUNG
Introduction
The available publication documents the variants and the systems, which were specifically
developed for the 1B^S. They are to be described here and in the detail represented, thus all
necessary information for the general knowledge of the vehicle and the operational principle of
the different plants, systems and above all the electronic controls be conveyed can.
2
MECHANICAL GROUPS
The all-wheel drive system Viscomatic, which finds with the new ISA BL use, was developed
exclusively by the Alfa Rome EO technical designers in co-operation with Steyr Puch.
With 164 was still continued to improve the characteristics of the all-wheel drive owing to the active
" drive system, in which the moment distribution varriert continuously according to the given logics,
depending upon driving condition (drive torque, guidance angle, driving speed, process between
front axle and rear axle), which are calculated by the electronic steering box VISCOMATIC.
One received so an all-wheel drive, which gives new 164 high driving safety " in each driving
condition and in the most diverse situations.
The reached advantages can be summarized in such a way:
- To limit active " interference of the system, which administers the torque process variable,
but continuously, without the travelling comfort;
- maximum stability when braking, by a special version of the ABS for 4WD;
- no influence of the drive with driving along curves, due to the construction;
- high achievements of the entire system, due to the good quality of the construction;
- A construction, which made possible it to accomplish an adjustment without large changes at- A construction, which made possible it to accomplish an adjustment without large changes at
the past model 164 with 2 drive wheels.
MECHANICAL GROUPS
4WD propelled
The unpublished construction solution of the drive for *$skk the Sl plans a
mechanical TRANSMISSION with 6 COURSES. The allocation of the drive over a
VISCOMATIC^ clutch with ELECTRONIC CONTROL, as well as a Torsen Diffe
rential an~cJer Hinteractrse. -
1.Course: 3.769
2. Course: 2.333
3. Course: 1.680
4. Course: 1.290
5. Course: 1.031
6. Course:
0,837 R. Gang:
3.720
1. Transmission
2. Front differential
3. Reduction gear
4. Drive shaft
5. Universal joint
6. Clutch VISCOMATIC
7. Rear differential Torsen
(The numbers indicate the number of teeth of the different wheel transmissions)
The kinematic pattern plans a VISCOMATIC clutch between the front axle and the rear axle.
The torque between the two wheels is subdivided in front by a conventional differential, while
on the rear axle a gate EN differential was used, so that the drive in each situation is maximally
used.
Owing to the special construction of the Torsen it makes this kind of self-locking that for
differential possible, with small adhesion of a Rades, the drive moment on the wheel with the
better road grip too transferred (up to the quadruple value).
MECHANICAL GROUPS
.16
Transmission
Transmission
With
( a
new transmission of the company GET-RISE UP with 6 courses begun, that
accordingly one designed, in order to make possible fast accelerations, due to the appropriate
gradations of the courses. In this way the maximum torque of the engine (which is very high) is,
always at all wheels and in each operating condition available. This results in an unexpected
acceleration behavior for a vehicle of this kind with constructional equipment opposite a 2-
Radantrieb.
The transmission range contains also the front differential and the drive for the cardan
shaft.
Hanging up
The hanging up were again designed, extensive and complex experiments to keep accomplished
around a maximum handling and comfort for this 4WD-Fahrzeug. This vote was reached together
with the optimization of the specific operating logics of the VISCOMATIC clutch, which are
connected in special way with the behavior of the hanging up.
Front suspension
The front suspension became within the range of the position of the steering arm (1) on the hub (2)
changed.
In addition all points of the suspension became to the specific sportiven characteristics
the vehicle adapted, thus high guidance precision was reached.
The feathers/springs and shock absorber have a special characteristic. In the shock absorbers
are additional feathers/springs, which intervenes in the delimitation phase as an anti-centrifuge
and an anti-pitch oscillation function. This makes one possible softer " measuring of the
external feathers/springs for the increase of the travelling comfort.
The applied solutions make possible to adapt the high achievements to the sensitivity of the steering
element, with from-following stability in curves, even if border situations
are reached.
MECHANICAL GROUPS
M
Rear suspension
It was completely again designed, in order to ensure the demands of the new drive system.
The new suspension is characterized by the following:
- A lower wishbone (3), which takes up the lateral load;
- An upper unreactive (2);
- A lever (4) and a linkage (5) in longitudinal direction;
- A stabilizer (1), for the entire reconciliation of the group.
The elasticity of the system under transverse loads makes an easy self-steering possible with
stabilizing effect.
1. Stabilizer
2. Upper unreactive
3. Lower Schwingarm
4. Semi-trailing arm
5. Linkage
7
MECHANICAL GROUPS
Also at the rear suspension feathers/springs and shock absorbers have specific measuring and
the shock absorbers to have an internal feather/spring, like the front.
The applied solutions make as a further improving, and an optimal power transmission at the
rear axle in the course for the steering control possible as also in the thrust.
Hanging up with controlled absorption
The electronic Kontroilsystem SCS varied in the measuring of the shock absorbers and is the
same system, which already worked with the other versions 164. The interference logic was
adapted to the new drive system.
Brakes
The brake assembly was again developed accordingly for this vehicle and equipped with a
specific power steering and ventilated brake disks.
Due to the high demanded achievements the brake pliers were again developed, in order to
thus achieve a higher efficiency.
MECHANICAL GROUPS
%
Power steering
The plant of the power steering was adapted to the specific characteristics of this vehicle. The
hydraulic guidance pump - propelled by the Poly V belt of the crankshaft - consists of two
separated pumps - power steering and Viscomatic -. Both pumps are attached at the same supply
cycle. The steering housing is specific, since in this the guidance sensor is, which belongs to
the VISCOMATIC system.
1. Hydraulic guidance pump
2. Header tank
3. Zulaufleitungen
4. Steering housing
5. Return pipes
6. Inlet and return pipes VISCOMATIC plant
1B1 El_________________________________MECHANISCHE
GROUPS
Wheels and vehicle drive
With vehicles with all-wheel drive, the automatic work on the wheels and the vehicle towing are
problematic, since the two axles must be separated before.
With is the VISCOMATIC system with an appropriate mechanical
System equipped that complete switching off makes possible for the VISCOMATIC clutch.
According to turning the engine (ignition off out) after approximately 4 min. the connection to the
rear axle is separated automatically.
Only after this time interval is:
- balancing the individual wheels at the vehicle
- towing the vehicle possible.
10
VISCOMATIC
Drive system VISCOMATIC clutch
To Alfa Romeo became between the two axles a Drehmomentverteiler also
electronic control of type VISCOMATIC assigned, as well as a rear differential type Torsen
(basic relationship 4: 1).
With ideal adhesion conditions of the four wheels the drive is made by the front wheels. When
revving the wheels up at the front axle, the VISCOMATIC plant distributes the drive torque to the
rear axle.
The Kontrollogik takes over the optimal distribution of the torque, that to the rear axle depending
upon driving condition is transferred (drive torque, vehicle speed, guidance angle and the slip
upon driving condition is transferred (drive torque, vehicle speed, guidance angle and the slip
between in front and in the back).
1. Electronic steering box control of 9
VISCOMATIC system // ^*W
1Q
Rear gate EN differential
Flange for left half wave
Planetary gear
Group of disk clutch
VISCOMATIC
Hydraulic piston for control
clutch
Towing protection
Flange for drive shaft
2.
3rd
4.
5th
6.
7th
8.
Signals of the steering box Motronic '^0
Signals of the steering box ABS 'i/M~reLC
Signal position of the hydraulic piston
Control signal for hydraulic control block
Supply of the hydraulic piston
Hydraulic control block with memory
11.
12.
13.
14.
15.
Supply hydraulic control block (of
the hydraulic guidance pump)
11
OVER EU_____________________________________________VISCOMATIC
VISCOMATIC
The VISCOMATIC consists of a planetary gear and a viscose rayon clutch with hydraulic
control. In addition an appropriate mechanical device makes a switching off for the power
transmission possible, which while towing the vehicle on only one axle becomes necessary. - _
1. Towing protection
2. Planetray gear
3. Sun wheel
4. Internal gear
5. Interior disk
6. External disk
7. Piston with hydraulic control
VISCOMATIC
ENTRANCE
Mixture silicone oil/air
without pressure
transferred torque
down
under pressure
transferred
torque highly
EXIT
The torque becomes from the planet pinion cage (1) transferred to the internal gear (2).
The translation from the planet pinion cage to the internal gear is possible, if the sun wheel f3) -
The translation from the planet pinion cage to the internal gear is possible, if the sun wheel f3) -
connected with the clutch and the brake function - also partly blockieittst. The more largely the
blocking, the more largely is the transferred torque.
The viscose rayon clutch (A) consists of lamellas and a mixture of silicone oil and air.
The transmission of the movement in the viscose rayon clutch is reduced by the inconsistency
of the oil, since the oil with air vesicles enriched itself. By the piston (4) the oil air mixture rising
printing values is suspended, thus reduce the air vesicles, which approach lamellas and it will
thus a higher torque transferred.
With the loosening of the clutch by the piston (4) the lamellas are pressed apart with the
pressure of warmed up air and the torque which can be transferred reduce.
Each position of the piston, steered of an electrical valve and the respective pressure in the
hydraulic system steers thus the torque which can be transferred.
13
VISCOMATIC
Viscose rayon clutch
The characteristic of the clutch (transferred torque M/speed difference on) can vary inside a
certain range (see illustration), that by the condition of the maximum transmission is limited
(HARD) and from that the minimum transmission (SOFT). The system places the clutch into a
certain point of function in the work area and thus arises the transmission of the necessary
torque on the rear axle.
Piston position max.
On
Piston in resting position
HARD
14
VISCOMATIC
Elimination rear axle
An appropriate mechanical system (towing protection) makes the complete Auschalten and thus the
separation of the rear axle for the viscose rayon clutch possible.
That is very important while towing the vehicle on only one axle, since towing with attached axles
would damage the VISCOMATIC clutch.
This concerns a mechanical device with hydraulic regulation: The clutch {switch shaft and shift
collar) is separated, if the pressure of the tax hydraulic system of the VISCOMATIC sinks under a
certain level: The interference value varies depending upon internal friction, temperature etc.:
Indikativer value approx. 20 bar.
Switched on clutch switched off clutch
The pressure (p) exceeds Kraft that the applied pressure (p) over cry
Feather/spring (m) and makes a scarf tet Kraft for the feather/spring possible (m) not and those
ten the clutch (G). Clutch (G) is not switched on.
REMARK: When switching the ignition off the hydraulic system needs a certain time (0.5 to 4
minutes), in order to arrive under 20 bar.
Therefore some minutes wait, before the vehicle is towed.
VISCOMATIC
Hinwels
The transmission system plans the use of 4 different liquids, as represented on the following
pattern:
16
VISCOMATIC
Hydraulic control circuit
Hydraulic control circuit
A hydraulic system with high pressure supplies an accumulator, which leads the necessary liquid
quantity with a sufficient pressure to the hydraulic system. The supply circle is integrated, and by
means of a pump by the crankshaft is propelled with that the power steering. This concerns a
double pump with 2 different pressure levels for the two circles:
1. max. 100 bar vane-type pump for the hydraulic guidance circle and
2. max. 200 bar - piston pump for the VISCOMATIC circle.
1. Ausgleichsbehiter
2. Double pump
3. Housing power steering
4. Accumulator with hydraulic control block VISCOMATIC
5. Clutch VISCOMATIC
17
Hydraulic
pattern
A =
hydraulic
control
block B =
VISCOMATIC
clutch
(*) von/zu
hydraulic
guidance
circle
1.
2.
Engine supply
pump
9.
10.
Relief valve ~G-*~~t ** " return
non-return valve
3. Header tank with Filterelement 11. Pressure filter cartridge
4. Sensor oil level 12. Return non-return valve
5.
6.
7th
8.
Electronic steering box
VISCOMATIC
Accumulator
Pressure sensor proportional
valve flow control
13.
14.
15.
16.
17.
Memory load valve
Piston attitude VISCOMATIC
Automatic bleed valve
Towing protection
Auxiliary filter
18
B^tl
^T^c
5
u~ 7h At& -2 7 ** Uf^Ur
VISCOMATIC
Description of function
The supply pump (2), propelled by the Poly V belt of the engine (1), the liquid leads to the hydraulic
guidance plant and to the hydraulic control block of the VISCOMATIC (A). The header tank (3) with
Filterelement in the oil return the reconciliation of the quantity varying of the oil, which arises during
the enterprise, guarantees due to the work quantity (of memory) and the thermal extension:
Altogether approx. 400 cm3. The sensor (4) the electronic steering box informs VISCOMATIC (5) in
case of of low oil level. The electrical valve at the accumulator (13) becomes from the steering box
(5) activated and loads the memory (6) up, whereby a pressure between 82 and 95 bar of a sensor
(7) is held. The memory (6) - capacity 0.5 dm3 - the necessary energy for the enterprise of the
VISCOMATIC guarantees inside the system; on the supply line a pressure filter (11) is - filter
achievement 20 u.m - that the whole group before foreign particles protects, which could damage
the valves, as well as a return non-return valve (12) that to the pump prevents the return flow of the
oil; a further auxiliary filter (17) protects the memory load valve (13). The valve (9) the system
protects against positive pressure and opens the circle at 110 bar. The return non-return valve (10)
return flow prevents into the VISCOMATIC group by the hydraulic guidance circle.
The proportional valve for adjustment (8) steer the VISCOMATIC clutch (B) and regulate the oil flow
in the chamber (I) of the piston (14); the oil pressure in the chamber (II) constantly by the memory
one maintains: therefore becomes on varying the quantity led into the chamber (I) shifting the
piston and thus varying the stiffness of the clutch reached. The function of the valve follows in
the detail:
A. Valve with a certain electric current supplies:
Liquid quantity to the chamber (I) of the piston
b: closed valve
C: Discharge the chamber (I) from the piston to the
container - with started engine -
D: Discharge the chamber (I) of the piston - with
turned off engine: It becomes a further river the
oil reservoir in the memory (6) and in the
chamber (II) reached, so that the whole plant
is emptied.
The pressure in the chamber (II) switching on of the clutch (towing protection on 16 controls): If the
pressure sinks, scolded the clutch mechanically the whole group of clutch rear differential out.
The valve (15) - calibrated on 102 bar - for the automatic exhaust of the plant one uses (for
further details see exhaust of the circle ").
; &g&, &*rw^
VISCOMATIC
Supply pump
1. Pump
(A)
Vane-type pump (from
aluminum)
Number of revolutions 500
1/min max. 7500 1/min
Quantity of 7 4 - 9 + 0.8 l/min.
max. pressure 100 bar
2. Pump
(B)
Piston pump (from casting)
1,4-^rr l/min. mixes 2000
1/min at number of
revolutions
max. pressure 200 bar
Hydraul ikl: TUTELA Gl/R
Hydraulic control block
In a building group all valves and components of the hydraulic system are accommodated for the
controlling of the VISCOMATIC clutch.
1. Accumulator
2. Pressure sensor
3. Speicherladeyentil
4. Hydraulics
proportional valve
5. Pressure filter cartridge
6. Return non-return valve
7. Return non-return valve
8. Relief valve
9. Auxiliary filter
VISCOMATIC_________________________________________________IB SSI
Exhaust of the hydraulic system VISCOMATIC
The exhaust of the circle is made by an appropriate valve inside the device, and is not thus not
accessible and not adjustable.
The exhaust is to be accomplished only with ALFA ROMEO the TESTER: This procedure plans the
start of the engine, whereby this is brought to 2000 revolutions; then sends a controlling of the tester
a constant river of 450 mA to the proportional valve and controls according to also the memory load
valve, increases the pressure of the circle over the maximum operating values, whereby the bleed
valve is opened (on 102 bar calibrated) and lets to the container air collected in the plant to stream
out. In the case of completion of this procedure it is possible to examine with the tester whether the
plant without air is.
V1SC0MATIC
Electronic Kontrollanlage
The electronic steering box VISCOMATIC controls the slip " between the foremost and
rear axle and limits it at certain values, depending upon the different driving conditions.
These conditions are inferred by several sensors or taken up by other plants (ABS or
Motronic). The steering box steers therefore the valves, which regulate the function of the
viscose rayon clutch. The operation diagramme points this out schematically:
SAFETY I RELAY
|
VISCOMATIC
The Kontrollogistik of the steering box, which steers the hydraulic system of the VISCOMATIC, plans
the availability of a series of data, which are inferred partly directly by sensors and are partly
again-processed. In accordance with these parameters the steering box regulates the electrical
valve (20) with a variable river (from 400 to 2300 mA) proportional for the speed of the piston, the
connection of the clutch varied and thus the allocation of the transmission moment on the rear
axle.
PRESSURE
HYDRAULIC
SYSTEM
SIGNAL LAMP
DISTURBANCE
PLUNGER
LIFTCLUTCH
ANSCHLUSSTECKER
ALFAROMEO TESTERS
GUIDANCE
ANGLE
HYDRAULIC
PROPORTIONAL VALVE
STOOD HYDRAULIC
OIL
MEMORYLOAD
VALVE
STEERING BOX
VISCOMATIC ^-
WHEEL SPEED
BUTTERFLY
VALVE ANGLE
ENGINE NUMBER OF
REVOLUTIONS
MANIPULATION
BRAKE
SWITCH ON
REVERSEGEAR
Sensors and Kontroilogistik
axle.
The directly inferred data are the following:
- The number of revolutions of the four wheels. The four data become from the abs system (1) taken over.
- The Drehzahi of the engine by the steering box Motronic (7).
- The opening angle of the butterfly valve (in the percentage), by the steering box Motronic
(5).
- The guidance angle (6), given by a specific sensor in the steering element housing.
- The position of the piston (2), whose stroke from 0 to 5 mm can vary; the position of maximum
resetting is recognized, if the river of the electrical valve (20) is with 900 mA.
- The pressure of the hydraulic system of the memory, measured of the sensor (8); this
pressure is held between 82 and 95 bar by a memory load valve (22).
- A signal during operation of the brake (3).
- A signal when switching on of the reverse gear (4) on.
- Sensor oil level (9).
1B^1 SO _________________________________________________VISCOMATIC
The system is with a control light (21) and with the possibility for the diagnosis with the Alfa
Romeo tester (10) equipped.
REMARK: The function of the steering box is dependently on the voltage level of the battery,
under 9 V scolded themselves it not.
There are parameters, which are not inferred directly by the sensors, but by the steering box in
accordance with special logics to be calculated, which are described as follows:
24
VISCOMATIC
1
Function logic of the system
The most important logics are described here, which are regulated by the software of the steering
box, in order to regulate the allocation of the torque by the clutch.
Drive torque
The drive torque at the wheels is calculated by the product of the torque, which is delivered by the
engine for the entire drive. It is indicated as percentage of its maximum value. The torque delivered
by the engine is inferred from the curves of the load diagram, which is stored in the steering box.
Each value of the number of revolutions and percentage of the butterfly valve opening, correspond
to a value of the torque, which is delivered by the engine.
The total drive is calculated against it by the relationship between engine number of
revolutions and number of revolutions of the front axle.
DRIVE TORQUE (%)
0 1000 2000 3000 4000
5000 6000 7000
ENGINE SPEED (1/min)
VISCOMATIC
Slip between foremost and rear axle
By slip one understands the proportional difference of the speed of the front axle opposite the
rear axle.
Front axle - rear axle x 100
Slip = speed difference -------------------------------------------------
Rear axle
In order to be able to have the value of the slip due to revving the tires up, one must take the
kinetic slip.
This kinematic slip is the result of the over each other setting of the two conditions:
First is due to the variability between the turning extent of the tires due to for example wrong
printing values, or different wear condition, unequal tire load, presence of the spare wheel etc.
The second condition, which determines the kinematic slip, is the different rotating speed of the
axles, which arises in the curve. The C.I.R. (center of the momentary turn) shifts depending upon
guidance angle, in addition, depending upon deviation of the tires.
Deviation of a Rads with tires under a lateral load.
This angle results from different variables, how: Kind of tire, pressure of the tire, trap
coefficient.
In addition it is directly proportional to the centrifugal energy (square of the radius speed,
guidance radius and measures of the vehicle) and the torque used at the wheel; it is opposite
proportional against it to the vertical load on the wheel.
The steering box regards only the kinematic effects and thus only the speed
parameters and guidance angles.
26
VISCOMATIC
- With standard speed the speed increase increases the deviation forward. That calls (see
illustration) a shifting of the center of the turn " (+) forwards, with from-following
reduction of the kinematic slip.
DRIVING DIRECTION
On the other hand the situation turned around when backing up: Shifting the center of the turn "
(+) causes an increase of the kinematic slip.
DRIVING DIRECTION
27
VISCOMATIC
There are tables over the normal trip and over the reverse movement. The kinematic slip is
reduced as described with increase of the deviation (standard speed) and with reverse
movement the slip increases.
The evaluation of the kinematic slip due to the curve movement is read from the system, and
compared with the stored tables in the program of the steering box - in that the important data
are contained -.
Positioning the piston
In order to guarantee that the distribution of the course torque on the two axles is made in
shortest time it is before-shifted, the regulation, as the piston is positioned depending upon
course torque. From this position one proceeds, in order to make the definite attitude
concerning the slip, if this arises.
STROKE PISTON
(%) 100}
* - TRACTION POWER
In order to guarantee a good function of the system, for example when fast starting, with which
the taken values of the important parameters close the piston during pre-setting, other signals
are not considered, which would cause mismatching partial openings of the piston. If the
system would consider for example small guidance angles at low speeds, the piston is opened,
whereby thereby disturbing conditions would arise when driving.
28
VISCOMATIC
Attitude of the course slip
With special circumstances the system does not intervene also at important slip values.
For example a high slip value is certified at low speeds. One avoids in such a way that the attitude
of small measuring errors of the speed and irregularity of the road surfacing, although small, is
affected, which would be important however in this case.
For the same reason the certified slip value increases, if the course torque is limited.
CERTIFIED SLIP
CERTIFIED SLIP
VEHICLE SPEED
COURSE TORQUE
29
16
VISCOMATIC
Attitude of the transverse slip of the rear axle
The closing differential (Torsen 4: 1) in the rear axle causes that in the curve the internal rear
wheel is loaded with a quadruple higher torque. This wheel tends to revving up, since in the curve
also the vertical load sinks. In this condition the slip between the two axles to inappropriate way
and the piston reduce tended to open and lead to an allocation of the torque between the two
axles with increase of the average speed of the rear wheels, which brings driving difficulties with
itself. In this case a function intervenes, which adds itself to the difference between the real slip
and the certified and is lost due to revving the internal rear wheel up. Therefore the piston
remains closed due to the signal by this wheel, whereby the movability of the vehicle is improved.
Attitude of the sliding operating slip
With sliding enterprise the exhaust brake works the vertical load on the rear axle, which can rev
up therefore easily particularly on the front axle, on the other side sinks in this condition.
REMARK: If the speed of the rear axle more highly than those the foremost
axle is, takes the slip negative values.
The certified negative slip at low speeds is therefore for the same reasons higher, from those, as
seen, at low speeds the course slip is high. At medium speeds the value of the certified slip is
limited, since a good torque value reduces the Untersteuern (with bad adhesion), which arises in
the curve particularly on the front axle on the rear axle.
At high speeds the threshold increases strongly, in order to let the exhaust brake affect only
the front axle and to thus guarantee a good driving stability.
* - VEHICLE SPEED
CERTIFIED SLIP (NEGATIVE)
30
VISCOMATIC
1
Attitude when braking
The system refers to the rear axle. When braking the real speed of the rear axle is not considered,
if this by a delay over 0,24 g is determined. At higher delay values the datum speed sinks not in
accordance with the real process separates gradually.
The VISCOMATIC normally intervenes, until the difference between the effective speed and the
delimitation speed does not exceed a certain threshold value (also function of the guidance angle:
This threshold is limited with low guidance angles). Above this threshold the VISCOMATIC does
not intervene during braking, except with exceptions, whereby malfunctions with the abs plant are
avoided (for further details see brake system ABS 4WD ").
CD
r \ 3
"
VISCOMATIC
Description of function
The system of the VISCOMATIC is administered by the controller N 75.
The permanent voltage supply of the controller is made via the battery, by the protection F1 (7.5
A) - additional fuse housing G 2 -, on the controller pin 1.
Against the pins rests 20 and 25 of the controller measure. The information ignition "
comes over the protection F 4 (3 A) - G 2 - on the controller pin 14.
The main supply for the controller is made over the change relay 1104.
Relay function:
no Fehler>
with Fehler> the
sensors:
Oil pressure sensor L 56
A =
measures
of B = 5 V
C = signal voltage
Pin 18 Stg
After the info. ignition " over pin 14 at the controller, this accomplishes a
Eigendiagnose
Relay becomes over the Kl. and supplies now the controller excites 86
with 12 V via Kl. 30 over Kl. 87, protection F 5 (10 A) - G 2 - at pin 13
with battery voltage.
Indicator light becomes of relays Kl. 87a with tension supplies and
shines.
Guidance protractor L 53
1 = 5 V
2 = signal voltage - > pin 3 Stg
3 = measures
Sensor plunger lift L 55
Pin 1 = 5 V -
Pin 2 = signal voltage - * pin 16 Stg
Pin 3 = measures
Sensor oil level L 54 schliot with small oil level and informs with a measure
signal the controller at pin 6th FF ** - * ** APPROX. H? tc *?
Switch reverse gear: H 2 informs the controller at pin 10 with 12 V that
the reverse gear is inserted.
HM3_________________________________________________VISCOMATIC
Except of the appropriate sensors, the steering box receives N75 information from the abs system
and Motronic system: The pins 7.8.9 and 21 of the N75 are connected with the steering box ABS
N51, from which they receive proportional signals for the speed of the 4 wheels; at the pins 15 and
12 comes against it from the steering box Motronic S11 the signals of the butterfly valve angle and
the engine number of revolutions.
The logic before shown processes the steering box the control signals of the actuators, which are
controlled accordingly: From the pin 11 the signal Duty Cicle (variable, 250 cycles per second)
comes, which the proportional valve inside the hydraulic control block M25 steers, of the pin 24
comes a continuous signal 12 V to the controlling (ON OFF) of the memory load valve of the
group of M25.
Pin 4 and 5 for the diagnostic possibility (plug T1) - line K and L - to the connection with
Alfa Romeo the TESTER. Pin 19 12 a V-signal for the control light of on-board board C10 in case
of of stored disturbances.
34
VISCOMATIC
Brake pedal switch H 3
1 =12 volt
2 = pedal pressed - * pin 23 Stg
H| 4 = pedal not pressed - pin 22 Stg
Components of the system
Electronic steering box (N75)
It is under the middle console, in the shown position:
1. 12 V-supply battery 14.
2.
Agreement at safety external switch (12 V)
15.
3. Signal guidance angle 16.
4. Diagnostics line K 17.
5. Diagnostics line L 18.
6. Signal oil level (5 V)
19.
7. Signal speed wheel in front rh (of ABS)
20.
8. Signal speed wheel rear. rh (of ABS) 21.
9. Signal speed wheel rear. left (of
ABS)
22.
10. Signal switched on reverse gear
(12 V)
23.
11. Control signal proportional valve (Duty Cicie) 24.
12. Signal Mptorendrehzahl (of Motronic)
13. 12 V-supply of safety external switch
2b.
12 V-supply (+15)
Signal butterfly valve angle (of
Motronic)
Signal plunger lift
Supply + 5 V for the sensors
Signal pressure hydraulic system
Signal for signal lamp on-board
board (12 V)
Measures of achievement circles
Signal speed wheel in front left (of
ABS)
Signal released brake pedal
(12 V)
Signal pressed brake pedal (12
V)
Signal control memory load valve
(12V)
Measures of system circles
VISC0MAT1C
Safety external switch (1104)
The steering box controls and regulates the supply of the achievement circles by an appropriate
external switch, which interrupts the supply at the actuators and thus the system switches off, if
it comes to disturbances.
The external switch is on the right side behind the combination instrument.
PIN-OUT steering box:
1104 safety external switches for steering boxes VISCOMATIC
VISCOMATIC
.1
Stop light switch (H3)
The same switch as for is the circle of the stop lights, 2 signals by the controller is processed:
approved and pressed brake pedal.
Reverse gear switch (H2)
The same switch as for is the circle of the backup lights, from which from the signal of the
switched on reverse gear proceeds.
Sensor oil level (L54)
It is on the expansion tank for the hydraulic guidance plant and VISCOMATIC (for further details
see power steering).
1. Sensor
2. Float
This concerns a switch (N.C), which is connected with a float, that opens it, if the level of liquid
the MIN - value reaches.
1.
VISCOMATIC
Sensor plunger lift (L55)
The sensor is in the VISCOMATIC group and is bound with a linkage at the pistons. This concerns
potentiometer, that the steering box a signal proportionally to the position of the piston sends (supply
voltage 5V, Rmax 2 k).
1. Sensor plunger lift
2. Group VISCOMATIC
The measuring of this sensor takes place automatically: Each time, if the attitude valve at minimum
value (< 900 mA) stays a certain time long, this reference value is taken as 0-Weg, while the final
stroke of the piston is accepted as maximum way (5 mm).
VISCOMATIC
Measuring of the sensor
- The vehicle with wheels on straightforward and steering wheel position -
to GUIDANCES FOR the REPAIR see microfiche
- The sensor into the steering housing do not build, which plugs attach.
- Attach ALFA ROMEO the TESTER to the steering box VISCOMATIC.
- The key to trip set and with the tester examine that the tension of the output signal of the sensor
is with approx. 2,5 V: If the tension should be approx. 0 V, that
Element of the sensor around 180 turn.
Sensor guidance angle (L53)
This concerns potentiometers, which is accommodated in the steering housing. It sends a
proportional signal to the steering box to the guidance angle (sign + " steering angle right, signs -
steering angle left).
- Supply voltage = 5 V
- Rmax = 1 k
- Range guidance angle = 330 (+ 3%)
1. Steering housing
2. Sensor
It fastens the sensor on the steering housing, makes certain that the steering element stands
in the position guidance center and is the tension signal with 2.5 0,04 V.
- The correct function examined, as the steering wheel is turned and at the right attack is kept two
seconds long, then likewise at the left attack and with the tester to examine that no error is
indicated.
39
VISCOMATIC
Electrical valve hydraulic control block (M25)
In the hydraulic control block (see hydraulic control circuit) are two electrical valves, which are
steered by the electronic steering box.
1. Hydraulic proportional valve
2. Memory load valve
3. Memory
Memory load valve
This concerns a valve ON/COFF that supplies the memory and holds the pressure between 82
and 95 bar, during the normal enterprise of the vehicle.
NOTE: The valve is only also activated at engine number of revolutions over 400 rpm
and at speeds over approx. 4 km/h.
40
VISCOMATIC.
Proportional valve river attitude
This concerns a servo valve that a liquid quantity proportional to the excitation stream lets flow
through. In this way the Kolbenkammer with the transfer of the piston is varied. The signal that
the steering box sends to this electrical valve is a variable Duty Cicle (12 V, max. 2.3 A) -
see illustration.
REMARK: With a direct supply (12 V) the valve was damaged, therefore the system
interrupts the supply, if this tension continues continuously longer than
100 ms.
Characteristic curve of the valve
With a certain river at the electrical valve one achieves a certain liquid quantity, which the pistons
from a position to the other one transferred and so the translation about a certain representation
with one talk " slip to another with one desired " slip brings, which was calculated by the
steering box.
Excitation stream (mA)
1
VISCOMATIC
Diagnostics of the system
A complex self diagnostic logic controls the complete system in each moment:
- Supplies of the circles of the system and the achievement circles
- Examination of the internal memory (only with the initial test).
- Examination of the detailed signals (range of the certified values, stages of varying and
plausibility) analogisch, as digital.
- Examination of the control signals of the actuators.
If an error or a disturbance is present, this information - by an appropriate error code - is
transmitted to the error memory (RAM) of the steering box; at the same time the disturbance signal
lamp on on-board board lights up and the fail-safe program is activated.
More than 70 different error codes can be inferred!
The disturbance signal lamp on on-board board shines for 1 -2 seconds when starting during the
initial at the beginning of the system on {storages and internal components).
If no errors arise, expire them, if the controller infers against it errors, remains the signal
lamp on.
The fail-safe program depends on the taken error: If an error arises with a sensor, which does not affect
the whole system completely, the signal value is corrected this sensor with a reference value
(Recovery ").
If against it an important disturbance of the system is inferred, like for example at the hydraulic
system, the system becomes cut out. If the errors in addition the achievement circle concern
scolded the steering box with the safety external switch the system out.
All stored Fehler-die current " as well as the previous " can only with the Alfa
Romeo tester to be read and deleted.
In order to delete and the fail-safe program switch the signal lamp off, it is sufficient to switch the
steering box off (keys on STOP). If during restarting the errors is no longer present, the signal lamp
does not light up any longer and the fail-safe program is not activated. The before taken up error
remains nevertheless stored.
For each error code a speedometer is intended: With the occurrence of an error this counter is
placed to its maximum value (255): With each restart the counter is lowered around 1, if the error is
no longer present; In this way an error is cleared after 255 restarts, if it arose coincidentally and
does not occur any longer, from the memory.
Likewise the delete operation brings all counters to Rome EO testers with the ALFA zero,
1
ABS
General description ABS "
The 164 4x4 is equipped with the electronic anti-skid system (ABS). This concerns a
specific version for this vehicle with all-wheel drive. VERSION with 6 sensors and 4
channels.
Speed sensors
The four sensors, which are assigned at the four wheels, indicate the respective wheel
speeds to the electronic steering box - they were again designed.
Sensors of the crosswise and longitudinal acceleration
These two sensors were added, in order to infer additional parameters, which are needed by the
specific Kontrollogik the braking. This concerns electromechanical devices, which are led during
accelerations (+) to react and their value to the electronic steering box.
REMARK: In the previous versions these sensors were simple on off switches. In this case it
bargains for around hall effect sensors,
proportional signal to the taken speed pass on: Makes possible for the
operating logic to activate different behaviors depending upon acceleration
borders, while before only one interference threshold could be considered.
Clutch switch
Makes possible the information to the steering box over the interrupted force river between
engine and transmission, in order to be able to correct according to the braking in this condition.
Function high-speed no-load operation (LDA)
ABS is in connection with the MOTRON IC system. When strong decelerations the vehicle and
on the basis of high engine speeds, due to the drive system the engine would tend when braking
to turning off. The steering box ABS informs the steering box in this case MOTRONIC. In addition
the engine brake effect became effective also at the rear wheels, which would brake more than
necessarily. For the avoidance of the over braking of the rear wheels, the logic of the system
seizes opening of the no-load operation automatic controller ".
Signals for the VISCOMATIC system
The steering box ABS sends the 4 Geschwindigkeitssignale of the wheels to the
VISCMAT system, which uses these information, in order the drive logic to define (see
system VISCOMATIC).
ABS
1J
Interference logic for the version 4 x 4
With the special version " the ABS all conventional interference logics receives 4 x 4 from
the brake system, in order to prevent the blocking of the wheels.
The presence of two additional sensors (the two accelerometers) has the development of other
specific logics for 4 x 4-Fahrzeuge rffl (3* in particular made possible.
1. Different adhesion of the wheels
In case of of different detention condition between the right and left side of the vehicle (e.g. layer
of ice), a different reaction at the ground at both sides arises: From it results one M-moment,
which is called craving " and which brings vehicle to the rotation around the point M ".
With vehicles with only two drive wheels this disturbance can be reduced easily by the
conventional abs system, the brake pressure accordingly modulated and in particular at the
demanded drive wheel reduced, as well as owing to the function SELECT low " (clocked
controls at the rear wheels). A drastic reduction of the yaw moment makes M. possible.
'* Zp&>*me*'%
With vehicles with four drive wheels craving is strengthened by the larger reaction of the two
responsible wheels, caused in the special by the viscous drive of the rear wheels: From this an
increase of the yaw moment M takes place in relation to the versions with front wheel drive.
The specific logic of the ABS intervenes thus, as the increase of the pressure on the wheels is
affected with higher adhesion, and so the yaw moment value M is strongly reduced. Thus driving
safety of the vehicle is improved, in the case of the different adhesion between the two sides of
the vehicle.
2. Curves with high speed (also with good adhesion)
The Kontrollogik of transverse acceleration intervenes, if the sensors infer different speed between
the wheels of the two sides, however impossible in case of a curve with high speed. The vehicle
would override, since the ABS would lower the pressure in the two outer wheels too strongly. The
reduction of the yaw moment M would let the over-regulation effect M become stronger, also with
easy brakings.
46
ABS----------------------------------------------------------------------------------\ imm &u
The sensor of transverse acceleration indicates the actual situation to the steering box, which
leads a certain brake pressure, above all to the rear. In addition the abs function is ahead-sent ",
which intervenes and in advance releases the brake pressure ".
3. Bad adhesion with acceleration (or in the sliding enterprise)
For example when driving a curve out with bad adhesion all four wheels have a certain slip. The
datum speed value, which is normally calculated, is very inaccurate and causes for one release
effect " of the brake printing with from-following adhesion problem. This value is thus corrected, as
acceleration or slowing down of the sensor longitudinal acceleration is measured. One reaches
so a braking with limited slip.
4. Snaps minimum number of revolutions (high-speed no-load operation)
With vehicles with four drive wheels, a delay of the rear wheels when braking or when simple
slowing down due to the engine brake, which brake from-following more than necessarily ",
increases. This situation is strengthened only partially by the VISCOMATIC clutch. The clutch
remains closed in some cases " and leads a certain torque to the rear range (for further details
see VISCOMATIC "). With bad adhesion, this problem solves the function high-speed no-load
operation ", which eliminates the effect of the engine brake at the wheels. The sensor of the
longitudinal acceleration infers the range of the slowing down and with bad adhesion (it intervenes
the ABS), sends it a signal, from LDA ", to the steering box of the Motronic that the number of
revolutions amends or lets the engine more softly " to the idling speed come.
REMARK this function however interrupted:
- pressed clutch pedal (situation by the appropriate switch on the clutch pedal
one takes).
- Speed of the vehicle too small
- Engine speed already with minimum value (no-load operation)
47
Localization components of the system
1. Inductive sensors vehicle speed 4.
2. Clay/tone wheels 5.
3. Hydraulic group with abs tax
housing 6.
Control light
Sensors along and
transverse
acceleration
Switch clutch pedal
48
ABS
Hydraulic's group with steering box ABS
This concerns the same building group (hybrid "), which was already installed in 164 the
super. In a block the electronic steering box with hydraulic's group and 4 electrical control
valves for the individual wheels.
PIN-OUT steering box; Plug A " (G273)
1
2
3
Signal lamp disturbance
Switch brake pedal sensor
longitudinal acceleration
4. -
5. Switch clutch pedal
6. Signal rear wheel left for VISCOMATIC
7. Signal front wheel left for VISCOMATIC
8. Signal front wheel left (measures)
9. Signal rear wheel left.
10. Signal front wheel rh (measures)
11. Supply for sensors acceleration
12. Signal front wheel rh.
13. Measures for sensors acceleration
14. Sensor transverse acceleration
15. Diagnostics line K
16. Diagnostics line
L 17. --
18. Signal front wheel rh for VISCOMATIC
19. Signal rear wheel rh for VISCOMATIC
20. Signal front wheel left.
21. Signal rear wheel left (measures)
22. Signal rear wheel rh (measures)
23. Signal rear wheel rh
24.
25. Signal LDA to the Motronic
PIN-OUT hydraulic's group: Plug B " (G272)
1. Supply (with 10 A-protection) Kl. 15
2. Direct supply of battery
3. Measures
4. Signal lamp disturbance
Ground connection C " (G275)
49
ABS
Sensors speed
The four sensors are on the hubs of the four wheels in the range of the clay/tone wheels -
44 teeth -. The sensors were again designed.
Air gap value between wheel and sensor:
Air gap for front wheels
air gap for rear wheels
T = 0.55 - p 1.2
mm T = 0.6
f1,3mm
Clutch switch
This concerns a double N.C. - Switch (closed), which opens, if the clutch pedal is pressed.
Parallel to the contact a resistance (R = 4.22 k) is, which serves for the examination of the
electric circuit.
Electrical pattern
pin 1 not attached
pin 2 not attached
pin 3 measures
pin 4 signal under tension to the steering box
closed contact < 1.25 V
opened contact > 1.25 V
< 3.00 V
separated switch > 3.00 V
< 4.50 V
50
ABS____________________________. ----------------------wmrn m^
Sensors acceleration (crosswise and lengthwise)
This concerns electromechanical devices with the principle of the measures/feather/spring: An
acceleration moves the measures, which act against the feather/spring, whose movement is
inferred by a magnet and by an element with hall effect is processed, which emits a tension signal
corresponding for taken acceleration. The two, sensors are under the center console, in the
proximity of the Barizentrums of the vehicle.
TENSION [V]
Electrical pattern
ACCELERATION [g]
pin 1 measure
to pin 2 output signal (under tension), see diagram
pin 3 supply (5 V)
REMARK: The two sensors are calibrated in the structure equal as well as on the same values:
The steering box processes the input values differently, which arrive at the
two pins.
TO THE AVOIDANCE OF THE MISTAKE, CREDIT THE TWO SENSORS ON THE HOUSING
DIFFERENT COLOR MARKINGS
1. TRANSVERSE SENSOR OF WHITE HOUSING
2. LONGITUDINAL SENSOR BLACK HOUSING
In addition the transverse sensor has an arrow, which shows in driving direction of the vehicle.
DRIVING
+0,8
DIRECTION
A. Measures
b. Feather/spring
NOTE:
The sensors contain a magnetic element. Therefore special caution, if in the
proximity with iron-magnetic material one works.
51
i
Description of function
The system is administered and steered by an electronic steering box, which is positioned inside
the hydraulic's group of N51.
The activation in the circle of the brake assembly is realized by the hydraulic's group of N51, which
control the pressure of the brake fluid after controlling of the electronic steering box; it contains the
electrical pump as well as the four electrical valves, one of the brake fluid with the respective
external switch for each wheel (so-called 4 channel 'version) with respective external switch.
The supply of the system is made directly from the battery and by ignition via the protection of
the specific protection G125 (10A).
The four sensors on the wheels L28, L29, L30 and L31, are connected with the steering box
and send a signal proportionally to the speed.
The two acceleration sensors N62 and N63, supplied at the pin 3 with 5 V and measures of the
pin a 1, supply a proportional signal for taken acceleration, which is handed over to the
steering box to the pin with 2.
By the signal of the switch the information about an arising braking is given to the brake H3,
which steers the stop lights.
The clutch switch H21 is directly connected with the steering box and sends a tension signal, which
informs engine and transmission about the separation. The steering box is connected (pin 25) with
the Motronicsteuergert S11, to which the demand is given to the accelerated minimum number
of revolutions (LDA).
LDA = idling speed rise = high-speed no-load operation.
In addition a connection with the controller N75 Viscomatic exists for the transmission
the Geschwindigkeitssignale of the four wheels.
The internal self diagnostic system in the steering box announces disturbances or not correct
function over pin 1 to the appropriate signal lamp of on-board board C10; the same signal is
announced also to errors in the hydraulic's group - pin 4 of the plug G272 -.
ABS_____________________________________________JI m
Same diagnosis
The available version of the ABS excludes the normal brake system from the Selbstdiagnose, which
holds continuously all components and parameters of the system under control: in case of of
disturbances or bad function scolded yourself the system automatically out and only the conventional
mechanical servo-supported system is active. This situation is indicated to the driver by an
appropriate signal lamp of on-board board. The signal lamp disturbance ABS " is activated with
switched on ignition - its expiring secures that the initial test test of the system was positive and is
present no disturbances.
53
1B^L GH___________________________________________MOTRONIC M 3.7
Electronic engine management Motronic M 3.7
A new electronic engine management steers and supervises all parameters of the engine,
optimizes achievement and consumption by fast responding in the different operating
5 6 7 8 9 10 11
conditions.
This concerns the version M 3,7 of the examined and reliable system BOSCH
MOTRONIC.
54
Oil
1
MOTRONIC M 3.7
MOTRONIC M 3.7
The new Motronicsystem M 3,7 equipped with a controller of the newest technological
development.
The electronic ignition with static distribution " was changed, with one coil each for each spark
plug (MONO COIL); in addition the achievement modules are contained inside the steering box;
this solution eliminates the external ignition circle, and increases thus the reliability and the security
of the ignition system.
With this version M 3,7 a phase injection (sequential) for each cylinder was realized. The injection
moment is not alike to no more for all cylinders, for each cylinder takes place this at the optimal
point of injection, which is calculated by the steering box, depending upon load, number of
revolutions and engine temperature.
REMARK:
The moment planned in the calculation is the injection, from which the duration of injection is
calculated. This is the thermodynamic point and its correct control makes possible a still more
exact optimization of the engine run. The system activates also a correction of the duration of
injection.
1. Electrical injection nozzle \|/
2. Mono coil 2
r
MOTRONIC M 3.7
With new concept and Design debit meter " (air mass measurer) is, with warmed up layer ". This
new air mass measurer does not contain as with the previous version with flap " the sensor of the
sucked in air temperature; with this version this sensor is separately attached before the debit
meter.
The phase sensor was changed (sensor cam angle): It concerns no longer around a sensor with
magnetic induction, but a sensor with hall effect.
1. Sensor air temperature
2. debit meters - air mass measurers
1. Sensor cam
angle
The number of revolutions and reference mark sensor at the front wheel remain unchanged.
59
MOTRONIC M 3.7
The exhaust system consists of two separated systems (front and rear Zylinderreihe)
with ever a catalyst and with ever an upstream Lambda probe (1 and 2).
Before the two separate main catalysts is in each case a Vorkatalysator (3).
The two same probes, send a signal to the steering box over the remainder oxygen quantity
in the exhaust gas, everyone concerning the Zylinderreihe. The steering box changes the
mixing proportion for the appropriate Zylinderreihe.
This solution makes a refinement for Lambda control possible ", which considers the
differences between the different cylinders, with from-following improving of the exhaust gases
and a reduction of the fuel consumption.
1. Lambda probe front Zyiinderreihe (cylinder No. 4; 5; 6)
2. Lambda probe rear Zylinderreihe (cylinder No. 1; 2; 3)
3. Vorkatalysator
60
MOTRONIC M 3.7
Function LDA " (idling speed rise)
In connection with the steering box ABS, activate the Motronic system the so-called LDA logic, i.e.
the waste curve of the engine speed without load is made in the form of steps (accelerotor pedal
fast approved with engine with high number of revolutions).
Speed v "
A = brake
beginning t =
response time
* with LDA
** without
LDA
Time t "
The information idling speed becomes also to the controller of the Viscomatic
passed on and evaluated.
Control empty run govern (signal PWM)
MOTRONIC M 3.7
IBJM
Operation diagramme injection and ignition system
SENSOR
MOTORENTEMR
SENSOR TEMR
SUCKED IN AIR
AIR MASS
MEASURER
FUEL PUMP
SENSOR
BUTTERFLY
VALVE
MONO IGNITION COILS
(6 X)
SENSOR
NUMBER OF REVOLUTIONS
AND 8EZUGSMARKE
ELECTRICAL INJECTION
NOZZLES (6 X)
MOTRONIC
STEERING BOX
INJECTION
AND IGNITION
M3.7
: SENSOR CAM
SHAFT
LAMSDA-SONDE1UND2
ACTUATOR ATTITUDE
CONSTANT ONE MINOESTDREHZAHL (NO-
LOAD OPERATION)
KNOCKING SENSORS 1
AND 2
ELECTRICAL
EVAPORATION VALVE (COAL ACTIVE
CONTAINER)
SPEEDOMETER
SIGNAL
(OF ON-BOARD
BOARD)
ON-BOARD BOARD
(SIGNAL TACHOMETER)
STEERING BOX
ALARM
INSTALLATION
LOADER AIR CONDITIONING
SYSTEM/CCOMPRESSOR
STEERING BOX
AIR
CONDITIONING
STEERING BOX V1SCOMATIC
ABS STEERING BOX
(LOA)
PLUG
ALFAROMEO
TESTER
1. Lambda probes
2. Tachometer
3. Speedometer
4. Air cleaner
5. Plug connection for ABS
6. Plug connection air conditioning system
7. Admission for diagnosis system
(Alfa Romeo tester)
8. Igniting and injection steering box
(Motronic)
9. Plug connection Viscomatic
10. Knock sensors
11. Temperature sensor coolant (NTC)
12. Sensor number of revolutions and
reference mark
13. Automatic controller fuel printing
14. Air mass measurer
15. Potentiometer butterfly valve
16. Temperature sensor sucked in air
17. Butterfly valve body
18. Actuator constant minimum number of
revolutions (no-load operation)
19. Oil steaming racer
20. Pulsationsdmpfer
21. Cam shaft sensor
22. Spark plugs
23. Ignition coils
24. Electrical injection nozzles
25. Electrical evaporation
valve (coal active
container)
26. Fuel filter
27. Electrical fuel pump
28. Fuel tank
29. Relay group
63
MOTRONIC M 3.7
1. External switch gasoline pump 42. Exit signal
PIN-OUT STEERING BOX
Electronic steering box
2. Actuator minimum number of revolutions
(opened)
Vehicle speed
3. Electrical injection nozzle, cylinder No. 1
43. Number of revolutions sensor
4. Electrical injection nozzle, cylinder No. 2
44. Sensor cam shaft
5. Electrical injection nozzle, cylinder No. 3
47. Exit signal engine number of revolutions
6. Measures of injection nozzles
48. Relay air-conditioning system
10. Measures of Lambda probe 2
50. Ignition cylinder No. 6
11. Measures of Lambda probe 1
51. Ignition cylinder No. 5
12. Signal Lambda probe 1
52. Ignition cylinder No. 4
13. Signal Lambda probe 2
54. Supply (by external switches
14. R measures measures for air masses
Motronic)
16. Number of revolutions sensor
55. Measures for ignition
23. Ignition cylinder No. 3
56. Supply over ignition
24. Ignition cylinder No. 2
59. Exit supply 5 V
25. Ignition cylinder No. 1
64. Signal air-conditioning system
26.
Supply (battery)
65. Signal air-conditioning system (compressor)
27. Agreement supply
66. Signal for alarm installation
(at external switch Motronic) 69. Knocking sensor 2
28. Electronic measures
70. Knocking sensor 1
(Screen sensors) 71. Measures for knocking sensors
29. Actuator minimum number of revolutions
(closed)
72. Absolute dimensions for sensors
31. Electrical injection nozzle, cylinder No. 4 73. Signal butterfly valve angle
32. Electrical injection nozzle, cylinder No. 5 77. Sensor air temperature
33. Electrical injection nozzle, cylinder No. 6 78. Sensor water temperature
34. Measures 82. Signal LDA (of abs steering box)
36.
64
Electrical evaporation valve 87. Diagnostics, line L
MOTRON1CM3.7.
Components
The electronic steering box receives the signals from the sensors, which read, process the function
of the engine " them after one inside the briefcases " stored logic, which connect among
themselves optimally the different parameters, and from-following the actuators activates, so that
the engine always functions with maximum achievement and uniformity.
Here the new and/or different components are described in relation to the previous version M
1,7
Air mass measurer (S5)
Operational principle air mass measurement
The heated surface is regulated on a constant temperature rise to sucked in air. The moving by
intake air cools and changes thereby the resistance of the heated surface (PTC behavior). The
filament current is thereby the measure for sucked in air mass.
1. Plug
2. Measuring channel
3. Sensor with warmed up
layer
A = air entrance
The measured river is proportional to sucked in air mass.
REMARK:
The air mass measurer determines directly air mass (and not the quantity as with the
previous versions with amount of air measurer).
MOTRONIC M 3.7
Electrical
pin 1 - Measures pin 2 -
absolute dimensions pin
3 - supply 12 V pin 4-
Me-Signal
A = air
R-S = sensor with warm layer
River, which flows by R-S
Quantity (kg/h) River (A)
0,640
0.25
0.80
12 3 4
RH = heating resistor affects thermally R-S
R-S = sensor resistance
G 1 = compensation resistance
Blank = air temperature feeler resistance
DATA CHARACTERISTICS SENSOR
m = quantity (kg/h)
U = tension between pin 4 and 2
U
[v]
NOTE:
The correct enterprise of the air mass measurer depends on the condition of the air
cleaner, which must be examined therefore regularly.
66
MOTRONIC M 3.7
Sensor cam shaft (S 52)
The phase sensor (sensor cam shaft) consists of a device with hall effect.
Electrical pattern
Pin 1 = supply pin 2 =
exit signal pin 3 =
measures
The tension signal (as) forms, if the pin goes past from the cam shaft at the sensor.
r v
Air gap T = 0.1 - 1.5 mm
Lambda probe (S 35a and S 35b)
The two Lambda probes are from the same design, as they are used also with the previous
versions.
Sensor air temperature (S 34)
The sensor for the sucked in air temperature is separate with this version from the air mass
measurer. This concerns a NTC sensor.
Electrical pattern
67
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A MOTRONIC M 3.7
Mono ignition coil (A8)
Each individual ignition coil on the cylinder heads, supplies directly a spark plug without
intermediate cables. The electrical pattern of the ignition coil is shown in the illustration.
The other components of the system do not differ from the before used Motronic M 1.7.
MOTRONIC M 3.7.
Selbstdiagnose
The steering box is equipped with a self diagnostic system and examines continuously the signals of
the different sensors and compares it with the permitted limit values: If these values are exceeded,
the system recognizes a disturbance and exchanges the abnormal values with average values
accordingly, so that a trip up to the next base of the customer service net is ensured. This function
is called Limp home ".
In addition the self diagnostic system makes a fast and effective putting possible of the disturbances
out under connection with Alfa Romeo the tester (see appropriate publications).
The system does not plan the examination by means of FLASHING CODES.
69
FUEL-SUPPLY NG
Fuel system circle
For the H'Ss SJwird a closed tank vent system with Kohieaktivbehlter used (fuel steams
arrive to the engine into the coal active container and over an electromagnetic valve are
supplied).
70
FUEL SYSTEM
,11
The tank was again designed due to the new rear axle and a larger capacity.
Due to the special form of the tank a special solution became concerning the arrangement of
the pump and the fuel condition giver (3) developed. In the upper range of the tank is a giver
with float.
1. Tank
2. Giver Kraftstoffstand
3. Giver Kraftstoffstand
4. Fuel separator
5. Connecting piece with tilting protection valve and 3-Wege-Lftungsventil
6. Pump with giver Kraftstoffstand
7. Filter
8. Coal active container
9. Solenoid valve (steered from the steering box Motronic)
When inserting the fuel condition giver (3 x) the installation direction must be considered
arrows ".
71
FUEL SYSTEM
The pump is in one of the two lower ranges and leads the fuel over the filter to the
injection nozzles. This concerns an electrical immersed pump, like with the previous
versions. Together with the pump a further giver is present.
1. Pump
2. Giver
The moreover the return pipe of the engine is, in it is together with the third giver a device
in the lower range, which passes the fuel on to the pump.
This concerns a device, which uses the suction effect due to the speed of the fuel return
and so the necessary energy supplies, in order to promote the fuel from this part of the tank
to the fuel pump.
1. Giver
2. Device fuel promotion
A: Return of the engine
B: to the pump C: of
the tank
B
FUEL SYSTEM
Electrical pattern
IO
I
j-9aj) Giver (under rear seat - left) Q-9tp
giver (under rear seat - right) CL9cT) giver
trunk
73
- M CZ&^iJwwne **
'
1B^E_______________________________________________ ON-BOARD BOARD
On-board board
Control light VISCOMATIC
In the number of the control lights is also the announcement VISCOMATIC ".
16 15 14 13 12
The signal lamp shines when starting (approx. 2 seconds) and expires then; it remains illuminating
against it if disturbances in the steering box arise VISCOMATIC. For further details, see section
VISCOMATIC ".
74
ON-BOARD BOARD
Indicate fuel and signal lamp to reserve
Also the activation of the fuel condition indicator and the signal lamp reserve is activated
differently than so far.
Only one signal comes from the 3 givers (Televel) in the tank; this concerns 3 potentiometers,
which are one behind the other switched and so an entirely proportional signal stood according
to the fuel in the tank devoted.
This signal is administered by an appropriate unit (interfaces absorption and reserve "), which
sends measures for the lighting of the signal lamp reserve, if the appropriate ohm value indicates
a very low being located in the tank; in addition it sends the signal concerning the
Kraftstoffstandes to the instrument.
This unit works with an internal delay of 15 seconds and absorbs " so fast changes of the signals,
which can occur in the curve or while driving downhill. For this reason the signal lamp not
falsely lights up.
Ohm value depending upon
announcements
Announcement on
that
Instrument
Q
0
1/2
4/4
285 - r 315
123 + 139
46 + 54
Signal lamp
Reserve*
-230
approximately 9 liters
ON-BOARD BOARD
On-board board: Interior pattern
REMARK:
Here only the specific part for the version is indicated
Notes/notes
77
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01.94/600/left