Honda Bmw 5 Service Manual

							
130-1 
130 Fuel injection 
General ........................... .I3 0.2 
Tools and test equipment .............. .I3 0.3 
Warnings and cautions ................ .I3 0.5 
Fuel Supply ....................... .I3 0.6 
Relieving system  fuel pressure .......... .I3 0.6 
Siemens MS  41 . 1. ................... 1 30-7 
ECM relay.  testing .................... .I3 0.7 
Mass air flow (MAF)  sensor. 
checking and replacing 
................ .I3 0.9 
Engine coolant temperature (ECT) sensor. 
testing and replacing 
.................. 130-10 
Intake  air temperature  (IAT) sensor. 
testing and replacing 
................. .I3 0.1  1 
Throttle position  sensor (TPS). 
testing and replacing 
.................. 130-1 2 
ldle speed control  valve. 
checking and replacing 
............... .I3 0.1 3 
Fuel injectors. checking and  replacing .... 130-15 
Evaporative emissions. overview ....... .I3 0.1 6 
Secondary  air  injection. overview ....... .I3 0-17 
Engine control  module (ECM). 
removing and installing 
................ 130-18 
Siemens MS 41.1 ECM  pin assignments . .I3 0.19 
Siemens MS 42.0  and MS 43.0. ..... .I3 0.23 
ECM relay. testing ................... .I3 0.27 
Mass air flow  (MAF)  sensor. 
checking and replacing 
............... .I3 0.28 
Engine coolant  temperature (ECT) sensor. 
testing and replacing 
................. .I3 0.30 
Intake air temperature  (IAT) sensor. 
testing and replacing 
................. .I3 0.31 
MS 42.0 throttle  valve assembly.  replacing . 130-32 
MS 43.0 throttle valve assembly.  replacing . 130-35 
Throttle cable. adjusting (MS 42.0) ...... .I3 0.38 
ldle speed control  valve. checking 
and replacing 
....................... .I3 0.38 
Evaporative  emissions control diagrams . . 130- 39 
Evaporative emissions control. 
(MS 
42.0 and MS 43.0). .............. .I3 0.39 
Engine control  module (ECM). 
removing and installing 
................ 130-40 
Siemens  MS 42.0 and MS 43.0 
ECM pin  assignments ................. 130-41 
Bosch M5.2 (M62  up to 911997) 
BOSC~ M5.2.1  (M62 911997 to 911998) 130-46 
M5.2 system features ................. 130-47 
M5.2.1 system features ............... 130-47 
ECM relay.  testing ................... 130-49 
Oxygen sensors. checking ............. 130-51 
Fuel injectors. checking and  replacing .... 130-52 
Mass air flow (MAF) sensor. replacing .... 130-53 
ldle  speed control valve.  testing 
and replacing 
....................... 130-54 
Throttle position  sensor (TPS). 
testing and replacing 
................. 130-55 
Engine  coolant temperature  (ECT) sensor. 
testing and replacing 
................. 130-55 
Intake  air temperature (IAT) sensor. 
testing and replacing 
................. 130-57 
Auxiliary throttle valve (ADS)  (M62  and 
M62 TU engine).  replacing ..... 130-57 
Evaporative system pressure 
leak diagnosis. overview 
(5.2.1 only) ..... 130-58 
Bosch 5.2 ECM  pin assignments 
(M62 UP to 911 997) ................... 130-59 
~osch 5.2.1 ECM  pin assignments 
(M62 911 997 to 911 998) ............... 130-62 
BOSC~ ME  7.2 ..................... 1 30-66 
ME 7.2 system overview ............... 130-67 
EDK  adaptation ..................... 130-69 
ECM  relay. checking .................. 130-69 
Engine coolant temperature 
(ECT)  sensor.  testing 
................. 130-71 
Engine coolant temperature 
(ECT) sensor.  replacing 
............... 130-71 
Oxygen sensors. replacing ............. 130-72 
Fuel injectors. removing  and installing .... 130-72 
Mass air flow (MAF) sensor. 
removing  and installing 
................ 130-73 
Evaporative system pressure 
leak  diagnosis. overview 
............... 130-74 
Secondary air  injection. overview ........ 130-75 
Bosch ME 7.2 ECM pin assignments .... 130-76   
						

							
130-2 
/Fuel Injection 
This repair  group covers service and repair  of the Bosch  and 
Siemens engine management systems  used on 
1997 
through 2002 E39 models. Additional engine management 
service  and repair  information  may also be found  in the  fol- 
lowing  repair groups: 
0 020 Maintenance 
120 Ignition  System 
160 Fuel Tank  and Fuel  Pump 
610 Electrical  Component Locations 
OBD  On Board  Diagnostics 
NOTE- 
Camshaft  position sensor, crankshaft speed sensor  and 
knoclc sensors  are covered in 120 Ignition  System. 
Table  a. Engine  management  system applications 
- - ~ ~ 
1 ~odellmodel year / Engine IDME system I - I 
5281, 1997-1 998 IM52. 2.8 liter ISiemens MS  41 .I I 1 
528i. 1999ZO00 1~52 TU, 2.8 liter ]siemens MS 42.0 I I 
5251, 2001-2002 1~54, 2.5 liter 1 Siemens  MS 43.0 I I 
530i, 2001-2002 1~54, 3.0 liter ISiemens MS 43.0 
5401 1999-2001 1~62 TU, 4.4 liter l~osch ME  7.2 
I 
OBI) II software and hardware is incorporated  in the engine 
management control systems.  The 
OED II system monitors 
components that influence  exhaust and evaporative emis- 
sions.  If a  problem  is detected, the 
OED I1 system stores the 
associated  fault code and  condition. 
540i. 1997 
4 If vehicle emission  levels exceed 1.5 times  Federally  mandat- 
ed  criteria,  the 
OED II system illuminates  a malfunction  indi- 
cator light 
(MIL) in  the instrument  cluster. 
For  the 
E39 cars covered  by this manual,  three  different 
MIL symbols were used,  depending  on year  and model. 
See  illustration. 
When faults  arise, or if the malfunction indicator lamp  (MIL) is 
illuminated,  begin troubleshooting by connecting  BMW ser- 
vice tester 
DISplus, MoDiC, GTl or  equivalent  scan tool. The 
capabilities  of OBD 
II software  has the potential  to save hours 
540i. 1998 IM62, 4.4  liter /Bosch M5.2.1 
M62, 4.4 liter Bosch M5.2   
						

							
- 
Fuel Injection 
of diagnostic time  and to help  avoid  incorrect  component re- 
placement  and possible  damage  to system components. 
NOTE- 
* Professional diagnostic scan tools available  at the  time  of 
this printing  include the BMW factory  tools and  a small 
number of  aftermarket  BMW-specific tools.  The 
CS2000 
from Baum  Tools Unlimited,  the Retriever from Assenma- 
chef Specialty  Tools, and the MT2500 from Snap-on are 
three examples. 
In  addition  to the BMW-specific  professional line of scan 
tools,  there are  inexpensive  generic OBD 
I1 scan tool soft- 
ware programs  and 
handheld units available. Although 
these  tools have limited capabilities as compared  to the 
dedicated  tools, they  are powerful  diagnostic tools. 
For  the 
DIY owner,  simple aftermarltet  DTC readeris avail- 
able through 
http://www.pealteresearch.com. This  tool is 
capable  of checlting  for 
DTCs as well as turning  off the  il- 
luminated 
MIL and  resetting the  service indicator  lights. 
Tools and test equipment 
If the equipment  required to do  the  job  is unavailable, it is  rec- 
ommended  that these repairs be left to an  authorized 
BMW 
dealer  or other  qualified BMW repair  facility. 
4 Low current test  light (noid) 
(Tool No. Baum 11 15a)   
						

							
Fuel Injection 
Factory DTC scan  tool 
(Tool  No. BMW 
DISplus / GTl / MoDiC Ill) 
4 Fuel  line plugs 
(Tool No. BMW  13 
5 281 1 13 5 282) 
I 
4 Fuel line clamp 
(Tool  No. BMW  13 3 
010) 
4 Fuel  rail to pressure gauge  fitting 
(Tool No. BMW 
13 5 220)   
						

							
Fuel Injection 
Warnings and cautions 
For  personal  safety, as well  as the  protection  of sensitive 
electronic  components,  adhere to the  warnings  and cautions 
on  the  following  pages. 
WARNING- 
Gasoline is highly  flammable and its  vapors are explosive. 
Do  not  smoke  or  work  on a car  near  heaters  or  other fire 
hazards when diagnosing  and repairing  fuel system  prob- 
lems.  Have a fire  extinguisher available  in case  of an  emer- 
gency 
Renew fuel  system hoses, clamps  and O-rings any 
time they  are removed. 
When  working  on an open fuel system,  wear suitable 
hand  protection,  as prolonged contact 
with fuel  can 
cause illnesses  and skin disorders. 
* The ignition  system produces  high voltages  that can be 
fatal.  Avoid  contact  with exposed  terminals.  Use ex- 
treme caution  when 
working on a car with the ignition 
switched on  or the engine  running. 
CAUTION- 
- Disconnecting  the battery  may erase fault code($ storedin 
memory  Check  for  fault  codes prior  to disconnecting  the 
battery cables.  Read the battery disconnection cautions  in 
001 General Warnings  and Cautions. 
a Connect  and disconnect  the DME system wiring and 
1 test equipment leads  only when the ignition  is switched 
off. 
Wait  at least 1 minute  after turning  off the ignition be- 
fore  removing the  engine control module  (ECM) con- 
nector.  If the  connector  is removed  before this  time, 
residualpower  in the system  relay may damage  the 
control  module. 
Fuel  system cleaners and  other chemical additives oth- 
er  than those specifically  recommended by BMW  may 
damage the catalytic  converter, the oxygen sensor  or 
other fuel supply components. 
* Do not connect any test equipment that delivers  a 12- 
volt power supply to terminal 15 (+) of the ignition  coil. 
The  current  flow may  damage the  ECM. In general, 
connect  test equipment  only as specified  by  BMW or 
the  equipment  maker. 
Only use  a digital 
multirneter for electrical  tests. Only 
use  an LED  test light  for 
quiclc tests.   
						

							
130-6 
Fuel Injection 
Fuel supply  to the  injection  system is  provided by a high pres- 
sure  electric  pump mounted inside  the fuel  tank.  The pump  is 
powered via  the fuel pump relay.  If the relay is faulty,  the fuel 
pump will not  run and  the engine will  not start. 
NOTE- 
* Fuel  delivery  volume and fuel pressure  are critical  to prop- 
er  operation.  Fuel pressure direcfly influences fuel deliv- 
ery 
Fuel pump  relay, fuel pressure  and fuel volume  tests are 
given in 160 Fuel Tank  and Fuel Pump. 
Relieving system fuel pressure 
The fuel system retains fuel  pressure in the  system  when the 
engine  is off. To prevent  fuel from spraying on a  hot engine, 
system fuel pressure  should be relieved beforedisconnecting 
fuel  lines.  One method is  to tightly  wrap 
ashop towel around a 
fuel  line fitting  and loosen  or disconnect  the fitting.  Cleanli- 
ness  is essential  when working with  fuel components. Thor- 
oughly clean the  unions before disconnecting  fuel lines. 
When system faults  are detected, a diagnostic trouble code 
(DTC) is stored  in the engine control module (ECM). The  MIL 
also iiluminates if an emissions-related  fault is detected 
When faults arise,  or if the malfunction indicator lamp (MIL)  is 
illuminated, begin  troubleshooting by connecting  BMW ser- 
vice tester 
DISplus. MoDiC, GTI or  equivalent scan tool. The 
capabilities  of OBD 
II software has the  potential to save hours 
of  diagnostic time and to help  avoid incorrect  component  re- 
placement and  possible damage to system  components. 
CAUTION- 
- The tests in this section may  set fault  codes (DTCs) in the 
ECM and  illuminate  the 
MIL. Affer all testing  is completed, 
access  and clear  DJC fault memory  using an 
OED I1 or 
BMW  compatible scan  tool. See OBD  On-Board  Diag- 
nostics. 
0 Only use  a digital multimeter for  electrical  tests. 
. Relay positions can  vary Be sure  to confirm relay posi- 
tion  by identifying  the wiring  in the socket  using the wir- 
ing  diagrams found  in ELE  Electrical  Wiring 
Diagrams.   
						

							
Fuel Injection 1 
Working in right  rear of engine compartment: 
Release interior  ventilation filter cover  latch 
(A) and re- 
move cover. 
Release plastic  locking  tab 
(6). 
Rotate duct inward (arrow) to unlock  from bulk head  and 
remove  duct. 
Release spring 
lock (C) to  remove  lower iilter housing. 
Slide filter housing  away from inner  fender  to remove. 
- Remove electrical  box (E-box)  cover fasteners  and remove 
cover. 
NOTE- 
OBD I1 fault  memory  (including  an illuminated MIL)  can 
only  be reset  using  an electronic scan  tool. Removing the 
connector from the  ECM or disconnecting  the battery  will 
not erase  the fault 
memory. 
The  BMW-dedicated 20-pin diagnostic linlc connector 
(DLC) is in the right rear  of the engine  compartment. 
The  16-pin  OBD 
I1 diagnostic connector (arrow) is located 
inside the  car on the  lower left  dash panel. 
ECM relay, testing 
Fuses lor ECM In E-bbx 502130488 
4 The engine control  module (ECM) relay  is energized  via the 
ECM  and supplies  battery  positive 
(B+) power to many  of the 
engine  management  components and subsystems. 
If this re- 
lay  is faulty,  the engine  will not start. 
Relay  positions  can vary.  Be sure  to confirm  relay position  by 
identifying the wiring  in the  socket  using the wiring  diagrams 
in 
ELE Electrical  Wiring Diagrams. 
NOTE- 
The ECM  relay is also  referred to  as the  DME main  relay.   
						

							
130-8 
Fuel Injection 
With ignition  off, remove main  relay (K6300) (arrow) in 
E-box. 
- With ignition on  and relay installed, check for  battery voltage 
on  terminal 
2 (87). 
4 Check for voltage  at terminal  8 (30) on relay socket. 
If  battery  voltage  is present, relay  has energized  and is 
functioning  correctly. 
Gmund from 6L (hot ~4th k~y key in Ern 
2I 1 
on position) 
to 
Fuel pump RdiWt Rd from Battery and other system components SOZI~O~~I~Y 
If  battery  voltage is  not present  and all earlier tests  are OK, 
relay  is faulty  and should  be replaced. 
If 
battery voltage  is present continue testing. 
If  battery  voltage  is not present, check fuse  109 (80-amp 
fusible  link)  under passenger seat carpet.  See ELE  Elec- 
trical Wiring  Diagrams. 
- Reinstall relay  and turn ignition on. Gain access to back  side 
of  relay socket  and check  for ground on terminal 
4 (85). 
If  ground  is present  continue testing. 
If  ground is  not present,  signal from ECM is missing. Check 
NOTE- 
If no  faults  are found  during testing  but power  is not  reaching 
the 
ECM or  other  components, check the fuses in the fuse 
carrier 
X8680 in the  E-box. 
wire 
between  ECM and relay.   
						

							
Fuel Injection I 
Mass  air flow (MAF)  sensor, 
checking and replacing 
4 The hot film  mass air flow  (MAF) sensor  (arrow) sends a 
varying voltage (approx. 
0.5 - 4.5 vdc)  to the ECM  represent- 
ing  the measured intake  air. The air mass input signal  is pro- 
duced electronically  by the 
MAFsensorusing a heated  metal 
film  in the  air flow stream. 
The  ECM  relay provides the operating voltage to the  MAF 
sensor.  As air flows through the MAF sensor, the film  is 
- 
cooled. To maintain  the film at a constant temperature, addi- 
tional heating current is necessary. It is  this additional  current 
that is  the basis  for the  input  signal. 
If  there  is no output signal  from the MAF sensor, the  ECM op- 
erates the engine using throttle position and engine  rpm in- 
puts.  A faulty  MAF sensor illuminates the  MIL. 
A  faulty  MAF sensor can produce the following  problems: 
Difficult  to restart  when engine is hot. 
Engine  starts then  stalls. 
Engine starts and runs  only with accelerator pedal  de- 
pressed. 
Disconnect electrical harness connector  from MAF  sensor 
(arrow). 
- Turn  ignition on  and check for voltage  and ground  at connec- 
tor. 
There should  be ground at pin 
1 and battery  voltage at pin 
3. 
If any faults  are found, check  for wiring breaks  between 
MAF sensor and  ECM and between MAF  sensor and ECM 
relay. 
NOTE- 
Visually  inspect the sensor  for damage,  missing or blocked 
screens.  The screens affect  air flow calibration. Also inspect 
the  sealing O-rings  where the sensor inserts  into the air 
filter 
housing  and intake boot. Ensure  the pin  connections are 
clean  and tight. 
4 Connect a  BMW-compatible scan  tool or an  OBD II generic 
scan  tool. Check  air mass  signal (load signal) with  the engine 
at  idle.  Raise idle speed and  check that load signal changes 
with  rpm. 
CA UTIOI\C 
Be sure ignition  is OFFbefore disconnecting  or reconnecting r 
1 DME svstem components. 1   
						

							
130-1 0 
Fuel Injection 
Remove  MAF sensor: 
Release clips  from air filter housing 
(A). 
Disconnect harness connector (B). 
Loosen intake boot clamp (C) and remove  MAF sensor. 
Note large sealing O-rings. 
Installation  is reverse  of removal. 
No  adjustment to  MAF sensor  is possible. 
Check  intake hoses  for cracks and vacuum leaks. 
Engine coolant temperature (ECT)  sensor, 
testing and replacing 
R 
1 -4 The ECT sensor is located  below cylinder 1 intake port 
The ECT sensor is  a dual temperature sensor. One circuit 
provides coolant temperature information to the  ECM while 
the other circuit provides coolant temperature information to 
the instrument cluster. 
The  ECM  determines the correct ignition timing  and 
airlfuel 
mixture required for the engine by monitoring an applied volt- 
age 
(5 vdc) to  the sensor.  The voltage  drop across  the sensor 
varies  as the  coolant  temperature  (sensor resistance) chang- 
es. 
NOTE- 
The  ECT  sensor  is an  NTC  (negative temperature  coeffi- 
cient)  type sensor.  in other  words,  as the temperature rises, 
resistance through the sensor  decreases. 
If the ETC sensor input is faulty  or non-plausible, the MIL is  il- 
luminated when 
OED II fault criteria are exceeded. The ECM 
assumes  asubstitute  value 
(80°C1 176°F) to maintainengine 
operation.  The ignition timing is  set to a 
conse~ativelsafe ba- 
sic  setting. 
- Check ECT sensor resistance using  a multimeter at sensor 
terminals. 
- 
WARNING - 
Due  to risk  of personal  injury, be sure  the engine  is cold  be- 
fore  disconnecting  or reconnecting  ECT sensor. 
ECT sensor  resistance @ 20 C (68°F) 2.2 - 2.7 
Temperature gauge sensor  resistance @ 20°C (~BF)( 6.7 k