Honda Bmw 5 Service Manual
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-. - Fuel Injection I 68 1 / Not used Table d. Bosch M5.2 ECM pin assignments I I I 69 1 input I AIC system standby signal (> 10 V) 1 Heating and AIC control module Pin 57 58 59 60 61 62 63 64 65 66 67 Type input input input input I 70 72 73 74 Componentlfunction Not used Not used Heated thermostat (characteristic map, cooling) Programming voltage input (voltage value) Signal input Evaporative emission valve Not used Fuel pump relay (ground) Not used Not used Not used Not used 75 76 77 78 79 80 Note Characteristic map, cooling Data llnlc connector Evaporative emission valve Fuel pump relay 71 1 ground I Control module ground I Ground splice input input 81 input input input input output Not used I Knock sensor signal Not used Not used Coolant temperature 82 1 I Not used 83 I I Knock sensor Dual temperature swltch Not used Heated oxygen sensor signal (voltage 0.1-1.0 V) Heated oxygen sensor signal (voltage 0.1-1.0 V) Crankshaft position sensor signal (speed and position, AC voltage) Right rear wheel speed signal TD signal (engine speed) 85 I I I Heated oxygen sensor II behind catalytic converter Heated oxygen sensor I behind catalytic converter Cranitshaft positionlrpm sensor ABSIASC control module TD signal splice 84 1 / Not used 1 output 88 86 1 input-output 1 CAN-Bus high I Transmission conlrol module (AGS) input-output Injection signal input-output Integrated instrument cluster control module (IKE) CAN-Bus low Transmission control module (AGS) Data linlc TxD Data link connector
130-62 Fuel Injection Bosch M5.2.1 ECM pin assignments (M62 from 911 997 to 911 998) Table e. Bosch 5.2.1 ECM pin assignments i I I 5 1 I Not used I I I Note I I I 7 lln~ut l~erminal 30 voltage supply I Fuse F4 Description Pin Ground point right-hand drive Ground connector X6460 I I I Signal Connector X60001 Ground 4 1 2 3 Ground Ground point right-hand drive Ground connector X6460 6 8 9 1 2 3 4 5 Not used Not used Not used - 6 7 8 9 10 11 12 Ground Input Connector X60002 Output Input Input Output Input Output Grniind . - 13 14 15 Ground - .- - Output Ground Ground Ground Ground 16 17 18 19 20 21 22 23 . Terminal 87 Not used Oxygen sensor heater slgnal Not used CAN-Bus low CAN-BUS high Ground Output Input ln~ut Fuse F1 Heater oxygen sensor II behind cataiytic converter Back up light switch Transmission control module (AGS) Transmission control module (AGS) Ground connector X6480 Not used Oxygen sensor heater signal Oxygen sensor heater ground Oxygen sensor heater ground Oxygen sensor heater ground Oxygen sensor heater ground Not used Input Input Output Output Output Heater oxygen sensor I behind catalytic converter Heater oxygen sensor II behind catalytic converter Heater oxygen sensor 1 in front of catalytic converter Heater oxygen sensor II in front of catalytic converter Heater oxygen sensor I behind catalytic converter Oxygen sensor heater ground Oxygen sensor heater ground Oxvqen sensor heater ground Heater oxygen sensor iI in front of catalytic converter Heater oxygen sensor II behind catalytic converter Heater oxygen sensor 1 in front of catalytic converter . - Oxygen sensor heater ground Oxygen sensor heater ground Signal, running losses Oxygen sensor iieater ground Not used Not used Not used Terminal 85 control Heater oxygen sensor II in front of catalytic converter Heater oxygen sensor I behind catalytic converter Fuel changeover (312 way valve) circuit Heater oxygen sensor 1 in front of catalytic converter Engine control module relay
Fuel lnjection Table e. Bosch 5.2.1 ECM pin assignments Pin Isignal 1 Description 1 Note Connector X60003 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ate alr empe Output Output Output Ground Ground Output Output Input Input Input Ground 22 23 24 25 26 27 28 29 30 Injection signal Injection signal Signal, evaporative emission valve Not used Not used Ground for electronic components Not used Not used Hot film mass air flow sensor ground Throttle position sensor voltage supply Signal, engine coolant temperature sensor Hot film mass air flow sensor signal Throttle position sensor slider voltage Shield, throttle potentiometer (DK) Not used Injection signal Injection signal Not used Not used Input Input Input Ground Output Output Evaporative emission valve Ground point right-hand drive Ground connector X6460 Hot film mass air flow sensor Throttle position sensor Signal, secondary air injection pump valve Terminal 30 voltage supply Alternator D+ (terminal 61) signal injection signal Injection signal Not used Not used Not used Not used Camshaft position sensor signal Ground Dual temperature switch Hot film mass air flow sensor Throttle position sensor Throttle position sensor Cylinder 8 fuel injection valve Cylinder 5 fuel injection valve Secondary air injection pump valve Starter Alternator (generator) Cylinder 7 fuel injection valve Cylinder 6 fuel injection valve Camshaft position sensor (Hall effect) Dual temperature switch
- Fuel Injection Table e. Bosch 5.2.1 ECM pin assignments Pin I~iqnal 1 Description 1 Note I I I 46 llnput ICrankshaft position sensor Icrankshaft positionlrpm sensor 38 39 40 41 42 43 44 45 Ground Input Output Output Output Output Ground 47 48 49 50 51 Not used I Not used 52 Shield, knock sensor Oil level - thermal Injection signal injection signal Idle speed control - opening winding Idle speed control - closing winding Not used Ground Ground -- Ground Input Ground Ground Not used Knock sensor Oil level sensor Cylinder 4 fuel injector valve Cylinder 1 fuel injector valve Idle speed control valve Idle speed control valve Shield, crankshaft sensor 5 6 7 12 Not used Ground Intake air temperature sensor Connector X60004 8 9 10 11 14 1 1 Not used I Shield, knock sensor Shield, sensor I Shield, sensor 3 Shield, itnock sensor Input - Knoclc sensor Knock sensor Knock sensor Knock sensor Instrument cluster Output 2 llnput l~erminal 30 voltage supply /Megrated instrument cluster control module (IKE) Alt. charge indicator signal, terminal 61 1 Not used Start signal terminal 50 Not used 15 16 17 18 Output Ignition switch Not used Not used Activation of relay for fuel pump Not used 19 Fuel pump relay Output Not used I I I 20 loutput ICARB signal /Data link connector Not used Not used Engine speed signal output (TD) Not used Light module 21 Cruise control module (Tempomat) 22 llnput I Right rear wheel speed signal /ABS/ASC or ABSIDSC control module Oulput Washer fluid level, brake fluid level
Fuel Injection Table Pin 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 e. Bosch 5.2.1 Signal Input Input Ground Output Input- output Output Input- output Input- output Output Connector X60005 Output Output Output Output Ground Output Output Output Output ECM pin assignments Description Not used Not used Voltage supply, terminal 15 Not used Not used Compressor ON signal from engine control module (DME) Ground Not used Diagnosis signal TXD Communication link (EWS) Signal, leak diagnosis pump Not used CAN-Bus high CAN-Bus low Not used Not used Start signal Terminal 1 signal Terminal 1 signal Terminal 1 signal Terminal 1 signal Ground Terminal 1 signal Terminal 1 signal Terminal 1 signal Terminal 1 signal Note Fuse F14 Heating and AIC control module Lealtage diagnosis pump Data iinit connector Electronic immobilizer (EWS) Leakage diagnosis pump (LDP) CAN link CAN link Starter relay Cylinder 7 ignition coil Cylinder 8 ignition coil Cylinder 2 ignition coil Cylinder 3 ignition coil Ground point Cylinder 1 ignition coil Cylinder 4 ignition coil Cylinder 5 ignition coil Cylinder 6 ignition coil
Fuel Injection When system faults are detected, a diagnostic trouble code (DTC) is stored in the engine control module (ECM). The MIL also illuminates 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, GTl 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. CA UTIOI\C The tests in this section may set fault codes (DTCs) in the ECM and illuminate the MIL. After all testing is completed, access and clear DTC fault memory using an OBD I1 or BMW compatible scan tool. See OBD On-Board Diag- nostics. . 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 Diaqrams. NOTE- = OBD I1 fault memory (including an illuminated MIL) can only be reset using the special scan tool. Removing the connector from the ECM or disconnecting the battery will not erase the fault memory. 0 The BMW-dedicated 20-pin diagnostic link connector (DLC) is in the right rear of the engine compartment. The 20-pin DLC was eliminated on models after 6/2000. The 16-pin OBD I1 diagnostic connector (arrow) is located inside the car on the lower left dash panel.
130-67 Fuel Injection / ME 7.2 system overview The Bosch ME 7.2 system is used on 1999 - 2002 540i mod- els. 1 4 The ME 7.2 enaine control module (ECM). located on the l and a combined total of 134 pins. --__-- 1 I. 9 pin connector 12 3 4 5 2 24 pin connector 0lliC;nii, 3. 52 pin connector 4. 40 pin connector 5. 9 pin connector The ME 7.2 system has the following functions or capabilities: Electronic throttle control (EDK) integrates idle and cruise control functions. ECM carries out all throttle and idle con- trol functions directly via EDK system. Leak diagnosis pump (LDP) control and feedback monitor- ing for evaporative system leak testing. Batterylalternator charge logic (idle speed varies with bat- tery state of charge). CAN-Bus communications with instrument cluster. EWS 111 (3.3) rolling code ISN interface. Ignition knock sensors. DSC (dynamic stability control) torque reduction. Monitoring and control of VANOS (camshaft timing) with active Hail sensor for camshaft position monitoring. Integrated altitude sensor. One touch engine start control Single speed secondary air injection system. Long life spark plugs. IHKA auxiliary (electric) cooling fan control. All emissions-related ME 7.2 electrical components are mon- itored for faults. if driveability complaints are encountered or the malfunction indicator light (MIL) is illuminated, interrogate fault memory using a compatible scan tool. 4 Use a break-out box for ME 7.2 system testing and diagnosis at the control module (break out box set: BMW special tool 90 88 6 121 300). Electrically heated (characteristic map) cooling system DME Harness Connector thermostat.
130-68 Fuel Injection 0 4 The ME 7.2 uses a non-return fuel rail. The fuel pressure reg- ulator is integrated into the fuel filter. I iY.,lii,in 4 The M62 TU engine uses a continuously variable VANOS system at each intake camshaft. This system enhances en- gine performance and reduces tailpipe emissions. Both cam- shafts are adjusted simultaneously within 20 (maximum) of the camshafts rotational axis. This equates to a maximum span of 40°crankshaft rotation. regulalor from luel pump NOTE- The fuel filter is available as a replacement part without the fuel pressure regulator. When replacing the fuel filter, trans- fer the fuel pressure regulator from the old filter to the new fil- ter. Engine idle speed control is a function of the EDK. The M62 TU engine does not use a separate idle control valve. Mmn CON,ROL EML < The M62 TU engine uses an electrically controlled throttle valve called EDK. The throttle plate is positioned by a DC gear reduction motor based on inputs signals to the ECM from the pedal position sensor (PWG). When the accelerator pedal is moved, the PWG provides a change in the monitored signals. The ME 7.2 control module compares the input signal to a programmed map and appro- priately activates the EDK motor via proportional pulse width modulated control signals. The control module self-checks its activation of the EDK motor via the EDK feedbaclc potentiom- eters.
-- Fuel Injection I The PWG potentiometers provide DC voltage signals as in- put to the ME 7.2 control module for throttle and idle control functions. Potentiometer signal 1 is the primary signal, poten- tiometer 2 is used for a plausibility cross-check. 1. Potentiometer 1 ground 2. Potentiometer 1 power 3. Potentiometer 2 ground 4. Potentiometer 2 power 5. Potentiometer 1 signal to ECM 6. Potentiometer 2 signal to ECM If errors are detected between potentiometer 1 and 2, the ECM calculates the engine intake air mass (from MAFsensor signal) and only utilizes the potentiometer signal that closely matches the detected intake air mass. The ECM control mod- ule uses the air mass signal for a comparative source to pro- vide fail-safe operation. If the ECM cannot calculate a plausible conclusion from the monitored potentiometerthe EDK motor is switched off and fuel injection cut-out is activat- ed (no fail-safe operation possible). EDK is continuously monitored during all phases of engine operation. If faults are detected, the EDK motor is switched off and fuel injection cut off is activated. The engine continues to run extremely roughly at idle speed. EDK adaptation When the EDK throttle assembly is replaced, the adaptation values of the previous EDK must be cleared from the ME 7.2 ECM using the BMW service testeroran equivalentscan tool. Once the old adaptation values have been cleared, the new EDK assembly should be installed and adapted as follows: 0 Switch ignition OFF for 10 seconds. * Switch ignition ON. Afler approximately 30 seconds, the EDK is briefly activated indicating that the replacement unit is now adapted to the ME 7.2 system. NOTE- This EDK adaptation procedure is also necessary after re- placing the ME 7.2 engine control module. However, the ad- aptation values do not require clearing since they have not yet been established. ECM relay, testing 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. NOTE- The ECM relay is also referred to as the DME main relay
130-70 Fuel Injection ECM relay -- CAUTION- Relay positions can vary Be sure to confirm relay position by identifying the wiring in the socl(et using the wiring diagrams in ELE Electrical Wiring Diagrams. Working in right rear of engine compartment: Release interior ventilation filter cover latch (A) and re- move cover. Release plastic locking tab (B). Rotate duct inward (arrow) to unlock from bulk head and remove duct. Release spring loclt (C) to remove lower filter housing. Slide filter housing away from inner fender to remove. - Remove electrical box (E-box) cover fasteners and remove cover. 4 With ignition off, remove main relay (arrow) in electronics box (E-box) at right rear of engine compartment. NOTE- Relay locations can vary Confirm relay identification by matching wiring colors and terminal numbers. 4 Check for voltage at terminal 6 of main relay socket (30-red wire). If battery voltage is present, continue testing. If battery voltage is not present, check large red wire in re- lay socltet. See ELE Electrical Wiring Diagrams. - Reinstall relay and turn ignition on. Gain access to underside of relay socket and check for ground at terminal 4 (85-brown wire). If ground is present, continue testing. If ground is not present, switched ground signal from ECM is missing. Check wire between ECM and relay. - With ignition on and relay installed, check for battery voltage at terminal 2 (87-redlwhite wire). If battery voltage is present, relay has energized and is functioning correctly. If battery voltage is not present and all earlier tests are OK. relay is faulty and should be replaced.