Wiring harness BMW 318i 1996 E36 User Guide

119-
6



LUBRICATION
SYSTEM

17
.
Raise
engine
as
much
as
possible
.
Check
carefully
for



22
.
Installation
is
reverse
of
removal
.

obstructions,
wiring
harness
clearance
and
pinched

hoses
or
lines
as
engine
is
raised
.



"
When
installing
oil
pan,
apply
a
b



d
of
non-hardening

sealing
compound
(3-Bond
1209
0
or
equivalent)
to

18
.
Remove
oil
pan
mounting
bolts
and
lower
oil
pan
to



front
and
rear
end
cover
seam
areas
on
block
.

subframe
crossmember
.



"
Position
oil
pump
pickup
tube
and
oil
pan
onto
block

and
install
pickup
tube
using
a
new
gasket
.

"
Be
sure
tab
on
gasket
faces
down
towards
intake
of

NOTE-



pickup
tube
.
If
the
oil
pan
does
not
separate
easily
from
the
engine



"
Tightenforward
oil
pan
screws
first,
then
tighten
rear
.

cylinder
block,
afew
taps
with
arubber
mallet
should



"
Fill
engine
with
oil
as
described
in
020
Maintenance
break
it
free
.
Do
not
pry
the
oil
pan
loose
.



Program
.

"
After
adding
engine
oil,
start
and
run
engine
.
Raise
en-

19
.
Remove
oil
pump
sprocket
mounting
nut
.
See
Fig
.
9
.



gine
speed
to
2,500
rpm
until
oil
pressure
warning

Lift
sprocket
off
together
with
drive
chain
.



lampgoes
out(about
5seconds)
.

Fig
.
9
.
Oil
pump
sprocket
mounting
nut
(left-hand
thread)
on
6-cylin-



OII
pan,
removing
and
installing

derengine(arrow)
.



(6-cylinder
engine,
1993
and
later
modeis)

NOTE-

The
oíl
pump
sprocket
nut
has
left
hand
threads
.

20
.
Unbolt
oil
pump
pickup
tubefrom
oil
pump
.
Unbolt
oil

pump
from
engine
block
.
See
Oil
pump,
removing

and
installing
(6-cylinder
engine)
.

21
.
Remove
oil
pan
from
rear
.

Tightening
Torques

"
Engine
mount
to

suspension
crossmember(M10
nut)
..
42
Nm
(31
ft-Ib)

"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
....
..
.
...
...
.
........
10
Nm
(89
in-lb)

10
.9
grade
.
.
..
.
..
...
.
.
.
.
.
.....
12
Nm
(106
in-lb)

"
Oil
pump
to
engine
block
.
...
...
.
..
22
Nm
(16
ft-Ib)

"
Oil
pump
sprocket
to
oil
pump
shaft

(M1
0x1
left-hand
thread)
...
..
.
.
..
.
25
Nm
(18
ft-Ib)

"
Power
steering
pump
to
bracket

(self-locking
nuts)
.....
.
....
..
.
...
22
Nm
(16
ft-lb)

"
Power
steering
pump
bracket
to
engine

block
or
oil
pan
(self-locking
nuts)
.
..
22
Nm
(16
ft-Ib)

NOTE-

Cars
built
after
9/92
use
a
different
suspension
cross-

member
¡han
earfier
productíon
cars
.
Oil
pan
removal

procedure
on
the
later
cars
requíres
that
the
engine
be

supported
from
aboye
and
the
front
suspension
cross-

member
be
unbolted
and
loweredfrom
the
chassis
.

1
.
Raisecar
and
place
securely
on
jackstands
.

2
.
Remove
splash
shield
fromunder
engine,
if
applicable
.

3
.
Drain
engine
oil
as
descríbed
in
020
Maintenance
Pro-

gram
.

4
.
Remove
alternator
cooling
duct
from
alternator
and
ra-

diator
support
.

120-
4



IGNITION
SYSTEM

2
.
Check
for
battery
voltage
o
cofs
.
If
voltage
is
not



Table
b
.
Ignition
Coil
Resistance

present,
check
wire
between
terminal
15
and
ignition



(M42
Engine)
switch
.
See
Electrical
Wiring
Diagrams
.

"
On
M42
engine,
connect
digital
multimeter
between
ter-

minal
15(+)
in
each
harness
connector
and
ground
.
See

Fig
.
4
.

"
On
M44
engine,
connect
voltmeter
between
terminal
2

(15+)
in
connector
and
ground
.
Turn
ignition
on
and

check
for
voltage
.
See
Fig
.
5
.

3
.
Turn
ignition
off
.

0
4a15

Fig
.
4
.



Ignition
coil
harness
connector
terminal
identification
for
M42

engine
.

Fig
.
5
.



Ignition
coil
harness
connector
terminal
identification
for
M44
engine
.

CAUTION-

The
wiring
to
the
coil(via
the
ignition
switch
15+)
is
not
fuse
protected
.
Use
care
when
testing
thiscircuit
.

4
.
Use
a
digital
multimeter
totest
coil
primary
resistance
.

"
On
M42
engine,
use
Table
b
asa
guide
to
check
coil

resistance
.
Make
checks
at
each
harness
connector
.

"
On
M44
engine,
use
Table,c
as
a
guide
to
check
coil
primary
resistance
.

5
.
Inspect
coil
housing
for
hairline
cracks
or
leaking
cast-
ing
material
.
See
Fig
.
7
.
A
leaky
ignition
coil
may
indi-



11502

cate
a
faulty
ECM
(engine
control
module)
.
Check
the
ECM
before
installing
a
new
coil
.



Fig
.
6
.



Ignition
coil
harnessconnector
terminal
identification
for
6-
cylinder
engine
.

IGNITION
SYSTEM
SERVICE

11502

Terminals
Resistance
(refer
to
Fig
.
4
.)

Coil
primary



1
(-)
and
15
(+)



10
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

Table
c
.
Ignition
Coil
Resistance

(M44
Engine)

Terminais
Resistance
(referto
Fig
.
5
.)

Coil
#1
primary



1
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#2
primary



6
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
#3
primary



7
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#4
primary



5
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

NOTE-

If
a
single
coilís
faulty
on
M44
engines,
the
complete
coil
pack
will
have
to
be
replaced
.

Ignition
coil,
testing
and
replacing

(6-cylinder
engine)

CAUTION-

Use
a
digital
multimeter
for
the
following
tests
.

1.
Remove
plastic
enginecovers
from
top
of
engine
by

prying
off
nut
covers
and
removingcover
mounting

nuts
.
See
113
Cylinder
HeadRemoval
and
Installa-

tion
.

2
.
Disconnect
harnessconnectorfromcof
.
Connect
mul-
timeter
between
terminal
15
(+)
in
connector
and

ground
.
See
Fig
.
6
.

3
.
Turn
ignition
on
and
check
for
batteryvoltage
.

"
If
batteryvoltage
is
not
present,
check
wire
between

terminal
15
and
ignition
switch
.
See
Electrical
Wiring

Diagrams
.

"mozo

120-
6



IGNITION
SYSTEM

Crankshaft
position/rpm
sensor,

testing
and
replacing
(front
mounted)

1
.
Disconnect
sensor
harness
connector
.

2
.
Using
a
digital
multimeter,
check
resistance
between
terminals
1
and
2
in
connector
.
See
Fig
.
10
.

n1
n2n3

Fig
.
10
.
Crankshaft
position/rpm
sensorconnector
.

Crankshaft
positionlrpm
sensor
specifications

"
Coil
resistance
(approx
.)
terminais
1
and
2
....
.
..
...
....
1280
±
10%
ohms

"
Air
gap
(sensor
distance
from
toothed
wheel)
..
.
.
........
.1
.0
±
0
.3
mm
(0
.04
±
0
.01
in
.)

3
.
If
the
resistance
is
not
correct,
the
sensor
is
faulty
and
should
be
replaced
.

NOTE
-

When
installing
the
new
sensor,
be
sure
thewiring
Is
rerouted
in
the
same
orientation
.
Secure
the
sensor
us-
ing
new
wire
ties
.

Tightening
Torque

"
Crankshaft
position/rpm
sensor
to
mounting
bracket
.........
.
.
5
t
1
Nm
(62
t
9
in-lb)

Crankshaft
position/rpm
sensor,



4
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring
replacing
(rear
mounted)



when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
1
.
Disconnect
sensor
harness
connector
.

6502AGN56

2
.
Locatesensor
on
rear
left
sideof
cylinder
block
.
Re-
move
sensormounting
bolt
and
remove
sensorfrom
cylinder
block
.

IGNITION
SYSTEM
SERVICE

3
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring

when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
Secure
sensor
using
new
wire
ties
.

NOTE-

It
may
be
easier
to
remove
the
sensor
working
from
the
underside
of
the
vehicle
.

Camshaft
Position
(CMP)
Sensor

The
camshaft
position
(CMP)
sensor
is
usedby
the
engine
management
system
for
sequential
fuel
injection
and
knock
control
.

Camshaft
position
(CMP)
sensor,

replacing
(4-cylinder
engine)

1
.
Remove
CMP
sensorfromtop
timing
cover,
just
above
coolantthermostat
housing
.
See
Fig
.
11
.

Fig
.
11
.
Camshaft
position
sensor
mounting
bolt
(arrow)
.
M42
engine
shown
.

2
.
On
M42
engines
to
9/93
:
Disconnect
CMP
harness
plug
just
above
oil
filter
housing
.

3
.
On
M42
from9/93
and
all
M44
engines
:
Remove
upper
intake
manifold
as
described
in
113
Cylinder
Head
Re-
moval
and
Installation
.
Then
unplug
CMP
sensor
har-
ness
connector
below
manifold
.

Camshaft
position
(CMP)
sensor,

replacing
(6-cylinder
engine)

1
.
Remove
plastic
cover
from
above
fuel
injectors
.

2
.
Disconnect
harness
connector
from
VANOS
solenoid

and
unscrew
solenoid
from
VANOS
control
unit
.
Re-



"
Clean
contactsurface
on
engine
block
before
fnstall

move
oil
supply
line
from
VANOS
control
unit
.
See
117



ing
knock
sensors
.

Camshaft
Timing
Chain
.

3
.
Remove
camshaft
position
(CMP)
sensor
from
left
frontof

cylinder
head,
next
to
top
of
oil
filter
housing
.



"
Knock
sensor
to
cylinder
block
....
20
Nm
(15
ft
.
lbs
.)

4
.
Disconnect
CMP
sensor
harnessfrom
under
intake

manifold
.

5
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring

when
installing
sensor
.
Be
sure
wiring
is
rerouted
in

same
orientation
.

Tightening
Torques

"
CMP
sensor
to
cylinder
head
....
.
.
..
5
Nm
(3
.5
ft-Ib)

"
VANOS
oil
supply
pipe
to

VANOS
control
unit
...........
.
..
32
Nm
(24
ft-Ib)

"
VANOS
solenoid
to
VANOS

control
unit
...
.
.................
30
Nm
(22
ft-Ib)

Knock
sensors,
replacing

Knock
sensors
are
usedon
engines
with
Bosch
DME
M1
.7,

Bosch
DME
M3
.3
.1,
Bosch
DME
M5
.2,
and
Siemens
MS
41
.1

engine
management
systems
.
The
knocksensors
are
bolted
to
the
left
sideof
the
cylinder
block
and
monitor
the
combus-

tion
chamber
for
engine-damaging
knock
.
If
engine
knock
is

detected,
the
ignition
point
is
retarded
accordingly
via
the
en-

gine
control
module
.

CA
UTION-

"
Label
knock
sensorharness
connectors
before

disconnecting
them
.
The
connectors
must
not
be

interchanged
.
Engine
damage
may
result
if
the
sensors
are
monitoring
the
wrong
cytinders
.

"
Note
the
installed
angle
of
the
knock
sensoron
the

block
before
removing
it
.
Reinstall
the
sensor
in

the
same
position
.
Be
sure
to
usea
torque
wrench

when
tightening
the
sensormounting
bola

NOTE
-

"
On
M52
engines,
a
single
harness
connects
the
twosensors
to
the
main
harness
connector
.
The
shorter
cable
lead
fs
for
the
knock
sensor
for
cytinders
4,
5,
and
6
.

Tightening
Torque

IGNITION
SYSTEM



120-
7

0012730

Fig
.
12
.
Knock
sensor
mounting
bolt
on
front
left
side
of
cylinder

block
.

NOTE-

Knock
sensor
function
Is
monitoredby
the
On-Board
Diagnostic
system
.
If
a
knock
sensor
is
detected
to
be
faulty,
an
appropriatediagnostic
trouble
code
(DTC)
may
be
stored
in
memory
.
See
100
Engine-General
for
information
on
retrieving
DTCs
.

On
6-cylinder
engines,
the
knock
sensors
are
accessible
af-
ter
removing
the
intake
manifold
.
On
4-cylinder
engines,
the

upper
section
of
the
intake
manifold
should
be
removed
to
ac-

cess
the
sensors
.
See
Fig
.
12
.
NOTE-

Intakemanifold
removal
and
installation
procedures
are



"
Cylinder
no
.
1is
at
the
front
of
the
engine
.

covered
in
113
Cylinder
HeadRemoval
and
Installation
.

Ignition
Firing
Order

Ignition
Firing
Order

"
4-cylinder
engines
.....
..
...
.
..........
.1-3-4-2

"
6-cylinder
engines
...........
..
.
.
..
..
1-5-3-6-2-4

IGNITION
SYSTEM
SCHEMATICS

Fig
.
13
through
Fig
.
17
show
ignition
system
schematics

usedon
the
enginescoveredby
this
manual
.

IGNITION
SYSTEM
SCHEMATICS

Starter,
removing
and
installing

(6-cylinder
engine
with

automatic
transmission)

The
starter
on
a
6-cylinder
car
with
automatic
transmission

ís
removed
from
above
.
It
is
necessary
to
remove
the
íntake

manifold
and
disconnect
a
number
of
electrical
harness
con-

nectors
.

1
.
Disconnect
negative
(-)
battery
cable
.

2
.
Remove
air
plenum
from
rear
of
engine
compartment
.

See640
Heating
and
Air
Conditioning
.

3
.
Remove
top
enginecovers
.
See
Fig
.
9
.

Fig
.
9
.



Remove
top
engine
cover
by
prying
out
plugs
and
removing
nuts
(A)
.
Make
sure
rubber
insulators
(B)
on
either
sideof
large
cover
do
not
fall
off
during
cover
removal
.

4
.
Remove
ignition
coil
harness
connectors
.
Remove
ground
connection
at
front
of
cylinder
head
.

5
.
Remove
two
retaining
bolts
and
lift
off
fuel
injector
har-
ness
connector
strip
.
Carefully
fold
away
all
harnesses
toward
right
side
of
engine
compartment
and
place
at
base
of
windshield
.
See
Fig
.
10
.

6
.
Remove
intake
manifold
.
See
113
Cylinder
Head
Re-
moval
and
Installation
.

7
.
Disconnect
wiring
from
starter
.

BATTERY,
STARTER,
ALTERNATOR



121-
9

Fig
.
10
.
Fuel
injection
harness
(A)
and
ignition
coíl
harness
connectors
(B)
being
lifted
off
engine
to
be
placed
at
base
ofwindshield
.
M50
engine
shown
.
Other
6-cylinder
engines
are
similar
.

8
.
Loosen
and
remove
bolts
and
nuts
fastening
starter
to
transmission
bell
housing
and/or
engine
block
.
Remove

starter
support
bracket
.

Fig
.
11
.
Starter
wiring
terminals
and
support
bracket(arrow)
.
Intake
manifold
has
been
removed
.

STARTER
SERVICE

Oxygen
Sensor
FUEL
DELIVERY
TESTS
FUEL
INJECTION



130-
9

"
Voltage
at
¡dle
..
.
..
..
....
0
.2
to
0
.8
VDC,
fluctuating



Checking
fuel
delivery
is
afundamental
part
of
trouble-
shooting
and
diagnosing
the
engine
management
system
.
Fuel
pressure
directly
influences
fuel
delivery
.
An
accurate

NOTE-



fuel
pressure
gauge
will
be
needed
to
make
the
tests
.

To
check
sensorresponse
to
lean
and
rich
mixtures,
createenairleak,
orpull
vacuumhoseofffue¡
pressure



There
are
three
significant
fuel
delivery
values
to
be
mea-

regulator
to
increase
fuel
pressure
.



sured
:

3
.
Separate
sensorharness
connector
from
sensor
.
Check

for
battery
voltage
between
terminals
3
and
4
(green

wire
and
brown
wire)
in
main
wiring
harness
side
of
con-

nector
with
engine
running
.
If
voltage
is
not
present,

check
oxygen
sensor
heater
relay
.
See610
Electrical

Component
Locations
.

4
.
Check
heater
element
resistance
between
terminals
3
and
4
in
sensor
side
of
connector
.
If
element
is
electri-

cally
open
(no
continuity),
replace
sensor
.

NOTE-

The
oxygen
sensor
heater
relay
is
mounted
in
the
main
power
distributfon
box
in
the
left
rear
of
the
engine
com-
partment
.
Refer
to
Fig
.
6
.
The
heater
relay
is
energized
wíth
positive
(+)
battery
voltage
from
the
main
relayanda
switched
ground
from
the
ECM
.
See
Electrical
Wir-
ing
Diagrams
.

"
Oxygen
sensor
to
exhaust
pipe
...
..
55
Nm
(41
ft-Ib)

"
System
pressure-created
by
the
fuel
pump
and
main-
tained
by
the
pressure
regulator
.

"
Fuel
delivery
volume-created
by
the
fuel
pump
and
af-
fected
by
restrictions,
suchasclogged
fuel
filter
.

"
Residual
pressure-the
pressure
maintained
in
the
closed
system
after
the
engine
and
fuel
pump
are
shut

off
.

Procedures
for
measuring
the
first
two
quantities
arede-
scribed
in
160
Fuel
Tank
and
Fuel
Pump
.
Residual
fuel
pres-
sure
is
checked
using
the
procedure
detailed
later
in
this

group
.

Operating
fuel
pump
fortests

To
operate
the
fuel
pump
for
testing
purposes
without
hav-

íng
to
runthe
engine,
the
fuel
pump
relay
can
be
bypassed
to

power
the
pump
directly
.
Fuel
pump
relay
location
is
shown
in

Fig
.
6
.

5
.
¡f
oxygen
sensor
doesn't
produce
a
fluctuating
voltage



To
runthe
fuel
pump,
remove
the
fuel
pump
relay
and
con-
and
preheater
circuit
is
OK,
replace
sensor
.



nect
the
socket
for
relayterminal
30
to
the
socket
for
relay
ter-

mina¡
87
with
a
fused
jumper
wire
.
After
completing
the
tests,

NOTE-



remove
the
jumper
wire
.

If
not
already
applied,
coat
the
oxygen
sensor
threads
with
an
anti-seize
compound
before
installation
.
Do
not



CAUTION-
getthe
compound
on
the
sensor
tip
.
"
Relay
locations
may
vary
.
Use
care
when
identi-
fying
relays
and
making
electrical
checks
at
the
fuselrelay
panel
.
See
610
Electrical
Compo

Tightening
Torque



nent
Locations
for
additional
relay
information
.

"
The
fuel
pump
relay
has
a
1
.5
mm2
red
wire
at
ter-
minal
30
in
the
relay
socket
.
Terminal
87
has
a
1
.5
mm
2
greenlviolet
wire
.
See
Electrical
Wiring
Di-
agrams
for
additional
wiring
information
.

NOTE-

Thejumper
wire
should
be
1.5
mm2
(14
ga
.)
and
in-
clude
an
in-line
tuse
holder
with
a15
amp
tuse
.
To
avoid
fuselrelay
panel
damage
from
repeated
connect-
ing
and
disconnecting,
also
include
a
toggle
switch
.
A
heavy-duty
jumper,
BMW
tool
no
.
61
3
050,
is
also
available
from
an
authorized
BMW
dealer
.

FUEL
DELIVERYTESTS

3
.
Observe
fuel
pressure
gauge
after
20
minutes
.
The

pressure
shouldnot
drop
off
more
than
0
.5
bar
from

system
pressure
listed
in
Tablec
.

4
.
When
finished
testing,
disconnect
pressure
gauge
and
reconnect
fuel
line
.

If
the
fuel
system
does
not
maintain
pressure,
check
visual-
¡y
for
leaks
in
fuel
lines
orat
unions
.
Leaks
can
also
be
due
to
a
leaking
injector
or
a
faulty
fuel
pump
check
valve
.
Check
the

pump
check
valve
by
repeating
the
test,
butbefore
turning
the

fuel
pump
off,
pinch
off
theretum
line
at
the
fuel
rail
.
If
the

pressure
is
now
maintained,
the
fault
is
most
likely
the
fuel

pump
check
valva
.

Tabla
c
.
Fuel
Pressure
Specifications

Engine



1
Fuel
pressure

4-cytinder



1
3
.0
t
0
.2
bar
(43
.5
t
2
.9psi)

6-cytinder
M50/S50US
engine



3
.0
t
0
.2
bar
(43
.5
±2
.9psi)
M52/S52US
engine



3
.5
f
0
.2
bar
(51
t
2.9psi)

Fuel
pressure
regulator
response

to
engine
load,
testing

1
.
With
fuel
pressure
gauge
connected,
reinstallfuel

pump
relay
.
Start
engine
and
allow
it
to
idle
.

NOTE-

The
fuel
pressure
should
be
lower
by0
.4-0.7
bar
from
the
specifications
listed
in
Table
c
.
Engine
vacuum
act-
ing
on
the
fuel
pressure
regulator
diaphragm
reduces
the
fuel
pressure
.

2
.
With
engine
idling,
remove
vacuum
hose
from
regula-

tor
.
Pressure
should
increase
.

3
.
Reconnecthose
and
check
that
pressure
decreases
.

4
.
When
finished
testing,
disconnect
pressure
gauge
and

reconnect
fuelline
.
Tighten
hose
clamp
.



0013190

Fig
.
13
.
For
electrical
tests,
4-cytinder
fuel
injector
harnessduct
can
be

If
fuel
pressure
does
not
drop
with
the
vacuum
hose
con-



accessed
between
intake
manifold
and
cytinder
head
cover
.

nected
and
no
faulty
are
found
with
fuel
the
pressure
regulator

vacuum
hose,
the
fuel
pressure
regulator
is
faulty
.



1
.
Check
that
ECM
signal
is
present
atinjector
connector
.

NOTE-

A
cracked
or
leaktng
pressure-regulator
vacuum
hose

may
cause
en
erratic
tdle
.

FUEL
INJECTION



130-
11

Fuel
rail
and
injectors,
checking

The
fuel
injectors
are
switched
on
and
off
(opened
and
closed)
by
the
ECM
.
The
injectors
are
connected
to
a
com-
mon
fuel
supply,
callad
the
fuel
rail
.

The
fuel
injectors
are
removed
by
first
removing
the
com-
plete
fuel
rail
assembly
and
then
unclipping
the
injectors
from
the
fuel
rail
.

CA
UTION-

Use
only
a
digital
multimeter
or
an
LED
injector
tester
when
testing
injectors
or
wiring
.
Use
of
ananalog
VOM
or
incandescent
testlight
may
dam-
age
the
engine
control
module
.

NOTE-

"
On
4-cytindercars
pry
up
the
injector
wiring
duct
and
then
pry
off
the
cover
.
See
Fig
.
13
.

"
On
6-cytinder
cars
it
is
necessary
to
remove
the
top
engine
cover(s)
to
access
the
fuel
rail
and
injectors
.

"
Back
probe
injector
harness
connector
using
digital

voltmeter
.
See
Fig
.
14
.

"
Operate
starter
or
run
engine
and
check
for
pulsad

voltage
signal
.
"
Repeat
for
each
injector
.

NOTE
-

To
quick-check
if
en
injectorfunctioning,
place
a
screw-
driver
or
stethoscope
on
the
injector
with
the
engine

running
.
If
the
injector
is
operating,there
should
been

audible
buzz
.

FUEL
DELIVERYTESTS

130-
1
2



FUEL
INJECTION

Fig
.
14
.
Voitmeter
connected
across
fuel
injector
connector
with
en-
gine
running
.
M50
engine
shown
.

2
.
If
no
signal
is
present,
check
for
b+
power
to
injectors
.
There
should
be
battery
voltage
(+)
at
red/whitewire
of

each
injector
connector
with
the
ignition
key
on
.
If
volt-

age
is
not
present,
check
main
relay
output
.
Injector
b+

power
comes
from
main
relay
(terminal
87)
.

NOTE-

If
there
is
positive
(+)
batteryvoltage
at
injectors
but
there
was
no
pulsedresponse
at
voltmeter,
check
the
wire(s)
from
the
ECM
to
the
injectors
.
If
no
wiring
faults
can
be
found,
the
pulsed
ground
signal
from
the
control
module
may
be
missing
.
Check
the
outputs
from
the
ECM
.

Fuel
rail
and
injectors,
replacing

1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
tront
of
this
manual
on
page
viii
.

2
.
M42
and
M50/S50US
engines
:
Working
at
end
offuel
rail,
disconnect
small
vacuum
hose
from
fuel
pressure
regulator
.

3
.
M50/S50US
engines
:
Remove
two
nuts
from
injector

duct
.
Carefully
pry
injector
wiring
duct
off
ínjectors
.
See
Fig
.
15
.

4
.
On
4-cylinder
cars,
remove
upper
intake
manifold
to
ac-
cess
the
fuel-rail
and
injectors
.
See
113
Cylinder
Head
Removal
and
Installation
.

FUELDELIVERYTESTS

Fig
.
15
.
Injector
wiring
harness
duct
being
removed
from
M50
engine
.

NOTE
-

Late-model
M42
and
all
M44
fuel
injectors
are
afr-
shrouded
.
See
Fig
.
16
.
When
removing
the
fuel
rail
it
is
necessary
to
remove
the
air
shroud
feeder
hose
from
the
intake
manifold
ducting
.

Fig
.
16
.
Cutaway
view
of
fuelinjector
usedon
M42
or
M44
engine
.

5
.
Disconnect
fuel
supply
line
and
fuel
retum
line
from
fuel
rail
ends
.

WARNING
-

"
Clamp
off
the
fuel
lines
and
then
wrapa
clean
shop
towei
around
the
lines
before
removing
them
.
Residual
fuel
pressure
is
present
in
the
lines
.

"
Fuel
will
be
discharged
.
Do
not
disconnect
any
wires
that
could
cause
electrical
sparks
.
Do
not
smoke
or
worknear
heaters
or
other
fire
hazards
.
Keepan
approved
fire
extinguisher
handy
.

130-
1
4



FUEL
INJECTION

NOTE-

Be
sure
to
retrieve
thrust
washer
behind
fuel
pressure
regulator
on
6-cylinder
engine
.

4
.
Installation
is
reverse
of
removal
.
Replace
O-rings
.

Fuel
pressure
regulator,
replacing

(under
car
mount)

WARNING
-

Fuel
will
be
discharged
.
Do
not
disconnect
any
wires
that
could
cause
electrical
sparks
.
Do
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
Keep
an
approved
tire
extinguisher
handy
.

On
late
4-
and
6-cylinder
cars,
the
fuel
pressure
regulator
is

mounted
beneath
the
left
sideof
the
car,
under
a
protective

cover
.
See
Fig
.
20
.

0012726

Fig
.
20
.
Fuel
pressure
regulatorlocation
underneath
car
(arrow)
.
Vac-
uum
hose
to
regulator
is
shown
at
A
.
(Protective
cover
has
been
removed
.)

5
.
Installation
is
reverse
of
removal
.
Replace
O-rings
.

BOSCH
DME
Ml
.
7
COMPONENT
TESTS
AND
REPAIRS

BOSCH
DME
Ml
.7
COMPONENT

TESTS
AND
REPAIRS

CA
UTION-

Use
only
a
digital
multimeter
when
testing
compo-
nents
and
wiring
.
Use
of
an
analog
VOM
may
damage
the
engine
control
module
.

4-cylinder
cars
with
M42
engines(1992
to
1995)use
the

Bosch
DME
M1
.7
fuel
injection
system
.

Electrical
tests
of
the
main
and
fuel
pump
relays
and
the

DME
engine
control
module
(ECM)
are
covered
earlier
in
this

section
.
Fuel
pump
tests
arecovered
in
160
Fuel
Tank
and

Fuel
Pump
.

Air
flow
sensor,
testing
and
replacing

DME
M1
.7
fuel
injection
uses
a
volume
air
flow
type
sensor

with
integrated
intake
air
temperature
(IAT)
sensor
.
The
sen-

sor
provides
a
varyingvoltage
signal
to
the
ECM
based
on
the

position
of
the
air
vane
.
As
the
vane
doorswings
open
thepo-
tentiometer
increases
the
voltage
signal
to
the
ECM
.
The
IATsensor
adapts
theoutput
signal
to
the
ECM
based
on
intake

air
temperature
.

1
.
Check
ECM
reference
voltage
to
sensor
:

"
Peel
back
rubber
boot
from
air
flow
sensor
harness

connector
.

"
Turn
ignition
keyon
.
"
Check
for
5
volts
between
terminal
1
of
harness
con-
nector
and
ground
.
See
Fig
.
21
.

"
Turn
ignition
key
off
.

"
If
voltage
is
not
present
or
incorrect,
check
wring
from

ECM
and
check
air
flow
sensor
reference
voltage
out-

put
at
ECM
.
See
Table
h
.
1
.
Working
under
car
below
driver's
seat,
remove
protec-
tive
cover
from
below
fuel
pressure
regulator
.

"
Remove
intake
air
bootfrom
sensor
.
2
.
Remove
vacuum
hosefrom
fuel
pressure
regulator
.



"
Connect
a
digital
multimeter
(ohms)
across
terminais
1

and
2
.
Swing
air
flow
sensor
vane
through
its
travel
3
.
Remove
locking
clip
retaining
fuel
pressure
regulator
.



range
.
Resistance
should
change
steadily
without
in-

terruption
.
4
.
Wrap
a
shop
rag
around
regulator,
then
remove
regula-



"
If
any
faults
are
found,
the
air
flow
sensor
is
faulty
and
tor
from
213
way
valve
by
pullingstraight
out
.



should
be
replaced
.

2
.
Check
air
flow
sensor
potentiometer
:

3
.
Check
IAT
sensor
resistance
:

"
With
harness
connector
disconnected
at
air
flow
sen-
sor,
check
resistance
across
sensor
terminais
4
and
5

of
air
flow
sensor
.
Compare
tests
results
to
values
in
Table
d
given
later
.
If
any
faults
are
found,
the
air
flow
sensor
should
be
replaced
.

130-
1
6



FUEL
INJECTION

Throttie
position
sensor
(TPS),



Idie
speed
control
valve,
testing
and
replacing



testing
and
replacing

The
throttie
position
sensor
(TPS)
is
mounted
on
the
side
of



¡die
speed
is
maintained
by
the
ECM
via
the
¡die
speed
con-

the
throttie
housing
and
is
directly
connected
to
the
throttie



trol
valve
.
See
Fig
.
24
.
¡die
speed
is
adaptive
through
the
valve
shaft
.
The
ECM
sends
a
voltage
signal
to
the
potentiom-



ECM
and
no
¡die
speed
adjustments
can
be
made
.
Before
eter-type
sensor
and
monitors
the
voltage
that
comes
back
.



testing
the
valve,
confirm
that
the
throttie
position
sensor(TPS)
is
working
correctly
.

Check
TPS
function
by
disconnecting
the
harnessconnec-

tor
and
checking
reference
voltage
and
sensor
resistance
.

See
Table
e
and
Fig
.
23
.
If
voltage
is
not
present,
check
the

output
voltage
signal
from
the
ECM
and
check
the
wiring
be-
tween
the
sensor
and
the
ECM
.
If
the
sensor
resistance
is
in-
correct,
replace
the
throttie
position
sensor
.

NOTE
-

The
throttie
position
sensor
is
not
adjustable
.
If
test
re-
sults
are
íncorrect,
the
sensor
should
be
replaced
.

Table
e
.
Throttle
Position
Sensor
Tests

(DME
1
.7)

Testconditions



1
Terminais



1
Test
value

Harness
connec-



(
1
and
ground
in



15
VDC
(approx
.)
tor
disconnected,



harness
connector
ignition
on

0013235

Fig
.
23
.
Throttieposition
sensor
terminal
identification
on
M42
engine
.

Harnessconnec-



I
1
and
3
at
sensor



(
4k
ohms
(approx
.)
tor
disconnected,



terminais
ignition
off
Connector
dis-



1
and
2
at
sensor



Continuously
vari-
connected,
igni-



terminais



able
from
1-4
k
tion
off
.
Throttle



ohms
(approx
.)
with
rotated
from
¡die



out
interruption
to
fui]
position

BOSCH
DME
Ml
.
7
COMPONENT
TESTS
AND
REPAIRS

Fig
.
24
.
¡die
speed
control
valve
(arrow)
on
M42
engine
.

NOTE
-

"
The
tests
given
below
are
electrical
checks
only
.
They
do
not
check
the
mechanical
operation
of
the
valve
or
if
the
valve
is
sticking
or
worn
.
If
the
valve
is
suspect,
substituting
a
known
good
valve
is
the
best
way
to
check
for
amechanical
fault
.

1
.
Check
battery
(+)
voltage
to
valve
:

0013226

"
Disconnect
harness
connector
from
valve
.
"
Check
for
battery
voltage
at
terminal
2
(red/white
wire)
.
"
If
voltage
is
not
present
check
wiring
between
valve
and
main
relay
(terminal
87)
.

2
.
Check
that
ECM
signal
is
reaching
valve
:

"
With
engine
running,
check
that
¡die
speed
control
valve
is
audibly
buzzing
.
"
If
valve
is
not
working,
disconnect
wiring
harness
con-
nector
.

"
Connect
12V
probe
light
across
connector
terminais
.
"
Turn
ignition
key
on
;
probe
should
light
.
lf
probe
does
nof
light,
check
the
wiring
from
the
ECM
(pin
29)
to
the
valve
.
See
Table
h
.
lf
probe
does
light
but
¡die
quality
is
poor,
the
valve
is
most
likely
sticking
and
or
worn
and
should
be
replaced
.