warning BMW M3 1992 E36 Repair Manual
Page 126 of 759
120-2
IGNITION
SYSTEM
Fig
.1
.
Ignition
characteristic
map
.
Disabling
Ignition
System
WARNING
-
The
ignition
system
is
a
high-energy
system
operat-
ing
in
a
dangerous
voltage
range
that
couldprove
to
be
fatal
if
exposed
terminals
or
live
parts
are
con-
tacted
.
Use
extreme
caution
when
working
on
a
car
with
the
ignition
on
or
the
engine
running
.
The
ignition
system
operates
in
a
lethal
voltage
range
and
should
therefore
be
disabied
any
time
senrice
or
repair
work
is
being
doneon
the
engine
that
requires
the
ignition
to
be
switched
on
.
The
engine
management
system
can
be
disabled
byremov-
ingthe
main
relay
.
The
relay
is
located
in
the
power
distribution
box
in
the
left
rear
of
the
engine
compartment
.
See
Fig
.
2
.
0013134
Fig
.
2
.
Maínsystem
relay
(arrow)
in
power
distribution
box
(left
rear
of
engine
compartment)
.
GENERAL
WARNING
-
"
Do
not
touch
or
disconnect
any
of
the
high
ten-
sion
cables
at
the
cotls
orspark
plugs
while
the
engine
ts
running
orbeingcranked
by
the
starter
.
Fatalvoltages
are
present
.
"
Before
operating
the
starter
without
starting
the
engine
(for
example
when
making
a
compression
test)
always
disable
the
ignition
.
CAUTION-
"
Prior
to
disconnecting
the
battery,
read
the
bat-tery
disconnection
cautions
gtven
at
the
front
of
thts
manual
on
page
viti
.
"
Do
not
attempt
to
disable
the
ignition
by
either
re-
moving
the
cotl
from
the
spark
plugs
(6-cylinder
engines)
or
disconnecting
the
coll
wires
from
the
plugs
(4-cylinder
engines)
.
"
Connect
or
disconnect
ignition
system
wires,
multiple
connectors,
and
ignition
test
equipment
leads
only
while
the
ignitionis
off
.
Switch
multtm-
eter
functions
or
measurement
ranges
onty
with
the
test
probes
disconnected
.
"
Do
not
disconnect
the
battery
while
the
engine
ts
running
.
"
Many
of
the
tests
of
ignition
system
components
require
the
use
of
high-impedance
test
equip-
ment
to
prevent
damage
to
the
electrical
compo-
nents
.
A
high
impedance
digital
multimeter
should
be
used
for
all
voltage
and
resistance
tests
.
AnLED
test
light
shouldbe
used
in
place
of
an
incandescent-type
test
lamp
.
"In
general,
make
test
connections
only
as
speci-fied
by
BMW,
as
described
inthis
manual,
or
as
described
by
the
instrumenta
manufacturer
.
Page 127 of 759
IGNITION
SYSTEM
DIAGNOSTICS
IGNITION
SYSTEM
SERVICE
Poor
driveability
may
have
a
variety
of
causes
.
The
fault
On
4-cylinder
engines,
an
ignition
coil
pack
is
mounted
to
may
lie
with
the
ignition
system,
the
fuel
system,
parts
of
the
the
passenger
side
strut
tower
in
the
engine
compartment
.
emission
control
system,
or
a
combination
of
the
three
.
Be-
The
coil
pack
integrates
4
individual
coils
.
cause
of
these
interrelated
functions
and
their
effects
oneach
other,
it
is
often
difficult
to
know
where
to
begin
looking
for
On
6-cylinder
engines,
an
ignition
coil
is
located
directly
problems
.
above
each
spark
plug
.
For
this
reason,
effective
troubleshooting
should
alwaysbe-
gin
with
an
interrogation
of
the
On-Board
Diagnostic
(OBD)
system
.
The
OBD
system
detects
certain
emissions-related
engine
management
malfunctions
.
When
faults
are
detected,
the
OBD
system
stores
a
Diagnostic
Trouble
Code
(DTC)
in
the
system
ECM
.
In
addition,
the
Check
Enginewarning
light
will
come
on
if
an
emissions-related
fault
is
detected
.
Two
generations
of
OBD
areusedon
the
cars
coveredby
this
manual
.
See
100
Engine-General
for
OBD
information
.
On-Board
Diagnostics
"
1992-1995
models
............
...
.
..
...
OBD
I
"
1996
and
later
models
.........
.......
..
OBD
II
NOTE-
"
On
carswith
OBD
ti,
specialized
OBD
11
scan
tool
equipment
mustbeused
to
access
DTCs,
either
using
the
BMW
special
tool
or
a
`generic"
OBD
11
scan
tool
.
"
The
OBD
11
fault
memory
(including
an
illuminated
Check
Engine
light)
can
only
be
reset
using
the
spe-
cial
scan
tool
.
Removing
the
connector
from
the
ECM
or
dísconnecting
the
battery
will
not
erase
the
fault
memory
.
Basic
Troubleshooting
Principies
An
engine
that
starts
and
runs
indicates
the
ignition
system
is
fundamentally
working-delivering
voltage
toat
least
some
of
the
sparkplugs
.
A
hard-starting
or
poor-running
engine,
however,
may
indicate
ignition
coil
problems,
cracked
or
dete-
riorated
spark
plug
wires
(4-cylinder
engines
only),
and
worn
or
fouled
spark
plugs
.
WARNING
-
Inefficient
combustion
(richair/fuel
mixture)
can
cause
the
catalytic
converter
to
overheat
and
plug
.
An
overheated
catalytic
converter
can
also
bea
tire
hazard
.
Checking
for
Spark
IGNITION
SYSTEM
120-
3
WARNING
-
If
a
spark
test
is
done
incorrectly,
damage
to
theen-
gine
control
module
(ECM)
or
the
ignitioncoil(s)
may
result
.
Checking
for
spark
is
difficult
onengines
with
distributorless
ignition
systems
.
Try
Rmovng
the
plugs
and
inspecting
for
differences
be-
tween
them
.
A
poor-firing
plug
may
be
wet
with
fuel
and/or
black
and
sooty,
butnot
always
.
If
a
coil
is
not
operating,
the
engine
management
system
will
electrically
disable
the
fuel
injectorto
that
cylinder
.
The
key
is
to
look
for
differences
be-
tween
cylinders
.
Ignition
coil,
testing
and
replacing
(4-cylinder
engine)
1.
Disconnect
mainharness
connector
from
coils
:
"
On
M42
engine,
remove
plastic
covering
from
coils
and
disconnect
individual
harness
connectors
.
"
On
M44
engine,
disconnect
main
harness
connectorat
end
of
coil
pack
.
See
Fig
.
3
.
Fig
.
3
.
Ignition
coil
pack
for
M44
engine
(arrow)
.
Coil
harness
con-
nector
shown
at1
.
IGNITION
SYSTEM
SERVICE
Page 132 of 759
120-8
IGNITION
SYSTEM
1
1
.0
GN
1
.0
Gl
.0
GN
I
Ign
coil
1
.0
GN
.
Tti
%ti
r,
_%ti
_
_
ice_
I
25
52
5524
51
54
56
I
Power
input
power
input
t
U
Engine
Control
Module
(Bosch
DME
Ml
.7)
II
Powerinput
Mainrelaycontrol
I
15
42
43
16442868
67
34
6
26
27
1
-----
__
V
_
--
_
~
8K
.35
BK
.35
13,1
1
.35
YE
1
.35
BK35
VE
.35
3
cyl
.1
1
11
E
S
2
1
.0
BR
2
.5
BR
Ign
.
coil
cyl
.
3
II
Ign
.
coil
Ign
.
coil
3
cyI
.
2
1
Y
_
Y
2
k
3
cyl
.
4
IGNITION
SYSTEM
SCHEMATICS
Battery
voltage
in
run
or
start
(
vía
ignition
switchterminal
15)
WIRING
COLOR
CODE
4
.0
GN
1
.0
BR'V
.
Camshaft
Knock
Sensor
Knock
Sensor
Position
(cyl
.1-2)
(cyl
.3-4)
Sensor
Fig
.
13
.
Bosch
DME
M1
.7
ignition
system
circuit
for
M42
engine
.
Ground
(RH
rearof
engine
compartment,
rear
of
shock
tower)
N[INS
Crankshaftlrpm
Position
Sensor
Battery
voltage
in
run
or
start
(vía
main
relay
terminal
87)
Ground
(RH
rearof
engine
compartment,
rearof
shock
tower)
5GN
BK
-
BLACK
BR
"
BROWN
RD
-
RED
YL-
YELLOW
GN
-
GREEN
BL
-
BLUE
VI
-
VIOLET
GY
-
GREY
WT
-
WHITE
PK
-
PINK
Warning
:
Lethal
voltagepresent
Battery
voltage
at
all
times
to
Main
relay
(terminal
85)
'Y
Y
---------------------
0013087
Page 136 of 759
120-12
IGNITION
SYSTEM
Warning
.
Lethal
voltagepresent
Battery
voltage
in
run
or
start
(via
ignitíon
switch
terminal
15)
I
t
IGNITION
SYSTEM
SCHEMATICS
Battery
voltage
in
run
or
start
(
via
ignition
switchterminal
15)
WIRING
COLOR
CODE
Knock
Sensor
Knock
Sensor
Crankshaftlrpm
Camshaft
(cyl
.
1-3)
(cyl
.
4-6)
Position
Sensor
Position
-
-
Sensor
-
Fig
.
17
.
Siemens
MS
41
.1
ignition
systemusedon1996
and
later
6-cylinder
engines
.
1.0
BR
PQ
1
.08~1
.0BKIRD
/1
.0BK/YL
'10BK/BL
'1
.03KIGN
10BKNI
4
1D
BK
-
BLACK
BR
-
BROWN
RD
-
RED
YL
-
YELLOW
GN
-
GREEN
BL
-
BLUE
VI-
VIOLET
GY
-
GREY
WT
-
WHITE
PK
-
PINK
Batteryvoltage
in
run
or
start
(via
main
relay
terminal
87)
!1
rl
1.0
B~
^
1.0
BK/RD
^
1.0
BKIYL
^
1
.0
BK/BL
n
1.0
BK/GN
n
1
.0
BKIVI
%~
r
-------
--------------_____________----_______-_-____
49
29
1
30
2
31
3
8754
1
power
input
Power
input
I
1
Engine
Control
Module
(Siemens
MS
41
.1)
1
1
grounds
1
n
1
Powerinput
Mainrelaycontrol
1
1-
57
___
58
_
59
_
__
63
_
38
83
48
40
64
43
65
41
28
32
34
4
26
73
1
-
-----------
-
_-----
-
------
_
------
-
------
-
---
-
.5Y1-
.5BKY.5GNY.5BRY
Y
.35BKY
1
Y
Y
.35BKY/Y35YY
75
.18R/
.5YL-1
1'
.
Batteryvoltage
at
all
times
to
Main
relay
(terminal
85)
Ground
v
(RH
rear
of
engine
Z
compartment,
rear
=
of
shock
tower)
Ground
(RH
rear
of
enginecompartment,
rearof
shock
tower)
0012731
Page 137 of 759
CHARGING
SYSTEM
TROUBLESHOOTING
.............
.
.
.
.
.121-2
Charging
System
Quick-Check
...
.
..
.
...
.
121-2
Static
current
draw,
checking
........
.
...
.
121-2
BATTERY
SERVICE
....................
121-3
Battery
Testing
.
.
.
.
.
.........
.
........
.
121-3
Hydrometer
Testing
.
...
.
.
.
...
.
.........
121-3
Battery
Open-Circuit
Voltage
Test
....
.
....
121-4
Battery
Load
Voltage
Test
.
.
.
.
.
.
.........
121-4
Battery
Charging
.
.
.
.
...
.
.
.
.
.
.
.
.........
121-4
ALTERNATOR
SERVICE
.
.
.
.
.
.
.....
.
...
121-4
Chargingsystem,checking
.
.
.
.
.
.........
121-4
Alternator,
removingand
installing
(4-cylinder
engine)
....
.
.
.
.
.
.
.
.........
121-5
Alternator,
removingand
installing
(6-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.........
121-6
GENERAL
The
charging
system
consists
of
a
belt-driven
alternator
with
integral
voltage
regulator
and
a
battery
mounted
in
the
luggage
compartment
.
Various
versions
of
alternators,
voltage
regulators,
starters,
and
batteries
are
used
in
the
E36
cars
.
It
is
important
to
re-
place
components
according
tothe
original
equipment
speci-
fication
.
Check
with
an
authorized
BMW
dealer
for
specific
application
and
parts
information
.
WARNING
-
"
Weargoggles,
rubbergloves,
and
a
rubberapron
when
working
around
batteries
and
battery
acid
(electrolyte)
.
"
Battery
acid
contains
sulfuric
acid
and
can
cause
skin
irritation
and
burning
.
ff
acid
is
spilled
onyour
skin
or
clothing,
flush
the
area
at
once
with
large
quantities
of
water
.
lf
electrolyte
gets
into
your
eyes,flush
them
with
largequantities
of
clean
wa-
terfor
several
minutes
and
call
a
physician
.
"
Batteries
that
are
being
charged
or
are
fully
charged
give
off
explosive
hydrogen
gas
.
Keep
sparks
and
open
flames
away
.
Do
not
smoke
.
BATTERY,
STARTER,
ALTERNATOR
121-1
121
Battery,
Starter,
Alternator
GENERAL
..
.
...
.
........
.
...
.
.
.
.
.
.
.
.
.
121-1
Voltage
regulator,
removing
and
ínstalling
.
.
.
121-6
Alternator
brushes,
inspecting
and
replacing
.121-7
STARTER
SERVICE
....
.
.
.
.
.
..........
.121-7
Starter
Troubleshootíng
121-7
15
..
.
.
.
.
.
........
.
.
.
Starter,
removing
and
installing
(4-cylinder
engine)
....
.
.
.
............
.
121-8
Starter,
removing
and
installing
(6-cylinder
engine
with
manual
transmission)
..
.
...........
.
...
121-8
Starter,
removing
and
installing
(6-cylinder
engine
with
automatic
transmission)
................
121-9
Solenoid
switch,
removingand
installing
....
121-10
TABLES
a
.
Battery,
Starter
and
Charging
System
Troubleshooting
............
.
.
.
.
:...
........
121-2
b
.
Specific
Gravity
of
Battery
Electrolyte
at
80°F
(27°C)
...............
.
.
..
..........
121-3
c
.
Open-Circuit
Voltage
and
Battery
Charge
........
121-4
d
.
Battery
Load
Test-Minimum
Voltage
.
..........
121-4
CAUTION
-
"
Prior
to
disconnectiog
the
battery,
read
the
bat-tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
"
Disconnecting
the
battery
cables
may
erase
fault
codes
stored
in
control
unit
memory
.
"
Always
disconnect
the
negative
()
battery
cable
first
and
reconnect
it
last
.
Cover
the
battery
post
with
an
insulating
material
whenever
the
cable
is
removed
.
"
After
reconnecting
the
battery,
the
power
window
motors
must
be
reinitialized
.
See
511
Door
Win-
dows
.
"
Never
reverse
the
battery
cables
.
Even
a
momen-
tary
wrong
connection
can
damage
the
alternatoror
other
electrical
components
.
"
Battery
cables
may
be
the
same
color
.
Label
ca-blebefore
removing
.
GENERAL
Page 140 of 759
121-
4
BATTERY,
STARTER,
ALTERNATOR
BatteryOpen-Circuit
Voltage
Test
Battery
Charging
Before
making
the
test,
load
the
battery
with
15
amperes
for
Discharged
batteries
can
be
recharged
using
a
battery
one
minute
with
a
batteryload-tester
or
turn
on
the
headlights
charger
.
The
battery
should
be
removed
from
the
luggage
for
about
one
minute
without
the
engine
running
.Then
discon-
compartment
during
charging
.
nect
the
battery
negative
(-)
cable
and
connect
a
digital
volt-
meter
acrossthe
battery
terminals
.
Open-circuit
voltage
Prolonged
charging
causes
electrolyte
evaporation
to
a
lev
levels
are
given
in
Table
c
.
el
that
can
damage
the
battery
.
Itis
bestto
use
a
low-current
charger
(6
amperes
or
less)
to
prevent
battery
damage
If
the
open-circuit
voltage
ís
OK
butthe
battery
still
lacks
caused
by
overheating
.
power
for
starting,
make
a
load
voltage
test
.
If
the
open-circuit
voltage
is
below
12
.4
volts,
recharge
the
battery
and
retest
.
WARNING
-
Hydrogen
gas
given
off
by
the
battery
duringcharg-
Table
c
.
Open-Circuit
Voltage
and
Battery
Charge
ing
is
explosive
.
Do
not
smoke
.
Keep
open
llames
away
from
the
top
of
the
battery,
and
prevent
elec
Open-circuit
voltage
State
of
charge
trical
sparks
by
turning
offthe
battery
charger
be-
12
.6
V
or
more
Fully
charged
fore
connecting
or
disconnecting
it
.
12
.4
V
1
75%
charged
12
.2
V
50%
charged
CAUTION-
12
.0
V
25%
charged
"
Battery
electrolyte
(sulfuric
acid)
can
damage
the
car
.
If
electrolyte
isspilled,
clean
the
area
11
.7
V
or
less
Fully
discharged
with
a
solution
of
baking
soda
and
water
.
Battery
Load
Voltage
Test
A
battery
load
tester
is
required
for
a
load
voltage
test
.
The
-
Always
disconnect
both
battery
cables
and
re-
test
is
made
by
applying
a
high
resistive
load
to
the
battery
ter-
move
battery
from
vehicle
during
battery
charg-
ing
.
Do
not
exceed
16
.5volts
at
the
battery
.
minals
and
then
measuring
battery
voltage
.
The
battery
should
be
fully
charged
for
the
most
accurate
results
.
The
battery
ca-
bles
mustbe
disconnected
before
making
the
test
.
If
the
volt-
ALTERNATOR
$ERVICE
age
is
below
that
listed
in
Table
d,
the
battery
should
be
replaced
.
WARNING
-
Always
wear
protective
goggles
and
clothing
when
performing
aload
test
.
Table
d
.
Battery
Load
Test-Minimum
Voltage
(apply
200
amp
load
for
15
seconds)
Ambient
temperature
Voltage
80°F
(27°C)
9
.6
V
60°F
(16°C)
9
.5
V
40°F
(4°C)
9
.3
V
20°F
(-7°C)
8
.9
V
0°F
(-18°C)
8
.5
V
ALTERNATOR
SERVICE
"
Always
allow
a
frozen
battery
to
thaw
before
at-
tempting
to
recharge
it
.
Before
checking
the
alternator
and
regulator,
make
sure
the
battery
is
fully
charged
and
capable
of
holding
acharge
.
Check
that
the
battery
terminals
are
clean
and
tight
and
the
al-
ternator
drive
belt
is
properly
tensioned
and
not
severely
worn
.
Charging
system,
checking
CAUTION-
Do
not
disconnect
the
battery
while
the
engine
is
running,
.
Damage
to
the
alternator
andlorengine
electronic
systems
may
result
.
1.
Turn
ignition
key
on
.
Check
that
the
chargewarning
lamp
comes
on
.
NOTE-
If
the
warning
light
does
not
come
on,
repair
any
wiring
or
bulb
faults
before
continuing
to
check
the
charging
system
.
Page 141 of 759
2
.
Remove
cooling
duct
or
terminal
cover
from
rear
of
al-
2
.
Remove
air
cleaner
upper
section
with
mass
air
flow
ternator
.
sensor
.
3
.
Check
for
battery
voltage
between
ground
and
terminal
3
.
Remove
terminal
cover
from
rear
of
alternator
.
Discon
B+
at
back
of
alternator
.
Then
turn
ignition
on
and
nect
wiring
.
check
for
battery
voltage
between
terminal
D+
and
ground
.
See
Fig
.
3
.
lf
voltage
is
not
present
at
either
4
.
Remove
drive
belt
from
alternator
pulley
.
See
020
point,
check
wiring
for
faults
.
Maintenance
program
.
001
¡987
Fig
.
3
.
Terminal
B+
is
supplied
battery
voltage
directly
from
the
bat-
tery
.
Terminal
D+
is
supplied
battery
voltage
via
the
charge
warning
bulb
when
thekey
is
on
or
the
engine
is
running
.
4
.
lf
no
faults
are
foundup
to
thispoint,test
alternator
out-
put
using
a
load
tester
.
5
.
If
a
load
tester
is
not
available,
a
crude
output
test
can
be
done
by
running
engine
at
about
2000
rpmand
turn-
ing
on
electrical
loads
(fans,
lights
and
rear
window
de-
froster,
wipers)
.
With
al¡
accessories
on,
battery
voltage
should
be
above
12
.0
VDC
.
A
replacement
alternator
should
have
the
same
rating
as
the
original
.
Alternator
manufacturer
and
ampere
rating
are
normally
marked
on
the
alternator
housing
.
1
.
Disconnect
negative
(-)
battery
cable
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.
BATTERY,
STARTER,
ALTERNATOR
121-
5
6
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-
ternator
.
See
Fig
.
4
.
NOTE
-
If
reusing
drive
belt,
mark
direction
of
rotation
on
belt
before
removing
.
5
.
On
M44
engine
with
hydraulic
belt
tensioner
:
Remove
tensioner
idler
pulley
(upper
roller)
from
alternator
bracket
.
Fig
.
4
.
Alternator
mounting
bolts
(arrows)
.
O
u
J
S
v~~
U
I
1
i
n
-12
.22
Alternator,
removing
and
installing
7
.
Installation
is
reverse
of
removal
.
Install
drive
belt
as
(4-cylinder
engine)
described
in
020
Maintenance
Program
.
Tightening
Torques
"
D+
vire
to
alternator
(M6
nut)
.
...
.
.
.
7
Nm
(53
in-lb)
"
B+
wire
to
alternator
(M8
nut)
..
.
.
.
.
.
13
Nm
(10
ft-Ib)
"
Pulley
to
alternator
(M16
nut)
...
..
..
60
Nm
(44
ft-Ib)
ALTERNATOR
SERVICE
Page 144 of 759
121-
8
BATTERY,
STARTER,
ALTERNATOR
1f
the
solenoid
audibly
cliicks
but
the
motor
does
not
turn,
Starter,
removing
and
installing
switch
on
the
lights
andtum
the
key
to
the
start
position
.
lf
the
(6-cylinder
engine
with
lights
go
out
while
attempting
to
start,
the
battery
cable
may
be
manual
transmission)
loose
or
the
starter
may
have
a
short
circuit
.
If
the
lights
stay
on,the
solenoid
is
most
likely
atfault
.
The
starter
on
a
6-cylinder
car
with
manual
transmission
is
Starter,
removing
and
installing
(4-cylinder
engine)
1
.
Disconnect
negative
(-)
battery
cable
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
2
.
Remove
guide
tube
for
oil
dipstick
.
3
.
Raise
vehicle
.
WARNING
-
Make
sure
the
car
ís
stable
and
wefl
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
forthe
purpose
.
A
floor
jack
is
not
adequate
support
.
4
.
Disconnect
wiring
from
starter
.
5
.
Remove
top
and
bottom
starter
bolts
.
Bottom
bolt
must
be
removed
from
below
car
.
Remove
starter
support
bracket,
if
applicable
.
removed
from
below
.
2
.
Raise
vehicle
.
3
.
Remove
reinforcing
cross
bracefromunder
transmís-
sion,
if
applicable
.
4
.
Remove
cover
from
fuel
filter
and
fuel
lines
on
left
side
underneath
car,
if
applicable
.
Detach
fuel
lines
and
har-
ness
connectors
from
retainingbrackets,
as
necessary
5
.
Disconnect
wiring
from
starter
.
6
.
Loosen
andremove
bolts
and
nuts
fastening
starter
to
transmission
bell
housing
and/or
engine
block
.
Remove
starter
supportbracket
.
7
.
Remove
starter
from
below
.
8
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.
9
.
Installation
is
reverse
of
removal
.
6
.
Pull
starter
downward
and
turn
until
solenoid
is
at
top,
Tightening
Torques
then
remove
from
car
.
"
Re¡
nforcing
cross
brace
to
chassis
(M10)
..
...............
42
Nm
(31
ft-Ib)
7
.
>Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)
age
.
"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)
"
Support
bracket
8
.
Installation
is
reverse
of
removal
.
to
engine
block
(M10
bolt)
.........
47
Nm
(35
ft-Ib)
"
Wire
to
terminal
50
(M6
nut)
.........
6
Nm
(53
ín-Ib)
"
Wire
to
terminal
30
(M8
nut)
.........
12
Nm
(9
ft-lb)
Tightening
Torques
"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-lb)
Wire
to
terminal
50
(M6
nut)
........
6
Nm
(53
in-lb)
"
Wire
toterminal
30
(M8
nut)
...
,
..:.
12
Nm
(9
ft-Ib)
STARTER
SERVICE
Page 147 of 759
GENERAL
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.........
130-2
Intake
air
temperature
(IAT)
sensor,
Principles
of
Operatinn
.
.
.
.
.
.
.
.
.
.........
130-2
testing
and
replacing
...
.
...
.
.
.
.......
.
130-19
Basic
Engine
Settings
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
:
.
130-3
Throttle
position
sensor
(TPS),
DISA
(Dual
Resonance
Intake
System)
.
.
.
.
.
130-3
testing
and
replacing
...
.
...
.
.
.
.
.
...
.
.
.130-19
On-Board
Diagnostics
(OBD)
Idle
speed
control
valve,
testing
.
.
.
.
.
.
.
.
.
.
130-20
and
Fault
Diagnosis
.
.
....
.
......
.
.
.
...
130-4
Idle
speed
control
valve,
replacing
.
.
.
.
.
.
..
130-21
SecondaryAir
Injection
.
.
.....
.
.........
.
130-5
BOSCH
DME
M5
.2
COMPONENT
Warnings
and
Cautions
.
.
...
.
.
.
.........
.
130-6
REPLACEMENT
.....
.
......
.
....
.
.
.
..
130-21
ELECTRICAL
CHECKSAND
Mass
air
flow
sensor,
replacing
.
.
....
.
....
130-22
COMPONENT
TESTING
.
.
.
.
.
.
.
.
...
.
.
.
.
.
130-7
Engine
coolant
temperature
(ECT)
Main
sensor,
replacing
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
130-22
rela
y
testing
130
-7
,...
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
Intake
air
temperature
(IAT)
sensor,
Fuel
pump
relay,
testing
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
130-7
rep
lacin
.
.
.
.
.
.
.
.
.
.
.g
.
.
.
.
.
.
.
...
.
.
.
..
.130-22
Oxygen
sensor,
testing
(Boschsystems
only)
130-8
Throttle
poson
sensor
(TPS)
replacing
13022
,
..
.-
FUEL
DELIVERY
TESTS
...
.
....
.
.
.
...
.
130-9
Idle
speed
control
valve,
replacing
...
.
....
.130-23
Operating
fuel
pump
for
tests
.
.
.......
.
...
130-9
SIEMENS
MS
41
.1
COMPONENT
Relieving
fuel
pressure
and
REPLACEMENT
.
...
.
.
.
.
.
.......
.
....
.130-23
connecting
fuel
pressure
gauge
......
.
..
130-10
Residual
fuel
pressure,
testing
.
.....
.
.
.
.
.
130-10
Mass
air
flow
sensor,
replacing
.
.......
.
.
.130-25
Fuel
pressure
regulator
response
Engine
coolant
temperature
(ECT)
to
engine
load,
testing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
130-11
sensor,
replacing
.....
.
.
.
.
.
.........
.130-25
Fuel
rail
and
injectors,
checking
...
.
.
.
.
.
.
.
130-11
Intake
air
temperature
(IAT)
sensor,
replacing
.
.
.
.
.
.....
.
.
.
.
.
.
.
.......
.
.
.130-25
Fuel
rail
and
injectors,
replacing
..
.
.
.
.
.
.
.
130-12
Throttleposition
sensor
(TPS),
replacing
.
.
.
130-26
Fuel
PressureRegulator
.........
.
.
.
.
.
.
.
130-13
Idle
s
eed
control
valve,
re
lacin
130-26
Fuel
pressure
regulatorreplacing
p
p
g
.'''...
.
'
,
(fuel
rail
mount)
...
.
.
.
.
.
.............
130-13
ECM
PIN
ASSIGNMENTS
.............
.
.
130-26
Fuel
pressure
regulator,
replacing
Engine
control
module
(ECM),
accessing
...
130-26
(undercar
mount)
.
.
.
.
.
.
.
.
.........
.
.
130-14
BOSCH
DME
M1
.7
COMPONENT
TESTS
AND
REPAIRS
.
.
.
.
.
...
.
.
.
.
.
.
.
.
130-14
Air
flow
sensor,
testing
and
replacing
.
.
.
.
.
.
130-14
Engine
coolant
temperature
(ECT)
sensor,
testing
and
replacing
...
.
.
.
.
.
.
.
.
130-15
Throttle
position
sensor
(TPS),
testing
and
replacing
.
..........
.
.....
130-16
Idle
speed
control
valve,
testing
and
replacing
.
.
.
.
.
............
130-16
BOSCH
DME
M3
.1
AND
M33
.1
COMPONENT
TESTS
AND
REPAIRS
.
.
.
130-17
Mass
Air
Flow
Sensor
.
.
.
.
.
.
.
.
.....
.
.
.
.
.130-17
Mass
air
flow
sensor
(hotwire),testing
and
replacing
.
.
.
.
.
.....
.
.
.
.
.
.
.
130-17
Mass
air
flow
sensor
(hot
film),
testíng
and
replacing
.
.
.
.....
.
.
.
.
.
.
.
.
.
130-18
Engine
coolant
temperature
(ECT)
sensor,
testing
and
replacing
..
.
.
.
.
.
...
.
130-18
130
Fuel
i
n
jection
FUEL
INJECTION
130-1
TABLES
a
.
Engine
Management
System
Variants
.........
.130-2
b
.
Mass
Air
Flow
Sensor
Variants
..
.
..
..........
.130-2
c
.
Fuel
Pressure
Specifications
..
.
.
...
..........
130-11
d
.
Engine
Coolant
Temperature
Sensor
or
Intake
Air
Temperature
Sensor
Test
Values
(DME
1
.7)
...
.
130-15
e
.
ThrottlePosition
Sensor
Tests
(DME
1
.7)
......
.130-16
f
.
Engine
Coolant
Temperature
Sensor
or
Intake
Air
Temperature
Sensor
Test
Values
(DME
3
.1/3
.3
.1)130-19
g
.
Throttle
Position
Sensor
Tests
(DME
3
.1/3.3
.1)
.
.130-20
h
.
ECM
Pin
Assignment-Bosch
DME
M1
.7
....
.
..
.130-28
i.
ECM
Pin
Assignment-Bosch
DME
M3
.1
.......
.130-30
j
.
ECM
Pin
Assignment-Bosch
DME
M3
.3
.1
.....
.130-32
k
.
ECM
Pin
Assignment-Bosch
DME
M5
.2
.......
.
130-34
I.
ECM
Pin
Assignment-Siemens
DME
MS
41
.1
..
.
130-36
Page 150 of 759
130-
4
FUEL
INJECTION
Main
Relay
Fig
.
2
.
DISA
system
components
.
DISA
is
controlled
via
theengine
control
module
(ECM)
.
Fig
.
3
.
DISA
manifold
runners
with
butterfly
valve
closed
for
lowrpm-
high
torque
operation
.
yje
q
GENERAL
high
power
operation
.
0012734
Fig
.
4
.
DISA
manifold
runners
with
butterfly
valve
open
for
high
rpm-
On-Board
Diagnostics
(OBD)
and
Fault
Diagnosis
Poor
driveability
may
have
a
variety
of
causes
.
The
fault
may
He
withthe
ignition
system,
the
fuel
system,
parts
ofthe
emission
control
system,
ora
combination
of
thethree
.
Be-
cause
of
these
interrelated
functions
and
their
effects
on
each
other,
it
is
often
difficult
to
know
where
to
begin
looking
for
problems
.
For
this
reason,
effective
troubleshooting
should
always
be-
gin
with
an
interrogation
of
the
On-Board
Diagnostic
(01313)
system
.
The
OBD
system
detects
certain
emissions-related
engine
management
malfunctions
.
When
faults
are
detected,the
OBD
system
storesa
Diagnostic
Trouble
Code
(DTC)
in
the
system
ECM
.
In
addition,
the
Check
Engine
warning
light
will
come
on
if
an
emissions-related
fault
is
detected
.
Two
generations
of
OBD
are
used
on
thecars
covered
by
this
manual
.
See
100
Engine-General
for
OBD
I
information
and
fault
codes
.
On-Board
Diagnostics
"
1992-1995models
....
.
...
...
.
...
......
OBD
I
"
1996-1998models
....
.
..
.
.
.
..
...
......
OBD
II