warning BMW 323i 1993 E36 Repair Manual

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
.

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

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

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

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

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
.

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

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

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

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