ESP BMW 328i 1993 E36 Owner's Manual

al
Icld

Table
e
.
Engine
Driveability
Troubleshooting

c
l



1



I



f



I



I
Oxygen
sensor
faulty



Test
oxygen
sensor
.

ENGINE-GENERAL
100-
1
5

SYMPTOMS

a
.
Engine
fafs
tostart

b
.
Engine
startsbut
stops
immediately

c
.
Erratic
engine
idle

d
.
Poor
engine
responseon
acceleration

e
.
Erratic
engine
operation
in
al¡
speed
ranges

f
.
Excessive
fuel
consumption
g
.
Poor
enginepower,
fails
to
rev
up
h
.
CO
content
toolow

i.
CO
content
too
high

CAUSES



CORRECTIVE
ACTION

a



Fuel
pump
faulty



Test
fuel
pump
.
Repair
Group
160

a



e



Ignition
system
faulty



Test
ignition
system
.
Repair
Group
120
a



Main
relay
or
fuel
pump
relay
faulty



Test
main
relay
.
Repair
Group
130
a



Crankshaft/rpm
position
sensor
faulty



Test
crankshaft/rpm
sensor
.
120
b



c



h



i



ldle
speed
control
valve
faulty



Test
idle
speed
control
valve
.

c



d



e



Throttle
position
sensor
faulty
or
idle
signal
to



Test
throttle
position
sensor
.
DME
control
module
missing
.

c



d



h



i



Mass
air
flow
sensor
faulty



Test
mass
air
flow
sensor
Repair
Group
130
a



b



c



d



e



h



Large
air
intake
system
leak



Check
for
major
intake
air
leaks
downstream
of
mass
air
flow
sensor
.

a



c



d



e



g



h



Fuel
pressure
too
low



Test
fuel
pressure
.
Repair
Group
130

?



I



F
ue
l
pr
essu
r
e
t
oo
high



T
est
f
u
el
pressure
.
Repair
Group
130
d



e



g



h



Fuel
pump
delivery
volume
too
low



Test
fuel
pump
delivery
volume
.
Repair
Group
160
a



c



e



f



h
q
C
oo
l
a
nt
t
e
mp
e
r
a
t
u
r
e
se
n
so
r
f
au
lty



--]
T
est
coo
l
a
n
t
temp
erature
sensor
.

c



e



~



f



i



~
Fuel
injectors
leaking



Check
fuel
injectors
and
replace
leaking
injectors
.

~
Repair
Group
130

Throttle
plate
binding
or
incorrectly
adjusted



Check
throttle
plate
and
adjust
if
necessary
.

a



c



Electrical
connections
loose,
broken,
or
cor-



Visually
inspect
connectors
and
correct
any
roded



faults
.
Repair
Group
600
Ground
connections
loose,
broken,
or
corroded



Visually
inspect
ground
connections
and
correct
any
faults
.
Repair
Group
600

c



e
~



f



CO
content
too
high



Test
air
flowor
mass
air
flow
sensor
.
Repair

~
Group
130
a



b



c



d



e



CO
content
too
low



Test
mass
air
flow
sensor
.
gb



c



d



e



f



g



h



i



Inputsignals
to
ECM
missing,
ECM
in
limp



Make
electrical
tests
at
DMEECM
relay
.
Repair

home
mode



Group
130
a
~
b
~
c
~
d



e]



f



g



h



i



ECM
faulty



Test
DMEECM
inputs
.
If
all
inputs
are
correct,
replace
ECM
.

DRIVEABILITY
TROUBLESHOOTING

113-
1
8



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION

CYLINDER
HEAD,
6-CYLINDER

Fig
.
46
.
Primary
chaintensioner
being
installed
.
Piston
cutout
must
engage
chain
rail
.

22
.
Install
intake
cam
cover
and
then
install
cylinder
head

cover
.
Check
for
correct
seating
of
half-moons
in
back

of
cylinder
head
cover
.
Use
a
small
amount
of
3-Bond
O

1209
orequivalent
seaiant
at
corners
of
half-moon
cut-

outs
.

23
.
Install
front
exhaust
pipes
to
manifolds
using
new
gas-
kets
and
nuts
.
Coat
manifold
studs
with
copper
paste
prior
to
installing
nuts
.

24
.
Installationof
remaining
parts
is
reverse
of
removal
.

Refill
cooling
system
as
described
in
170
Radiator
and

Cooling
System
.
Change
engine
oil
and
filter
as
de

scribed
in
020
Maintenance
Program
.
Check
adjust-

ment
of
accelerator
cable
.
Additional
tightening
torques

are
given
below
.
Reconnect
battery
last
.

25
.
Installationof
remaining
parts
is
reverse
of
removal,

noting
the
following
:

"
Make
sure
all
sealing
surfaces
are
clean
and
free
of
old

gasket
material
.
Insta¡¡
new
intake
manifold
gasket
.

"
Reinstall
harness
connectors
for
oil
pressure
switch

and
coolant
temperature
sensor
before
installing
in-

take
manifold
.

"
Refill
cooling
systemas
described
in
170
Radiator

and
Cooling
System
.

"
Change
engine
oil
and
filter
as
described
in
020
Main-

tenance
Program
.

"
If
necessary,
adjust
accelerator
cable
.

"
Reconnect
battery
last
.

CAUTION-

To
prevent
damaging
engine
electronic
systems,
be
sure
to
install
all
ground
wirespreviously
re-
moved,
including
the
ground
wires
at
the
cylinder
head
for
the
ignition
coils
.

Tightening
Torque



Tightening
Torques

"
Cylinder
head
cover



"
Coglant
drain
plug
to
cylinder
block
.
.
25
Nm
(18
ft-Ib)

to
cylinder
head(M6
screws)
.
.
.....
10
Nm
(89
in-lb)



"
Intake
manifold
to
cylinder
head
.
...
.
15
Nm
(11
ft-Ib)

"
Radiator
cooling
fan
to
coolant
pump
.
40
Nm
(30
ft-Ib)

"
Radiator
drain
screw
to
radiator



.
..
2
.5
Nm
(22
in-lb)

116-
4



CYLINDER
HEAD
AND
VALVETRAIN

NOTE-

"
The
camshaft
bearing
caps
are
coded
with
a
letter
anda
number
.
Forexample,
'541"is
the
exhaustcam-
shaft
bearing
cap
at
the
front
of
the
engine,
and
`El"
is
the
intake
camshaft
bearing
cap
at
the
front
of
the
engine
.

"
Camshafts
are
stamped
with
a
code
letter-'E"
for
the
intakeside
and
A"
for
the
exhaust
side
.

"
"E"
isfor
Einla3,
(German
for
intake)
and
A"
is
for
Auspuff,
(Germen
for
exhaust)
.

"
The
front
of
the
engine
is
at
the
front
of
the
car
.

8
.
Camshaft
installation
is
reverse
of
removal,
noting
the

following
:

"
Prior
to
installation,
check
all
components
for
wear
as

described
below
underCylinder
Head
and
Val-

vetrain
Reconditioning
.
"
Lubricate
camshafts
prior
to
installation
.
"
Reinstall
timing
chain
sprockets
and
tensioner
and
set
valve
timing
before
reinstalling
rocker
arms,as
spe-

cifically
described
in
117
Camshaft
Timing
Chain
.

"
Be
sure
corresponding
camshaft
lobe
is
pointing
up

before
installing
rocker
arms
.
Note
that
each
rocker
arm
angles
away
from
corresponding
spark
plug
hole
.
See
Fig
.
4
.

"
Wait
at
least
10
minutes
for
hydraulic
cam
followers
to
fully
compress
before
cranking
engine
over
with
start-

er
for
the
first
time
.

Tightening
Torques

"
Camshaft
bearing
caps

to
cylinder
head
(M7)
.............
15
Nm
(11
ft-Ib)

"
Cylinder
head
cover

to
cylinder
head
(M6)
.............
10
Nm
(89
in-lb)

"
Primary
timing
chain
tensioner
plug

to
cylinder
head
.
................
40
Nm
(30
ft-lb)
(sea
117
Camshaft
Timing
Chain)

"
Spark
plugs
(M12)
.............
...
23
Nm
(17
ft-lb

Timing
chaincover
(upper)
to
cylinder
head
M6
.....
.
.
...
................
.
10
Nm
(7
.5
ft-Ib)
M7
....
..
.
.
........
.
.....
.
...
.
15
Nm
(11
ft-Ib)

"
Timing
chain
sprockets
to
camshaft

M6
....
.
.
..
..............
.
..
..
10
Nm
(7
.5
ft-Ib)
M7
....
....
..............
.
..
..
.15
Nm
(11
ft
.lb)
(sea
117
Camshaft
Timing
Chain)

Camshafts,
removing
and
installing

(6-cylinder
engine)

Camshafts
on
6-cylinder
engines
can
be
removed
with
the
cylinder
head
mounted
on
the
engine
.
The
first
step
is
to
re-
move
the
cylinder
head
cover
.
See
113
Cylinder
Head
Re-
moval
and
Installation
.

CYLINDER
HEAD,
DISASSEMBLYAND
ASSEMBLY

Fig
.
4
.



Correct
installation
position
ofrocker
arms
(arrows)
on
M44
engine
.

Special
BMW
service
tools
should
always
be
used
to
re-

move
and
instan
the
camshafts
.
Removal
of
camshafts
with-

outthe
special
tools
can
result
in
personal
injury
and/or
cylinder
head
damage
.

WARNING
-

The
processof
evenly
loosening
the
camshaft
bear-
ing
cap
nuts
is
NOT
en
acceptable
method
of
re-
moving
the
camshafts
.
Special
tools
shouldalways
be
used
lo
remove
the
camshafts
.
Be
sure
to
read
the
procedure
through
before
starting
ajob
.

1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpaga
viii
.

516
2
.
Setengine
to
TDC
and
lock
into
position
by
installing
BMW
special
tool
11
2
300
through
transmission
bell-
housing
and
into
hole
in
flywheel
or
drive
platea
See
Fig
.
5
.

NOTE-

Arrows
on
camshaft
sprockets
shouldbe
pointing
up
.
Sea
117
Camshaft
Timing
Chain
.

3
.
Remove
VANOS
control
unit
from
cylinder
head
.
Re-
move
timing
chainsprockets
from
camshafts
.
See117

Camshaft
Timing
Chain
.

4
.
Remove
sparkplugs
and
insta¡¡
BMW
special
tool
11
3
260/11
3
270
to
cylinder
head
.
Tighten
tool
retaining
bolts
in
spark
plug
holes
.
Do
not
ovar-tighten
bolts
.
See
Fig
.
6
.

CYLINDER
HEAD
AND
VALVETRAIN,

RECONDITIONING

Thís
section
provides
the
specifications
and
special
recon-
ditioning
information
necessary
to
repair
the
cylinder
heads

covered
by
this
manual
.

If
machine
shop
services
are
not
readily
available,
one
al-

ternative
is
to
install
a
remanufactured
cylinder
head
froman

authorized
BMW
dealer
.

Cylinder
head

NOTE-

When
replacing
the
cylinder
headon
engines
with
re-
movablecamshaft
carriers,
be
sure
to
check
the
cam-
shaft
carrier
bearing
surfaces
for
warpage
.

4-cylinder



1
140
.0
mm
(5
.512
in)



1
139
.55
mm
(5
.494
in)

6-cylinder



1



140
.0
mm
(5
.512
in)



1



139
.7
mm
(5
.500
in)

CYLINDER
HEAD
AND
VALVETRAIN



116-
7

A

The
disassembled
cylinder
head
should
be
inspected
for



Fig
.
9
.



Front
víew
of
cylinder
head
showing
minimum
resurfacing
di-

warpage
and
cracks
.
Check
the
valve
guides
and
valveseats



mension
(A)
.

for
wear
before
machining
a
warped
head
.
Always
decarbon-

ize
and
clean
the
head
before
inspectiog
it
.
A
high-quality



Camshaft

straíght
edge
can
be
used
to
check
for
warpage
.
Camshaft
wear
is
usually
caused
by
insufficient
lubrication
.

Visually
inspect
the
cylinder
head
for
cracks
.
If
acracked



Visually
inspect
the
camshaft
lobes
and
journals
for
wear
.

cylinder
head
is
suspected
and
no
cracks
are
detected



Camshaftwear
specifications
are
given
in
Table
b
.

through
the
visual
inspection,
have
the
head
further
tested
for

cracks
byan
authorized
BMW
dealer
.
A
cracked
cylinder
head



Table
b
.
Camshaft
Specifications

must
be
replaced
.



4-cylinder
engines

Axialplay
M42
engine



0
.065-0
.150
mm
(0
.0025-0
.0059
in)

M44
engine



0
.065-0
.150
mm
(0
.0025-0
.0059
in)

Radial
play(Plastigage)



0
.020-0.061
mm
(0
.0008-0
.0024
in)
M42
engine
M44
engine



0
.040-0
.082
mm
(0
.0016-0
.0032
in)

6-cylinder
engines
A
warped
cylinder
head
can
be
machined
provided
no



Axial
pla
y
more
than
0
.3
mm
(0
.012
in)
of
material
is
removed
.
If
further



All



0
.020-0.054
mm
(0
.0008-0
.0021
in)

machining
is
required,
the
head
should
be
replaced
.
Remov-



Radial
play(Plastigage)
0
.150-0.330
mm
(0
.006-0.013
in)
ing
more
than
this
amount
will
reduce
the
size
of
the
combus-



All

tion
chamber
and
adversely
affect
engine
performance
.
A
0
.3

mm
thicker
gasket
is
available
from
an
authorized
BMW
parts

department
for
machined
heads
.



NOTE-

-
On
M44
engines,
check
the
oil
sprayer
tube
in
the
top
Before
machining
the
head
to
correct
for
warpage,
measure



of
the
cylinder
head
coverand
the
tubesea¡
in
the
cyl-

the
total
height(thicknessof
the
cylinder
head)
.
See
Fig
.
9
.



inderhead
.Acloggedsprayertubeoradefectiveseal

Minimum
height
specifications
are
given
in
Table
a
.



will
reduce
oil
flowto
the
camshaft
.
See
Fig
.
10
.

-
If
the
camshaft
is
being
replaced
due
to
cam
lobe
Table
a
.
Cylinder
Head
Height



wear,
the
corresponding
rockerarms
orcam
followers

Engine



New



Minimum
height



shouId
also
be
replaced
to
avofd
damaglng
the
new

(dimension
A)



camshaft
.

CYLINDER
HEAD
AND
VALVETRAIN,
RECONDITIONING

116-
8



CYLINDER
HEAD
AND
VALVETRAIN

0012502

Fig
.
10
.
Location
of
camshaft
oil
sprayer
tube
sea¡
in
M44
cylinder
head
(arrow)
.

Hydraulic
valve
adjusters,

checking
and
replacing
(M44
engine)

The
M44
engine
uses
hydraulic
valveadjusters
(HVA)
to
keep
valve
clearances
within
a
limited
working
range
.
See
Fig
.
11
.
HVAs
are
sealed
units
and
require
no
maintenance
.

1
.
Camshafts
2
.
Rocker
arms
3
.
Hydraulic
valve
adjusters
(HVA)
4
.
Valve
and
conical
valve
spring

Fig
.
11
.
Cutaway
view
of
M44
cylinder
head
.

Under
some
circumstances,
such
as
a
cold
start,
thehy-
draulic
units
may
become
noisy
.
Hydraulic
valve
adjusternoise
is
usually
ahigh-pitched
tapping
or
chattering
noise
.
In
most
instances,
this
is
consídered
normal
aslong
as
the
noise
goes
away
in
a
few
minutes
(maximum20
minutes)
.
If
thenoise
does
not
go
away,
either
the
hydraulic
unit
is
faulty
orthe
oil
pressure
tothe
adjuster(s)
is
low
.

CYLINDER
HEAD
AND
VALVETRAIN,
RECONDITIONING

NOTE-

8efore
checking
valveadjusters,
make
sure
engine
oil
is
fresh
and
at
proper
level
.

1
.
Run
engine
until
it
reaches
normal
operating
tempera-

ture
.

2
.
Turn
engine
off
and
remove
top
engine
cover,
spark

plugs,
and
cylinder
head
cover
.
See
113
Cylinder
Head
Removal
and
Installation
.

3
.
Use
a
plastic
or
wooden
stick
to
press
down
on
top
of

rocker
armend
(side
away
from
camshaft)
.
If
any
play
can
be
detected,the
HVA
is
faulty
and
should
be
re-

placed
.

NOTE-

When
checking
the
HVA,
make
sure
the
camshaft
lobe
is
facing
upso
that
there
is
no
valve
spring
pressure
on
the
adjuster
.

4
.
To
remove
an
HVA,
turn
engine
over
until
camshaft
lobe

points
straight
up
.
Using
BMW
special
tool
no
.
11
5
130,
depress
valvespring
and
remove
rocker
arm
from
under
camshaft
.
See
Fig
.
12
.

Fig
.
12
.
BMW
special
tool
no
.
115
130
(arrow)
being
used
to
depress
valve
stem
to
remove
rocker
arm
.

WARNING
-

Removed
rocker
armsmustbe
reinstalled
in
the
same
locations
.

5
.
Pull
hydraulic
valve
adjuster
straight
out
of
cylinder

head
.
See
Fig
.
13
.

Fig
.
13
.
Remove
hydraulic
valve
adjuster
by
pulling
straight
out
ofcyl-
inder
head
(arrow)
.

6
.
Installation
is
reverse
of
removal
.
Be
sure
to
inspect

HVA
bore
in
the
cylinder
head
for
wear
or
scoring
.

Tightening
Torque

"
Cylinder
head
cover
to
cylinder
head/timing
chain
cover

M6
bolt
.........
..
..
...
........
10
Nm
(89
in-lb)

M7
bolt
.......
.
.
..
...
.
...
.
.....
15
Nm
(11
ft-Ib)

Hydraulic
cam
followers,

checking
and
replacing

(M42
and
al¡
6-cylinder
engines)

The
M42
engine
and
al¡
6-cylinder
engines
use
self-adjust-

ing
hydraulic
cam
followers
to
keep
the
valveclearances
with-

ina
limited
working
range
.
The
cam
followers
are
sealed
units

and
require
no
maintenance
.
See
Fig
.
14
.
.

Under
some
circumstances,
suchasa
cold
start,
the
cam

followers
may
become
noisy
.
Hydraulic
cam
follower
noise
is

usually
a
high-pitched
tapping
or
chattering
noise
.
In
most
in-

stances,
this
is
considered
normalas
long
as
the
noise
goes

away
in
a
fewminutes
(maximum
20
minutes)
.
lf
the
noise

does
not
go
away,
either
the
follower
is
faulty
or
the
oil
pres-

sure
to
the
follower
is
low
.
Hydraulic
cam
follower
replace-

ment
requires
that
the
camshaft
first
be
removed
.

NOTE-

Before
checking
valve
adjusters,
make
sure
engine
oil

ís
fresh
and
at
proper
level
.

CYLINDER
HEAD
AND
VALVETRAIN



116-
9

Fig
.
14
.
Section
view
of
camshaft
(A),
hydraulic
cam
follower
(B),
and
valvewith
conical
valvespring
(C)
usedon
M52
engine
.

1.
Run
engine
until
it
reachesnormal
operating
tempera-

ture
.

2
.
Turn
engine
off
and
remove
top
engine
covers,
ignition

coils,
and
cylinder
head
covers
.
See
113
Cylinder

Head
Removal
and
Installation
.

3
.
Use
a
plastic
or
wooden
stickto
press
down
on
top
of

cam
follower
.
See
Fig
.
15
.
If
there
is
any
noticeable

clearance,
the
follower
is
faulty
and
should
be
replaced
.

811107

Fig
.
15
.
Hydraulic
cam
follower
in
M52
enginebeing
checked
.
Note

that
camshaft
lobe
is
pointing
up
.

CYLINDER
HEAD
AND
VALVETRAIN,
RECONDITIONING

116-12



CYLINDER
HEADAND
VALVETRAIN

Valve
Seats



Valve
Springs

The
valve
seats
should
be
resurfaced
whenever
new
valves



The
valvesprings
should
be
checked
for
fatigue
.
To
quickly
or
valve
guides
are
installed
.
Cutters
are
required
to
resurface



check
the
springs,
line
them
up
in
a
row
.
Place
a
straight
edge
the
seats
.
Always
check
thevalves
for
leaks
after
recondition-



across
thetop
of
the
springs
.
Any
spring
that
is
significantly

ing
a
valve
seat
as
described
above
.
Table
e
lists
valve
seat



shorter
than
theothers
is
worn
and
should
be
replaced
.

dimensions
.

NOTE-
NOTE-



Valve
spring
specifications
and
wear
límits
arenot
Standard
size
replacement
valve
seats
are
not
avail-



available
from
BMW
.
ablefrom
BMW
.
Replacement
valve
seats
are
only
available
from
BMW
in
0
.4
mm
oversize
(oversized
in
both
height
and
diameter)
.
The
manufacturer
does
not
provide
specífications
for
valve
seat
replacement
for
the
enginescovered
by
this
manual
.

Table
e
.
Valve
Seat
Dimensions

"Y

Valve
seat
outside
dia
.
(B)

CYLINDER
HEAD
AND
VALVETRAIN,
RECONDITIONING

60
°
yl
1
B11110c

Specification



M42
engine



M42
engine



M44
engine



M50
engine



M501M52
engines



S50USIS52US
(1992)



(
(1993-1995)



I
(1996-1998)



(1992)



I
(1993-1998)



I
engines
(1995-
1998)

Valve
seat



45°



451



145°



145°



(
45°



145°
angle

Correction



1
15°



15°



115°



(
15°



15°



15
angle,
outside

Correction
60°



60°



I60°



60°



I60°



I60°
angle,
inside

Va
lve
seat
width
(A)
intake



1
1
.65
±0
.25
mm



1
1.65
±0
.25
mm



1
1
.65
t
0
.25
mm



1
1
.4
-1
.9
mm



1
1
.65
±0
.25
mm



1
1
.65
±
0
.25
mm
(0
.065
+0
.014
in)



I
(0.065
t
0
.014
in)



(0
.065
:E
0
.014
in)



(0
.055-0.075
in)



(0
.065
t
0
.014
in)



l(0
.065t0
.014
in)
____
___
exhaust



12
.0
±0
.25
mm



12
.0
t
0
.25
mm



1
1
.65
t
0
.25
mm



1
1
.4
-
1
.9
mm



11
.65
±
0
.25
mm



1
1
.65
:t
0
.25
mm
(0.079
±
0
.014
in)



1
(0
.079
t0
.014
in)



1
(0
.065
±
0
.014
in)



1
(0
.055-0.075
in)



1
(0
.065
t
0
.014
in)



1
(0.065
t0
.014
in)

intake



32
.4
mm
(1
.276
in)



32
.4
mm
(1
.276m)



32
.4
mm
(1
.276
in)



32
.4
mm
(1
.276
in)



32
.4
mm
(1
.276
in)



29
.4
mm
(1
.157
in)

exhaust



30
.1
mm
(1
.185
in)



30
.1
mm
(1
.185
in)



30
.1
mm
(1
.185
in)



30
.1
mm
(1
.185
in)



29
.4
mm
(1
.157
in)



26
.4
mm
(1
.039
in)

Fig
.
36
.
BMW
special
tool
no
.
11
2
300
installed
through
bellhousing
and
finto
flywheel
.

8
.
Remove
oil
line
fitting
from
VANOS
control
unit
.

NOTE-

Wrap
the
VANOS
oil
line
fitting
with
a
shop
to
absorb
leaking
oil
.

9
.
Using
hollow
bolt
and
seals
from
oil
supply
line,
instan

BMW
special
tool
no
.
11
3
450
(air
line
fitting)
and
con-
nect
a
supply
of
compressed
air
(30-115
psi)
to
VANOS

oil
fitting
.

10
.
Measure
and
record
distance
between
trigger
plate

edge
and
side
of
secondary
timing
chain
tensioner
.

See
Fig
.
37
.

Fig
.
37
.
VANOS
reference
measurement
(dimension
A)
between
trig-
ger
píate
(sender
gear)
and
side
of
secondary
chain
tensioner
.

CAMSHAFT
TIMING
CHAIN



117-
1
5

11
.
Disconnectharness
connector
from
VANOS
solenoid
.
Connect
BMW
special
tool
no
.
12
6
410
(electrical
test
lead)
to
VANOS
solenoid
connector
.

"
Connect
positive
(+)
test
lead
to
positive
(+)
terminal
ofbattery
Connect
negative
(-)
test
leadto
chassis
ground
.
solenoid
should
audibly
click
and
intake
cam-
shaft
should
advance
.

CA
UTION-

"
Be
sure
to
connect
the
test
hamess
polaritycor-
rectly
.
lf
the
polarity
is
reversed,
the
intemal
diode
in
the
VANOS
solenoid
will
be
destroyed
.
Although
the
solenoid
will
still
functionwith
a
faultydiode,
a
fault
code
may
be
set
in
the
ECM
memory
.

"
To
confirm
voltage
polarity,
turn
the
ignition
on
and
check
for
positive
(+)
batteryvoltage
at
the
terminal
corresponding
to
the
redlwhite
wire
in
the
main
harness
connector
.
Check
that
the
pos-
itive
terminal
(+)
in
the
main
connector
corre-
sponds
to
the
same
terminal
in
the
solenoid
connector
that
is
being
connected
to
the
battery
.

12
.
With
solenoid
actuated,
measure
and
record
new
dis-

tance
between
trigger
plate
edge
and
side'of
second-
ary
timing
chain
tensioner,
as
shown
in
Fig
.
37
.

13
.
Difference
between
first
measurement
(step
10)
andsecond
measurement
(step12)
should
be
at
least
8
.5
mm
(0
.3346
in
.)
.
lf
any
faults
arefound,
solenoid
may

be
faulty,
or
hydraulic
control
unit
may
be
faulty
or
incor-
rectly
installed
.

14
.
Check
VANOS
solenoid
byremoving
it
from
control
unit
.
Check
that
solenoid
plunger
and
control
unit

plunger
move
freely
.
Install
solenoid
using
tighteníng

torque
given
below
.

NOTE-

"
The
solenoid
is
available
asareplacement
part
.
lf
the
control
unit
plunger
is
sticking,
the
complete
control
unit
will
have
to
be
replaced
.

"lf
the
VANOS
system
does
not
advance
correctly
and
no
other
faults
can
be
found,
itis
possible
that
the
VANOS
control
unit
may
Nave
been
fnstalled
incor-
rectly-especially
if
the
camshaft
sprockets
have
pre-
víously
been
removed
for
other
repairs
.
Check
the
installation
by
removing
and
reinstalling
the
control
unit
as
described
later
.

VANOS
(VARIABLE
VALVE
TIMING)

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

130-2



FUEL
INJECTION

GENERAL

This
repair
group
covers
fuel
injection
system
component

testing
and
repair
.
Special
equipment
is
necessary
for
some

of
the
procedures
given
in
this
repair
group
.
If
you
do
not
have

the
equipment
required
to
do
the
job,
it
is
recommended
that

these
repairs
be
left
to
an
authorized
BMW
dealer
.
The
BMW

dealer
is
equipped
with
sophisticated
diagnostic
test
equip-

ment
that
is
capable
of
quicklypinpointing
hard-to-find
fuel
in-

jection
problems
.

NOTE-

"
Wiring
diagrams
for
the
engine
management
system,

can
be
found
at
the
rear
of
the
manual
under
Electri-
cal
Wiring
Diagrams
.

"
For
ignition
system
repairinformation,
see120
Igni-

tion
System
.

"
For
fuel
supply
system
testing
and
repair,
see160



The
engine
control
module
(ECM)
uses
electrical
signals

Fuel
Tank
and
Fuel
Pump
.



from
the
mass
air
flow
sensor,
the
air
and
coolant
temperature

sensors,
the
crankshaft
position/rpm
sensor,
the
knock
sen

Principies
Of
Operation



sors
and
the
oxygen
sensorsas
the
primary
inputs
to
electron-

ically
control
fuel
delivery
and
ignition
timing
.

There
are
five
versions
of
engine
management
systems

usedon
the
E36
cars
.
Each
has
the
same
basic
components

and
operating
principles
.
The
most
notable
difference
is
that

1996
and
later
cars
use
a
sophisticated
OBD
II-compliant
sys-

tem
.
See
Table
a
.

Table
a
.
Engine
Management
System
Variants

Engine
code/year



1
System

4-cy1inder
M42
(1
.8
I)
1992-1995



Bosch
DME
Ml
.7
M44
(1
.91)
1996-1998



~
Bosch
DME
M5
.2
(OBD
II)

6-cylinder
M50
1992
(2.5
I)



Bosch
DME
M3
.1
1993-1995
(2.5
I)



Bosch
DME
M3
.3.1
(VANOS)
M52
1996-1998
(3281-
2
.8
I)



Siemens
MS
41
.1
(OBD
II)
1998
(3231
-
2
.5
I)



Siemens
MS
41
.1
(OBD
II)
M-Power
S50US
(M3
-
3
.01)
1995



Bosch
DME
M3
.3
.1
S52US
(M3
-
3
.21)
1997-1998



Siemens
MS
41
.1
(0131)
11)

NOTE-

-
Descriptions
and
procedures
in
the
first
partof
this
re-

pairgroup
refer
to
all
the
various
engine
management
systems
.

"
Particulars
of
each
fuel
injection
system
are
treated
in
separate
sections
in
the
second
part
of
this
repair
group
.

GENERAL

Fig
.1
.



OBD
II
diagnostic
connector
locatíon
.

The
fuel
injection
system
is
completely
electronic
in
opera-

tion
.
Air
flow
is
measured
electronically
via
a
mass
air
flow

sensor
and
additional
sensors
supply
information
about
en-

gine
operating
conditions
.
The
ECM
calculates
the
amount
of
fuel
needed
for
the
correct
air-fuel
ratio
and
actuates
the
fuel

injectors
accordingly
.
The
amount
offuel
metered
to
theen-

gine
is
determined
by
how
long
the
injectors
are
open
.

Airintake
.
Air
entering
the
engine
passes
through
a
pleat-

ed
paper
air
filter
in
the
air
cleaner
.
Intake
air
volume
or
mass

is
then
measured
bya
mass
air
flow
(MAF)
sensor
.
In
al¡
ex-

cept
the
vane
type
sensor
(DME
M1
.7),
a
reference
current
is

used
to
heat
a
thin
wireor
film
in
the
sensor
when
the
engine

is
running
.
The
current
used
to
heat
the
wire/film
is
electroni-

cally
converted
into
a
voltage
measurement
corresponding
to

the
mass
of
the
intake
air
.

Table
b
.
Mass
Air
Flow
Sensor
Variants

System



Al
r
flow
sensor
type

Bosch
DME
M1
.7



Vane
(volume
sensor)

Bosch
DME
M3
.1



Hot
wire
(mass
sensor)

Bosch
DME
M3
.3
.1



Hot
film
(mass
sensor)

Bosch
DME
M5
.2



Hot
film
(mass
sensor)

Siemens
MS
41
.1



Hot
film
(mass
sensor)

"
The
16-pin
OBD
11
diagnostic
connector
is
located
on



NOTE-

the
lower
left
dashpanel
.
See
Fig
.
1
.



On
cars
equipped
wíth
tractioncontrol,
an
additional
throttle
valve
is
controlled
by
an
electronic
throttle
actu-
ator
(motor)
.
This
valve
is
used
for
engine
speed
inter
vention
.
Repair
information
forthis
system
is
notcovered
here
due
to
the
special
electrical
testing
equip-
ment
required
to
service
it
.