Starter BMW 328i 1997 E36 Owner's Manual

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-
6



BATTERY
STARTER,
ALTERNATOR

Alternator,
removing
and
installing

(6-cylinder
engine)

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
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Remove
alternator
cooling
duct
and
air
filter
housing

assembly
from
car
.
Disconnect
wiring
from
rear
of
alter-

nator
.

3
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

4
.
Remove
alternator
drive
belt
from
alternator
pulley
.
On

engines
with
hydraulic
belt
tensioner,
remove
tensioner

idler
pulley
(upper
roller)
from
alternator
bracket
.
See

Fig
.
5
.

ALTERNATOR
SERVICE

Fig
.
5
.



Pry
off
cover
from
tensioner
and
then
lever
tensioner
clock-
wise
to
release
belt
tension
.
Remove
upper
roller
(A)
once
belt
ís
removed
.

NOTE-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt

before
removing
.

5
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-

ternator
.

6
.
Installation
is
reverse
of
removal
.
Note
locating
notches
on
tensioner
idler
pulley
(upper
roller)
alternator
brack-

et
when
installing
pulley
.

Tightening
Torques

"
D+
wire
to
alternator
(M6
nut)
.......
7
Nm
(53
in-lb)

"
B+
wireto
alternator
(M8
nut)
.......
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
.......
60
Nm
(44
ft-Ib)

Voltage
regulator,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

NOTE-



2
.
Remove
alternator
as
described
earlier
.

The
radiator
cooling
fan
nut
(32
mm
wrench)has
left-
hand
threads
.



3
.
Remove
cooling
duct
from
rear
of
alternator
.
See
Fig
.
6
.

Alternator

.
.g-



p~
J

-..
.

Fig
.
6
.



Alternator
assemblyand
related
parts
.

Cooling
duct

0012524

4
.
Remove
voltage
regulator
mounting
screws
and
re-

move
regulator
from
alternator
.

5
.
Installation
is
reverse
of
removal
.
Clean
brush
contact

surfaces
in
alternator
and
check
brush
length
asde-

scribed
later
.

Alternator
brushes,



STARTER
SERVICE
inspecting
and
replacing

Regulator
brushesarenot
available
as
replacement
parts
from
BMW
.
Replacement
brushes
may
be
available
from
af-

termarket
sources,
however
.

1
.
Remove
voltage
regulator
as
described
above
.

2
.
Clean
brush
contact
sürfaces
and
measure
brush
pro-trusion
.
See
Fig
.
7
.

Check
for
battery
voltage
at
terminal
50
of
the
starter
motor
Fig
.
7
.



Regulator
brush
protrusion
(A)
.



with
the
key
in
the
start
position
.
See
Fig
.
8
.
If
voltage
is
not
present,
check
the
wiring
between
the
ignition
switch
and
the
starter
terminal
.
If
voltage
is
present
and
no
other
visible
wir
Voltage
Regulator



ing
faults
can
be
found,
the
problem
is
most
likely
interna¡in

"
Brush
protrusion
(minimum)
.......
.
..
5
mm
(
1
/4
in
.)



the
starter
motor
.

3
.
To
replace
brushes,
carefully
and
as
quickly
as
possi-

ble,
unsolder
brush
lead
from
brush
holder
termina¡,

withdrawing
brush
from
holder
at
same
time
.

4
.
Remove
any
traces
of
solder
frombrush
holder
termi-
nal
using
solder
wick
.

5
.
Fit
spring
into
brush
holder
and
inserí
new
brush
.

6
.
Guide
brush
lead
into
terminal
and
solder
into
place
.

Check
for
free
movement
of
brushes
when
solder

cools
.

7
.
Check
brush
slip
rings
in
alternator
for
wear
.
Lightly
clean
slip
rings
using
fine
abrasive
cloth
.

BATTERY,
STARTER,
ALTERNATOR



121-
7

Starter
Troubleshooting

If
the
starter
tucos
the
engine
slowlyor
fails
to
operate
when
the
ignition
isin
the
start
position,
check
the
battery
first
.
In-
spect
the
starter
wires,
terminals,
and
ground
connections
for
good
contact
.
In
particular,
make
sure
the
ground
connections
between
the
battery,
the
body
and
the
engine
are
completely
clean
and
tight
.
If
no
faults
can
be
found,
the
starter
may
be
faulty
and
should
be
replaced
.

NOTE
-

"
Starting
in1194,
a
factory-installed
drive-away
protec-
tion
system,
alsoreferred
to
as
EWS
or
EWS
11,
was
used
on
all
E36
cars
.
This
system
prevenís
operation
of
the
starter
when
the
system
is
engaged
.
See
515
Central
Locking
and
Anti-theft
.

"
On
cars
with
automatic
transmission,
a
starter
relay
and
a
neutral
safetyswitchare
used
to
present
theen-
ginefrom
starting
in
gear
positions
other
than
park
or
neutral
.
ff
voltage
is
not
present
atterminal
50
with
the
key
in
the
startposition,
check
these
components

To
make
the
most
accurate
check
of
the
battery
cables
and
starterwiring,
make
a
voltage
drop
test
on
the
cables
and
wir-

ing
as
described
in
600
Electrical
System-General
.

Terminal
30
'
\



/
Terminal
30h

0012518

8
.
Reinstall
regulator
and
alternator
.



Fig
.
8
.



Typical
starterwiring
terminal
identification
.
Large
wireat
ter-
minal
30
is
direct
battery
voltage
.
Smaller
wire
at
terminal
50
operates
starter
solenoid
via
ignition
switch
.

STARTER
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

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

121-1
O



BATTERY,
STARTER,
ALTERNATOR

9
.
Remove
starter
from
above
.

10
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.

11
.
Installation
is
reverse
of
removal
.

Tightening
Torques

"
tntakemanifold
to
cylinder
head

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

M8
nut/bolt
.............
.
.
..
...
22
Nm
(16
ft-Ib)

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

to
engine
block
(M10
bolt)
.
.
..
..
...
47
Nm
(35
ft-Ib)

"
Wire
toterminal
50
(M6
nut)
.
..
.....
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
.....
12
Nm
(9
ft-Ib)

Solenoid
switch,
removing
and
installing

1
.
Remove
starter
as
described
above
.
Tightening
Torque

2
.
Remove
cover
from
solenoid
switch
.



"
Field
winding
strap
to
starter
(M8)
...
.
12
Nm
(9
ft-Ib)

3
.
Disconnect
fieid
winding
strap
between
starter
motor

and
solenoid
switch
.

NOTE-

The
condition
of
the
field
winding
strap
is
critical
.
If
it
is
damaged,
bumed
or
partially
melted
through,
a
new
or

rebuilt
starter
motor
is
needed
.

4
.
Remove
solenoidswitch
mounting
screws,
and
sepa-

,
rate
solenoid
from
starter
.
See
Fig
.
12
.

CAUTION-

When
installing
fieid
winding
strap
to
starter,
posi-

tion
it
so
that
it
does
not
contact
the
starter
body
.

STARTER
SERVICE

131~184

Fig
.
12
.
Starter
solenoid
mounting
screws
(arrows)
are
tight
.
Use
en
impact
screwdriver
to
loosen
the
screws
.

5
.
Installation
is
reverse
of
removal
.
Lubricate
solenoid
pistos
with
light
grease
.

130-
6



FUEL
INJECTION

Warnings
and
Cautions

For
personal
safety,
as
well
as
the
protection
of
sensitive

electronic
components,
the
following
warnings
and
cautions

should
be
adhered
to
when
working
on
the
engine
manage-

ment
system
.

GENERAL
WARNING
-

"
The
ignition
system
produces
high
voltages
that

can
be
fatal
.
Avoid
contact
with
exposed
termi-

nals
.
Use
extreme
caution
when
working
onacar
with
the
ignition
switched
on
or
the
engine
run-
ning
.

"
Do
not
touch
or
disconnect
any
high
voltage
ca-

bles
from
the
coils
or
spark
plugs
while
the
engine

is
running
or
beingcranked
by
the
starter
.

"
Connect
and
disconnect
the
DME
system
wiring
and
test
equipment
leads
only
when
the
ignition
is
switched
off
.

"
Gasoline
is
highly
flammable
and
fts
vaporsare

explosive
.
Do
not
smoke
or
work
on
a
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repalring
fuel
system
problems
.
Have
a
tire
extinguisher
avaílable
in
case
of
an
emergency
.

"
When
working
onan
open
fuel
system,
wear
suit-
able
hand
protection,
asprolonged
contact
wfth
fuel
can
cause
illnesses
and
skin
disorders
.

"
Renew
fuel
system
hoses,
clamps
and
O-rings
any
timethey
are
removed
.

"
Before
makingany
electrical
tests
that
require
the
engine
to
be
cranked
using
the
starter,
disable
the
ignition
system
as
described
in
120
Ignition
System
.

CAUTION-

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnectinn
cautions
given
at
the
front
of
this
manual
onpage
vifi
.

"
Do
not
connect
any
test
equipment
that
delivers

a
12-volt
power
supply
to
terminal
15
(+)
of
the
ig-

nitioncoil
.
The
current
flow
may
damage
the

ECM
.
In
general,
connect
test
equipment
only
as

speclfied
by
BMW,
this
manual,
or
the
equipment

maker
.

"
Only
use
a
digital
multlmeter
for
electrical
test
.

"
Only
use
an
LED
test
light
for
quick
tests
.

"
Disconnecting
the
battery
may
erase
fault

code(s)
stored
in
memory
.
Check
for
fault
codes

prior
to
disconnecting
the
battery
cables
.
ff
the

Check
Engine
light
ís
illuminated,
see100En-
gine-General
for
DME
fault
code
information
.
ff
any
other
system
faults
have
been
detected
(indi-
catedbyan
illuminated
warning
light),
see
an
au-
thorized
BMW
dealer
.
Additional
systems
with
self-diagnostic
capabilities
include,
ABS
(Anti-
lock
brakes),
SRS
(Airbags),
EML
and
ASC+T
and
AST
(Traction
Control)
.

"
Do
not
run
the
engine
wfth
any
of
the
spark
plug
wires
dlsconnected
.
Catalytic
converter
damage
may
result
.

"
Always
waitat
least
40
seconds
afterturning
off
the
ignition
before
removing
the
engine
control
module
(ECM)
connector
.
ff
the
connector
isre-
moved
before
this
time,
residual
power
in
the
sys-
tem
relay
may
damage
the
control
module
.

"
Cleanliness
is
essential
when
working
onan
open
fuel
system
.
Thoroughly
clean
fuel
line
con-
nections
and
surroundlng
areas
before
loosen-
ing
.
Avoid
moving
the
car
.
Only
fnstall
cleanparts
.

"
Fuel
system
cleaners
and
other
chemical
addi-
tives
other
than
those
specifically
recommended
by
BMW
may
damage
the
catalytic
converter,
the
oxygensensor
or
other
fuel
supply
components
.

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

Table
j.
ECM
Pin
Assignment-Bosch
DME
M3
.3
.1

Pin



~
Signal



1
Componentffunction



1
signal

FUEL
INJECTION



130-
33

45



ground



Ignition
circuit
shield



Ground
shieldfor
ignition
circuit
monitoring

46



output



Fuel
consumption
(KVA
signal)



To
instrument
cluster

47



output



Crankshaft
rpm



Engine
speed
(TD)
signal
to
instrument
cluster

48



output



A/C
compressor
control



A/C
compressor
relay
terminal
85
49
vacant
-



-

50



output



Ignition
coil
control,
cyl
.
1



Primary
signal,
ignition
coil
1

51



output



Ignition
coil
control,
cyl
.
2



Primary
signal,
ignition
coil
2

52



output



Ignition
coil
control,
cyl
.
3



Primary
signal,
ignition
coil
3

53
vacant
-



-

54



input



Power
supply



Battery
voltagefrom
main
relay
(terminal
87a)

55



ground



Ground



Ground
for
ignition
control

56



input



Power
supply
(terminal15)



Batteryvoltage
with
key
on
or
engine
running

57



input



Ignition
timing
intervention



From
A/T
control
module
58
vacant
-



-

59



output



Throttleposition
sensor
(TPS)



Voltage
supply
to
TPS
(5
VDC)

60



input



Programming
voltage



Data
link
connector

61
vacant
-



-

62
vacant
-



-

63
vacant
-



-

64



input



A/C
on
signal



From
integrated
climate
control
module
65



input



A/C
pressure
signal



From
integrated
climate
control
module
via
A/C
pressure
switch

66



input



On-board
computer



Drive-away
protection
enable
(starter
immobilization
relay)

67
vacant
-



-

68
vacant
-



-

69



input



Knock
sensor
#2
(cyl
.
4,5,
6)



Knock
sensor
#2
signal

70



input



Knock
sensor
#1
(cyl
.
1,2,
3)



Knock
sensor
#1
signal

71



ground



Ground



Ground
for
knock
sensors
and
shields

72
vacant
-



-

73



input



Throttleposition
sensor
(TPS)



Throttleposition
signal

74
vacant
-

75
vacant
-



-

76
vacant
-

77



input



Intakeair
temperatura



Intakeair
temperatura
sensor
(0-5
VDC)

78



input



Engine
coolant
temperature



Engine
coolant
temperature
sensor
(0-5
VDC)

79
vacant
-

80
vacant
-



-

81



input



Automatic
transmission
gear
positionlneutral



A/T
parkor
neutral
position
signal
safetyswitch

82
vacant
-



-

83
vacant
-



-

84
vacant
-



-

85
vacant
-



-

86
vacant
-



-

87



input



Diagnostic
connector
(RxD)



Diagnostic
RxD
(receive)
signal
to
pin
15
in
Data
link
connector

88



input/output



Diagnostic
connector
(TxD)



Diagnostic
TxD
(transmit)
signal
to
pin
20
in
Data
link
connector

ECM
PIN
ASSIGNMENTS