Ignition coil BMW 525i 2001 E39 Service Manual

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Fuel Injection
Check resistance of valve across valve terminals
Idle speed control valve coil resistance
Terminals
1 and 2 20 i2.0.
Terminals 2 and 3 20 i2.0.
Terminals 1 and 3 40 i4.0.
CAUTIOIG
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
- To remove valve, remove cable bracket mounting bolt and
idle speed control valve mounting bracket bolts from front of
throttle housing and remove idle speed control valve with at-
tached bracket.
NOTE-
When installing idle speed control valve, remove intake boot
sealing ring from valve and install into intake air boot. Then
install valve info sealing
ring.
Evaporative emissions control diagrams
MS 42.0 (LDP) ,-a"-
Evaporative emissions control,
(MS 42.0, MS 43.0)
E39 models with MS 42.0 or MS 43.0 engine are equipped
with a fuel system evaporative pressure leak diagnosis sys-
tem. The main component of this system is the leak diagnosis
pump (LDP or DM-TL). The function of either system is to
pressurize the fuel tank and the evaporative emission system
for the purpose of detecting leaks.

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130-40
Fuel Injection
Engine control module (ECM),
removing and installing
The ECM uses stored functions and processing programs to
process the input signals from the sensors. These input sig-
nals are used to calculate the control (output) signals to the
actuators
(e.g., ignition coils, injectors).
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
- Disconnect negative (-) battery cable. Wait approximately
one minute.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions
in 001 General Warnings and Cautions.
4 Access engine control module (ECM):
Release
interlor ventilation filter cover latch (A) and re-
move cover.
Release plastic loclting tab
(B).
Rotate air duct inward (arrow) to unloclt from bulk head
and remove duct.
Release spring lock
(C) to remove lower filter housing.
Slide
f~lter hous~ng away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
- If testing ECM or connected components, use breakout box
to allow tests to be made with connector attached to ECM.
This prevents damage to small terminals in connector.
- - As an alternative, harness connector housing can be sepa-
rated so that electrical checks can be made from
back of con-
nector.
4 If replacing ECM, disconnect control module harness con-
nector (arrow) by releasing fastener and pivoting connector
up and off ECM.

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Fuel Injection
Table c. Siemens MS 42.0 and MS 43.0 ECM pin assignments (continued)
40
I I - . I -
9 llnput /signal, ignition coil 4 I Ignition coil 4
Not used
1
2
3
4
5
6
7
8
Connector X60005 9-pin
Input
Input
Input
Ground
Ground
Input
Input
Signal, ignition coil 3
Signal, ignition coil 2
Signal, ignition coil 1
Not used
Ground Ground
Signal, ignition coil
6
Signal, ignition coil 5
Ignition coil 3
Ignition coil 2
Ignition coil 1
Ground connector
Ground connector
Ignition coil
6
lqnition coil 5

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Fuel Injection
M5.2 system features
The Bosch M5.2 system used on 1997 540i models uses an
88-pin control unit. The
M5.2 system has the following func-
tions and capabilities:
Fully sequential cylinder-individual fuel injection.
Integrated adaptive knock control.
Oxygen sensor fuel mixture control.
0 Self-diagnosis and emergency operation characteristics.
CAN-Bus link.
0 OED II functions (misfire detection, catalytic converter
monitoring, oxygen sensor monitor, and fuel tank ventila-
tion system).
Electronic vehicle immobilization via EWS.
One-touch starter function.
Control of characteristic map thermostat.
M5.2.1 system features
The Bosch M5.2.1 system is used on 1998 540i models. The
M5.2.1 control module utilizes the SKE (standard shell con-
struction housing) with 5 connectors and a combined total of
134 pins.
The M5.2.1 systefn has
tile following functions or capabilities:
Separate power supply relay for ignition coils. Leak diagnosis pump (LDP) control and feedback
rnonitor-
ing for evaporative system leak testing.
Fuel evaporative system providing ORVR (on-board refuel-
ing vapor recovery) compliancy.
Batterylalternator charge logic (idle speed varied with the
battery state of charge).
CAN-Bus communications with the instrument cluster
EWS
Ill "rolling code" ISN interface.
More sensitive ignition
knock sensors.
Pulse width modulated (P-W-M) Heating and
AIC (IHKA)
status signal.
Running loss (312-way) solenoid valve.

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- Fuel Injection
ECM relay, testing
The engine control module (ECM) relay is energized via the
ECM and supplies battery positive
(B+) power to many of the
engine
management components and subsystems. If this re-
lay is faulty, the engine will not start.
CAUTIOI\C
Relay positions can vary. Be sure to confirm relay position by
identifying the wiring
in the socket using the wiring diagrams
in ELE Electrical Wiring Diagrams.
NOTE-
The ECM relay is also referred to as the DME main relay.
ECM relay powers:
* ECM
Ignition coils
Fuel injection
Evaporative leak detection pump
(5.2.1 only)
Idle air actuator
Camshaft sensors Evaporative emissions valve
Hot film mass air flow sensor
Fuel pump relay
Oxygen sensor heaters
4 Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate duct inward (arrow) to unloclc from bulk head and
remove duct.
0 Release spring lock (C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.

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.. .-
/Fuel lnjeciion
NOJE-
With engine oft disconnect harness connector and checlc
heating element resistance between white wires on the sen-
sor side of harness. If the element is electrically open (no
continuity), replace sensor.
- If oxygen sensor does not produce a fluctuating voltage and
preheater circuit is
OK, replace sensor.
NOJE-
If not already applied, coat oxygen sensor threads w~th anti-
seize compound before installat~on. Do not get the com-
pound on the sensor tip.
Tightening torque Oxygen sensor to exhaust system
55 Nm (41 ft-lb)
Fuel injectors, checking and replacing
The fuel iniectors are switched on and off (oaened and
closed)
by'the ECM. The injectors are connkcted to acom-
mon power source. A ground signal from the ECM is used to
open and close the injectors.
CA U JIOG
Use only a digital multimeter or an LED injector tester when
testing injectors or wiring. Use of an analog
VOM or incan-
descent test light may damaqe the engine controlmodule.
4 Remove fuel rail cover. See 110 Engine Removal and in-
stallation.
With the engine running, place the point of a long screwdriver
on each injector and check for a cliclting vibration.
If no vibra-
tion is found do the voltage
checit shown below.
Injector electrical loom removal:
- Loosen mounting nuts A.
Remove ground wire C.
Disconnect ignition coil harness D

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130-54
I Fuel Injection ldle speed control valve,
testing and replacing
ldle speed is maintained by the ECM through the idle speed
control valve. The idle control function compensates for en-
gine load and engine operating conditions. ldle speed is
adaptive through the ECM and no adjustments can be made.
Before checking valve, confirm that throttle position sensor is
working correctly.
NOTE-
The test given below is an electrical check only. It does not
check the mechanical operation of the valve. If the valve is
sticking, hanging up or is sluggish in operation, substituting a
Inown good valve is the best way to check it.
With engine running, check that idle speed control valve is
buzzing.
Turn on
AIC or shift car into drive. ldle should remain steady
or increase slightly.
If valve is not buzzing, or if idle decreases in step above, stop
engine and disconnect harness connector from valve.
4 Check resistance of valve across its terminals. Test values
are listed below.
ldle speed control valve coil resistance
Terminals
1 and 2 20 +2%
Terminals 2 and 3 20 +2Q
Terminals 1 and 3 40 +4%
NOTE-
If you suspect an intermittent fault, lightly tap the valve while
testing resistance.
With valve harness connector disconnected, check for bat-
tery voltage at redlwhite wire in connector with ignition on.
If . ~~ ~~
there is no voltage, check wiring between connector and 7 ECM relay. See ELE Electrical Wiring Diagrams.
NOTE- - The idle speed control valve receivespositive (+) battery volt-
age from the ECM (DME main) relay

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130-60
/Fuel lniection
Tabled. Bosch M5.2 ECM pin assignments
Note
Pin
21
20 I output / Crankshaft position sensor (speed and position) I Crankshaft positionlrpm sensor
23
I - I I 29 1 output I Idle speed control - opening winding I Idle speed control valve (cycled ground)
Type
22
1 output I Cvl. 6 ignition signal (primary signal) I Cyl. 6 ignition coil (RZV adapter)
output
25
26
27
28
Component/function
24 1 outout I Cvl. 7 iqnition siqnal (primary signal) I Cyl. 7 ignition coil (RZV adapter)
output
4 outbut I' I - I Cyl. 3
fuel injection valve I Cyl. 3 fuel injection valve (cycled ground)
Camshaft position
sensor (cylinder reference)
output input
output
oround
30
31
32
ground Hall effect camshaft position sensor
Cyl. 3 ignition signal (primary signal)
output
I
Cyl. 3 ignition coil (RZV adapter)
. - . .. . .
Cyl. 2 ignition signal (primary signal)
Terminal 30
Engine control module relay
Ground for electronics and sensor shield
output
output
outout
Remaining output stages ground
(not iclnition and fuel iniection valves) Cyl.
2 ignition coil (RZV adapter)
Fuse carrier, engine electronics
Engine control module relay
Ground splice ,
Cyl. 2 fuel injection valve
Oxygen sensor heater signal
Cyl. 5
fuel injection valve
Cvl. 8 fuel iniection valve
AIC comuressor relav sianal
Heated oxygen sensor I in front of catalytic converter,
Heated oxygen sensor
iI in front of catalytic converter
Cyl.
5 fuel injection valve (cycled ground)
Cvl. 8 fuel iniection valve (cycled ground)
. -
Not used Ground point
Cyl.
2 fuel injection valve (cycled ground)
Heatinq and AIC control module (ground - compressor OFF)
38 Not used
40 39
1 I Not used
I'
I . I
I' I -. I
46 1 ground I Heated oxygen sensor signal (voltage 0.1-1.0 V) I Oxygen sensors
41
1 inuut I Knock
sensor signal I Knock sensor
input
I
I I
Instrument cluster
I' I I 55 1 ground I Ignition ground I Ground point
Knock sensor signal
43
1 I Not used I
Fuel reserve signal
42
Throttle position sensor
47
48
49
50
51
52
53
54
Knoclc sensor
input
45
1 outout I Hot film mass air flow sensor signal (0-5 V) I Hot film mass air flow sensor
Throttle position sensor signal
(0.4-4.2 V) 44
input
output
output
output
output
output
inout
I - I
Not used
Not used
Cyl. 1 ignition signal (primary signal)
Cyl. 5 ignition signal (primary signal)
Cyl. 4 ignition signal (primary signal)
Cyl. 8 ignition signal (primary signal)
Throttle position sensor
(c 5 V voltage supply)
Terminal 87
f> 10 V)
ignition switch
56
Cyl. 1 ignition coil (RZV adapter)
Cyi. 5 ignition coil (RZV adapter)
Cyi.
4ignition coil (RZV adapter)
Cyl. 8 ignition coil (RZV adapter)
Throttle position sensor
Fuse
F1
input Terminal 15 (> 10 V)

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Fuel Injection
Table Pin
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
2
3
4
5
6
7
8
9
e. Bosch 5.2.1
Signal
Input
Input
Ground
Output Input- output
Output
Input- output
Input- output
Output
Connector
X60005
Output
Output
Output
Output
Ground
Output
Output
Output
Output
ECM pin assignments
Description
Not used
Not used
Voltage supply, terminal
15
Not used
Not used
Compressor ON signal from engine control module
(DME)
Ground
Not used
Diagnosis signal TXD
Communication
link (EWS)
Signal, leak diagnosis pump
Not used
CAN-Bus high
CAN-Bus low Not used
Not used
Start
signal
Terminal 1 signal
Terminal
1 signal
Terminal
1 signal
Terminal
1 signal
Ground
Terminal
1 signal
Terminal
1 signal
Terminal
1 signal
Terminal 1 signal Note
Fuse
F14
Heating
and AIC control module
Lealtage diagnosis pump
Data
iinit connector
Electronic immobilizer (EWS)
Leakage diagnosis pump (LDP)
CAN link
CAN link
Starter relay
Cylinder
7 ignition coil
Cylinder 8 ignition coil
Cylinder
2 ignition coil
Cylinder
3 ignition coil
Ground point
Cylinder
1 ignition coil
Cylinder
4 ignition coil
Cylinder 5 ignition coil
Cylinder
6 ignition coil

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130-72
Fuel Injection
I Oxygen sensors, replacing
4 Four Bosch oxygen sensors (2 precatalytic converter sen-
sors and
2 post-catalytic converter sensors) provide a vary-
ing voltage signal
[0.2 vdc (max. lean) to 0.8 vdc (max. rich)]
to the ME
7.2 ECM representing oxygen content in the ex-
haust gas.
WARNING-
Exhaust manifolds and pipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
- Using a special oxygen sensor socltet, remove the threaded
sensors from the exhaust system.
- If not already applied, coat the new oxygen sensor threads
with an anti-seize compound before installation. Do not get
compound on the sensor tip.
Tightening torque
Oxygen sensor to exhaust system
50 Nm (37 ft-lb)
Fuel injectors, removing and installing
The ME 7.2 system uses ball seat type fuel injectors. This de-
sign
prov:des precise seal'ng when the iniector is closed
therebv eiminalinq raw HC (unb~rned fue ) formalion in tne
intake.-~he fuel inkctors areswitched on and off by the ECM
at the ground side.
- Remove plastic cover from above fuel rail. See100 Engine
Removal and Installation.
- Disconnected battery negative (-) cable.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given at the front of this manual. See 001
General Warnings and Cautions.
- Remove both ignition coil covers.
Disconnect ignition coil connectors.
Remove left and right ignition coil ground wires,
4 Remove fuel injector loom boxes.
Loosen mounting fasteners
(A).
Disconnect electrical plugs (B and D).