Car engin BMW 528i 1997 E39 Workshop Manual

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Fuel Injection 1
Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(6).
Rotate duct inward (arrow) to unlock from bulk head and
remove duct.
Release spring
lock (C) to remove lower iilter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
NOTE-
OBD I1 fault memory (including an illuminated MIL) can
only be reset using an electronic scan tool. Removing the
connector from the ECM or disconnecting the battery will
not erase the fault
memory.
The BMW-dedicated 20-pin diagnostic linlc connector
(DLC) is in the right rear of the engine compartment.
The 16-pin OBD
I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
ECM relay, testing
Fuses lor ECM In E-bbx 502130488
4 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.
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.

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130-8
Fuel Injection
With ignition off, remove main relay (K6300) (arrow) in
E-box.
- With ignition on and relay installed, check for battery voltage
on terminal
2 (87).
4 Check for voltage at terminal 8 (30) on relay socket.
If battery voltage is present, relay has energized and is
functioning correctly.
Gmund from 6L (hot ~4th k~y key in Ern
2I '1
on position)
to
Fuel pump RdiWt Rd from Battery and other system components SOZI~O~~I~Y
If battery voltage is not present and all earlier tests are OK,
relay is faulty and should be replaced.
If
battery voltage is present continue testing.
If battery voltage is not present, check fuse 109 (80-amp
fusible link) under passenger seat carpet. See ELE Elec-
trical Wiring Diagrams.
- Reinstall relay and turn ignition on. Gain access to back side
of relay socket and check for ground on terminal
4 (85).
If ground is present continue testing.
If ground is not present, signal from ECM is missing. Check
NOTE-
If no faults are found during testing but power is not reaching
the
ECM or other components, check the fuses in the fuse
carrier
X8680 in the E-box.
wire
between ECM and relay.

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Fuel Injection
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
Remove engine coolant temperature sensor:
Unclip crankcase vent hose
(C) from cylinder head cover.
Remove plastic cover
(6) from atop intake manifold run-
ners.
Working under front of intake manifold, disconnect ECT
harness.
Unscrew ECT sensor
(C) from cylinder head.
Installation is reverse of removal:
Use new copper sealing washers when installing sensor.
Replace any engine coolant lost.
Tightening torque
Temperature sensor to cylinder head
13 Nm (10 it-lb)
Intake air temperature ([AT) sensor,
testing and replacing
4 The intake air temperature (IAT) sensor (arrow) signal is
used by the ECM to monitor intake air temperature for fuel
and
igntion adaptation. The sensor is .ocared in rne 'ntane
man:lold behind the throttle housng.
The ECM monitors an applied voltage (5 vdc) to the sensor
The voltage drop across the sensor varies as the intake air
temperature (sensor resistance) changes.
NOJE-
The IATsensor is an NTC (negative temperature coefficient)
type sensor. In other words, as the temperature rises, resis-
tance through the sensor decreases.
If the IAT sensor input is implausible, a
fault code is set.The
MIL is illuminated when OED II fault criteria are exceeded.
The ECM then operates the engine using only the engine
coolant temperature (ECT) sensor input.
The intake air temperature sensor can be tested using a
mul-
timeter across its terminals:
/ IAT sensor resistance @ 20" C (68°F) / 2.2 - 2.7 lkCk
~ -- ~~ -
CAUTION--
Be sure ignition is
OFFbefore disconnecting or reconnecting
DME system components.

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I Fuel Injection
Release injector locking clips at each injector and pry injector
wiring duct up off injectors.
Clamp off fuel supply line and fuel return line at end of fuel
rail. Disconnect fuel supply fuel return lines from fuel rail.
WARNING -
Clamp off the fuel lines and then wrap a clean shop towel
around the lines before removing them. Residual
fuelpres-
sure is present in the lines.
Fuel is discharged. Do not disconnect any wires that
could cause electrical
sparks. Do not smoke or work
near heaters or other fire hazards. Keep an approved
I fire extinguisher handy. I
- Remove fuel rail mounting fasteners
- Pull up on fuel rail and remove individual injectors by remov-
ing injector retaining clip and pulling injector from rail.
- Installation is reverse of removal. Fit new O-rings when in-
stalling injectors. For ease of installation, lightly lubricate in-
jector O-ring with
SAE9O gear lube.
Tightening torque Fuel rail to
intake manifold 10 Nm (89 in-lb)
Evaporative emissions, overview
On E39 MS 41 .I cars, the evaporative emissions system is
combined with the tank ventilation system. The evaporative
system is monitored by the ECM for correct purge operation
and leak detection.
The carbon (purge) canister is purged using engine vacuum
via the
purgevalve.The purgevalve (located nextto the mass
airflow sensor) is ECM controlled and regulates the purge
flow into the intake manifold. The valve is powered open and
closed by an internal spring.
If the evaporative emission valve circuit is faulty, a fault code
is set and the MIL is illuminated when OBD
II fault criteria are
exceeded. If the valve is mechanically faulty, poor driveability
may result and a mixture adaptation fault is stored in the
ECM.
The leak diagnosis pump (LDP) is activated by the ECM and
pressurizes the fuel tank and evaporative system as apart of
theOED I1 leakdetection monitor. If the LDP orthe LDP circuit
is defective, afault code is set and the MIL is illuminated when
OBD
I1 fault criteria are exceeded. The LDP is mounted the
left rear wheel well behind the fender liner.

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I Fuel Injection
Table b. Siemens MS 41.1 ECM pin assignments (continued)
Pin
l~iqnal I Componentlfunction 1 Notes I - I I
5 loutput I Fuel injector control, cyl. 2 I Pulsed ground (pulse width in ms), cyl. 2 I I I
6 loutput /Fuel injector control, cyi. 1 I Pulsed ground (pulse width in ms), cyl. 1
I I I
14 linput I Intake air temp. sensor (IAT) I Intake air temperature signal
- 7
8
9
10
11
12
13
ground
input
output
input
input
15
16
17 18
19
20
21
22
I - I I
35 loutput /Secondary air injection ISecondary air inj. pump relay control
25
26
27
28
29
30
31
32
33
36
/output I Engine speed output IEngine speed signal
Mass air flow sensor
Mass air flow sensor
instrument cluster
Engine coolant
temp.
(ECT) sensor
Not used
Throttle position sensor (TPS)
Not used
input
input
input
input
output
output
out~ut
37 1 - /Not used I
Mass air flow sensor signal
Mass air flow sensor signal
Fuel consumption signal
ECT signal
Throttle position signal
ground
input
output
ground
output
output
output
ground
output
Traction control (rear engine speed signal) Automatic climate control
Not used Electronic immobilizer control (EWS)
Auto. climate control
(AIC on input)
instrument
cluster
Camshaft actuator control (VANOS)
Fuel iniector control, cvl.
3
AES/ASC module
Automatic climate control instrument cluster (CARE signal)
Camshaft actuator (VANOS), switched ground
Pulsed ground (pulse width in
ms), cyl. 3
Oxygen sensor heater (no. 1 in front of catalytic
converter)
Power supply (terminal
30)
Idle speed control valve
Ground
Ignition coil control, cyl.
1
Ignition coil control, cyl. 3
Ignition coil control, cyl. 5
Ground Fuel injector control, cyl.
5
Oxygen sensor heater ground
Battery voltage
(E+) at all times
Pulsed ground-open signal (See pin
53)
Ground
Primary signal, ignition coil
1
Primary signal, ignition coil 3
Primary signal, ignition coil 5
Ground
Pulsed ground (pulse width in ms), cyl
5

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- -.
Fuel Injection
SIEMENS MIS 42.0 AND 43.0
When system faults are detected, a diagnostic trouble code
(DTC) is stored in the engine control module (ECM). The MIL
also illuminates
if an emissions-related fault is detected.
When faults arise, or
if the malfunction indicator lamp (MIL) is
illuminated, begin troubleshooting by connecting BMW ser-
vice tester
DISplus, MoDiC, GTI or equivalent scan tool. The
capabilities of OBD
II software has the potential to save hours
of diagnostic time and to help avoid incorrect component re-
placement and possible damage to system components.
CAUTION-
* The tests in this section may set fault codes (DTCs) in tlie
ECM and illuminate the MIL. After all testing is completed,
access and clear DTC fault
memory using an OBD I/ or
BMW compatible scan tool. See
OBD On-Board Diag-
nostics.
Only use a
dgital multimeter for electrical tests.
Relay positions can vary. Be sure to confirm
relayposi-
tion by identifying the wiring in the socket using the wir-
ing diagrams found in
ELE Electrical Wiring
Diagrams.
NOTE-
- OBD I1 fault memory. (including an illuminated MIL! can
only be reset using the special scan tool. Removing the
connector from the ECM or disconnecting the battery will
not erase the fault memory.
The BMW-dedicated 20-pin diagnostic
linlc connector
(DLC) is in the right rear of the engine compartment The
20-pin DLC is discontinued on models after
6/2000.
The 1 &pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
The MS
42.0 and MS 43.0 systems manage the following
functions.
- Air:
Idle speed valve
Electronic throttle
Hot film mass air flow (MAF) sensor
Resonance-turbulence intake control
- Fuel:
* Fuel supply
Running losseslnon return
Fuel injection

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130-28
Fuel Injection
ECM Relay
4 Check for voltage at terminal 6 (30) at reiay socket
If battery voltage is present continue testing.
if battery voltage is not present, check fuse 109 (80-amp
fusible link) under passenger seat carpet. See 610 Electri-
cal
Component Locations.
- Reinstall relay and turn ignition on. Gain access to back side
of reiay socket and check for ground at terminal
4.
If ground is present continue testing.
If ground is not present, signal
from ECM is missing. Check
wire between ECM and relay.
- With ignition on and reiay installed, check lor battery voltage
at terminal
2.
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and
ail earlier tests are OK,
relay is faulty and should be replaced.
NOTE-
If no faults are found during testing but power is not reaching
the ECM or other components, check the fuses
in the fuse
carrier
X8680 in the E-box.
Mass air flow (MAF) sensor, checking and
replacing
4 The hot f~lm mass air flow (MAF) sensor sends a varying volt-
age (approx. 0.5 - 4.5 vdc) to the ECM representing the mea-
sured
Intake air. The alr mass input signal is produced
electron~caily uslng an electrically heated metal fllm in the air
flow stream.
The ECM relay provides the operating voltage to the MAF
sensor. As air
flows through the sensor, the film is cooled. To
maintain the film at a constant temperature, additional current
is necessary. It is this additional current that is the basis lor
the input signal.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using the throttle position and engine rpm
inputs. A faulty MAF sensor illuminates the MIL.

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/Fuel Injection
4 Remove dipstick guide tube:
Disconnect wiring harness brackets from tube (A).
Unclip fuel lines from dipstick tube
(El).
Remove lower guide tube mounting bolt (C). Pull out dip-
stick guide tube.
< If necessary, disconnect electrical harness connector at fuel
tank venting valve (A). Disconnect hose at quick disconnect
fitting (arrow).
Working at throttle housing, turn harness plug counterclock-
wise and disconnect. Remove throttle assembly mounting
fasteners (arrows) and pull assembly off manifold.
Installation is reverse of removal
Replace sealing ring between throttle assembly and intake
manifold.
0 Reattach throttle assembly harness connector with care.
Arrow on fully tightened connector must line up with corre-
sponding arrow on throttle assembly housing.
* Connect BMW test equipment or equivalent and carry out
throttle plate adaptation following the on-screen directions.
Reattach throttle cable and check cable adjustment as de-
scribed under Throttle cable, adjusting
(MS 42.0).

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-.
Fuel Injection 1
4 If necessary, disconnect electrical harness connector at fuel
tank venting valve (A). Disconnect hose at quick disconnect
fitting
(arrow).
< Worlting at throttle housing, turn harness plug counterclock-
wise and disconnect. Remove throttle assembly mounting
fasteners
(arrows) and pull assembly off manifold.
- Installation is reverse of removal.
0 Replace sealing ring between throttle assembly and intake
manifold.
Reattach throttle assembly harness connector with care.
0 Arrow on fully tightened connector must line up with corre-
sponding arrow on throttle assembly housing.
- Use BMW scan tool to reset ECM adaptation values.

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130-38
Fuel Injection
Throttle cable, adjusting
(MS 42.0)
The throttle assembly on MS 42.0 cars uses a throttle cable.
The cable should be adjusted any time it is disconnected or
replaced. This procedure requires the factory scan tool or an
equivalent to read and adjust throttle angle. It is recommend-
ed the procedure be done by an authorized
BMW dealer ser-
vice department
Basic adjustment:
Ensure that at idle (accelerator pedal in rest position) throt-
tle cable has detectable play at throttle lever attaching
point. Play must not exceed maximum allowable.
Adjust by turning knurled adjuster
(arrow) on end of throt-
tle cable sheath at throttle housing.
NOTE-
Faulty throttle adjustment values must be reset using the
BMW service tester
DISplus, MoDiC, GTI or equivalent.
Max.
play at throttle plate lever
ldle speed control valve,
checking and replacing
3 mm (0.125 in)
The Idle speed control valve regulates Idle speed by red~rect-
ing air around the throttle valve. The ldle speed control valve
is mounted
d~rectly above the throttle housing. Accessing the
valve is best accomplished by
flrst removing the air fllter
housing and associated ducting.
Thevalve is supplied with batteryvoltage from the ECM relay.
The idle speed control valve incorporates a two-coil rotary ac-
tuator. The ground sides of each coil are pulsed simulta-
neously by the ECM. The duty cycle of each circuit is varied to
achieve the required idle speed.
A faulty idle speed control valve sets a fault code and the MIL
is illuminated when
OED II fault criteria are exceeded.
Before checking the idle speed control valve, confirm that the
throttle position sensor is working correctly.
- With engine running, check that idle speed control valve is
buzzing.
- Turn on AIC system or shift transmission into drive. ldle
should remain steady or increase slightly.
- If idle speed valve is not buzzing, or if idle decreases when
AIC is turned on, stop engine and disconnect harness con-
nector from idle speed valve.