drive BMW 528i 1997 E39 Manual PDF

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121-23
Battery, Starter, ~lternatorl
Solenoid switch, removing and installing
- Remove starter as described previously.
- Disconnect field winding strap between starter motor and
solenoid switch.
NOTE-
If the field winding strap is damaged or burned, a new or
rebuilt starter motor is needed.
< Remove solenoid switch mounting screws (arrows), and
separate solenoid from starter.
Unhoolc solenoid plunger from lever in starter drive
- Installation is reverse of removal. Lubricate solenoid piston
with light grease.
CAUTION- When installing field winding strap to starter, position
itso that
it does not contact the starter body.
Tightening torque
Field strap to starter
13 Nm (10 ff-lb)

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130-1 3
Fuel Injection I
< Unplug harness connector (arrow) from sensor.
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
NOTE-
Do not confuse the throttle position sensor on the main Nirot-
tle body with the throttle position switch on the secondary
throttle body, where applicable.
- Remove two mounting screws holding sensor to throttle
housing.
- Installation is reverse of removal. Clear adaptation settings
from ECM using BMW-compatible scan tool.
NOTE-
Poor idle quality may be noticeable for a period if the adapta-
tion settings are not cleared after installing new TPS.
ldle speed control valve,
checking and replacing
The idle speed control valve regulates idle speed by redirect-
inq airaround the throttlevalve.The idlespeed control valve is
mounted on the underside of the intake manifold adjacent to
the dipstick tube bracket. Accessing the valve is best accom-
plished by first removing the air filter housing and the throttle
body assembly.
The valve issupplied with
batteryvoltagefrom the ECM relay.
The idle speed control valve incorporates a two-coil rotary ac-
tuator. The ground sides of each coil are pulsed
sirnulta-
neously by the ECM. The duty cycle of each circuit is varied to
achieve the required idle speed.
Afaulty ldle speed control valve sets afault 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.

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Fuel injectors, checking and replacing
The fuel injectors are electronically controlled solenoid valves
that provide precisely metered and atomized fuel into the en-
gine intake ports.
The injectors receive voltage from the ECM relay. The ECM
controls the opening by activating the ground circuit
forthe in-
jector valve solenoids. The ECM varies the duration (in milli-
seconds) of "opening" time to regulate the
airlfuel ratio.
For a quick
check of the injectors, run the engine and touch
each injector with a screwdriver or stethoscope. You should
feel a vibration or hear a buzzing
Remove fuel injection harness from injectors by unclipping
locking clip at each injector. Lift harness off injectors.
CA U JIOG
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
Use a multimeter to test injector coil resistance between in-
jector terminals.
l~uel injector coil resistance 16R at 20" C (68" F)
Disconnect negative
(-) battery cable
CAUTIOG
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven
in 001 General Warnings and Cau-
tions.
4 Remove plastic trim plugs (arrows) and fasteners, then re.
move cover from above fuel injectors.
- Disconnect vacuum line from fuel pressure regulator.
- Remove wiring harness duct mounting fasteners.

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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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Fuel Injection
4 Remove electrical harness connector (arrow) from IAT sen-
sor.
CAUTION-
Be sure the ignition switch is in the off position before repiac-
ins the intake temperature sensor.
- Depress loclting clip on side of temperature sensor and pull
straight out of intake manifold.
- Installation is reverse of removal
- Use a new sealing O-ring at base of sensor and lubricate with
assembly lubricant for
ease of installation
MS 42.0 throttle valve assembly, replacing
< The motor driven throttle valve for the MS 42.0 system is re-
- ferred to as MDK (motor driven throttle valve). The MDK unit
is electronically operated to regulate intake air flow by the
ECM.
The
MS 42.0 system uses a throttle cable from the accelera-
tor pedal to the MDK unit. The throttle cable is connected di-
rectly to the integral pedal position sensor
(PWG) in the MDK
unit. This sensor communicates pedal position to the ECM,
which in turn electronically regulates throttle plate position.
The MDK pulley is linked to the throttle shaft by springs to al-
low ASC intervention to override the driver's pedal position.
NO TE -
The MDIC unit is non-adjustable and must be replaced as
a complete unit if found to be faulty.
if replacing the
MDK unit, the adaptation values stored in
the ECM must be clearedand the new unit initialized using
BMW special service tools.
CAUTION-
If the adaptation process is not completed correct& the en-
gine wiii
not start.
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battern read the battely discon-
nection cautions in
001 General Warnings and Cautions.

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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.

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Fuel Injection
Table c. Siemens MS 42.0 and MS 43.0 ECM pin assignments (continued)
Pin
42
43
44
45
46
47
48
49 50
51
52 Componentlfunction
Signal, evaporative emissions valve
Signal, throttle
valve drive
Signal, throttle valve drive
Signal, engine coolant thermostat
Signal, close idle speed control valve
Signal, open idle speed control valve
Signal, shield
ltnock sensor
Signal, resonance valve
intake system
Not used
Not used
Signal, secondary air injection pump valve
Signal
Input
Input
Input
Input
input
Input
Ground
Input
Input
Notes
Evaporative emissions valve
Throttle valve
Throttle valve Engine coolant thermostat (map controlled)
idle speed control valve
Idle speed control valve
Shield,
knock sensor
Resonance valve intake system
Secondary air injection valve
Connector
X60004 40-pin Notes
instrument cluster control unit
Instrument cluster control module
Secondary air injection pump relay
Electric (auxiliary) fan motor
Pedal position sensor (PWG) (MS 43.0)
Pedal position sensor (PWG) (MS 43.0)
Pedal position sensor (PWG) (MS 43.0)
Fuel pump relay
1
Instrument cluster control module
ComponenVfunction
Signal, battery charge indicator lamp
Feedback signal, engine start
Signal, secondary air injection pump
Signal, electric cooling fan
Not used
Not used
Pedal position sensor (PWG) (MS 43.0)
Signal, pedal position sensor (PWG) (MS 43.0)
Pedal position sensor (PWG) (MS 43.0)
Signal,
fuel pump relay 1
Signal, oil pressure switch
Pin
1
2 3
4
5
6
7
8
9
10
11 Signal
Input
Input
input
input
Input
Input

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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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Fuel Injection
Intake air temperature
([AT) sensor,
testing and replacing
Disconnect harness connector from intake air temperature
sensor
(A) at air filter housing.
Turn ignition on. Using a digital voltmeter, check for
5 volts
between supply voltage wire in connector and ground.
If volt-
age is not present, test ECM
inputs/outputs as described lat-
er.
With harness connector disconnected, test resistance across
sensor terminals. If any faults are found, replace IAT sensor.
IAT test resistance
0 lV *lac (50" i-2°F) 7-1 1.6 k.0.
020' kl°C (68' 322°F) 2.1-2.9 it.0.
080" ?lac (176" i-2°F) 0.27-0.40 itn
Auxiliary throttle valve (ADS)
(M62 and M62 TU engine), replacing
ADS components 540i models with ASC and DSC are fitted with a motor-driv-
en auxiliary throttle valve and housing ahead of the standard Throttle position switch throttle housing. The ADS throttle valve controls engine throt-
tle intervention based on signals from the DME control mod-
ule if road conditions, such as slipping driven wheel, warrant
reduced engine power.
ADS throttle housing
Bowden cable NOTE-
Before replacing the ADS throttle housing, read DME fault
ADS lhroltle actualor codes.
- ADS throttle housing replacement:
Switch off ignition and disconnect electrical connector on
ADS throttle body.
Remove hose from idle control valve.
Loosen hose clamps and remove throttle housing air in-
take boot.
Disconnect cable from ADS throttle body.
- Unscrew 3 bolts and remove ADS throttle body.
Installation is reverse of removal.
- Adjust cable so that no free play is present.