Ignition key BMW 528i 1997 E39 Workshop Manual

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020-4
Maintenance
1997 to 2000 models
1997 to 2000 models are equipped with a data link connector
(DLC) plug in the right side engine compartment:
Reset
SII using BMW service and scan tool (DISplus or MoD-
iC, GTI) or a specialty tool from another manufacturer. Plug
tool (arrow) into DLC.
CAUTION-
Follow the manufacturer's directions when resetting the Sll. If
the reset procedures are done
incorrect& the tool or the elec-
tronic Service Interval Indicator
may be damaged.
Aftermarket reset tools that can reset all models with the DLC
can be purchased from one of the following suppliers:
Specialty tool suppliers
Assenmacher Specialty Tools
6440
Odell Place
Boulder, CO 80301
303-530-2424
[email protected] http://www.asttool.com
Baum Tools Unlimited,
Inc.
P.O. Box 5867
Sarasota, FL 34277-5867
800-848-6657
[email protected]
http://www.baumtools.com
Peake Research. Automotive Products Division
P.O. Box 28776
San Jose, CA 95159
408-369-0406
support @peakeresearch.com
http://www.peal~eresearch.com
2001 and later models
On vehicles without the data link connector (DLC) in the en-
gine compartment (2001 and latercars), the reset tool can not
be used. Instead, the
Sll can be reset with the trip odometer
reset button in the instrument cluster.
Make sure ignition key is in OFF position.
* Press and hold trip odometer button in instrument cluster,
and turn ignition key to ACCESSORY position.
Keep
button pressed for approximately 5 seconds until
either of following appear in display: OIL SERVICE or
INSPECTION, with RESET.
Press button again and
hold for approximately 5 seconds
until RESET flashes.

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.-
ignition System
Disabling ignition system
The ignition system operates in a lethal voltage range and
should be disabled any time engine service or repair work is
being done that requires the ignition to be switched on.
The engine management system can be disabled by remov-
ing the DME main relay. The relay is located in the electronics
box (E-box) in the left rear of the engine
compartment, be.
neath the interior microfilter housing.
CAUTION- Relay locations may
vary. Use care when identifying relays.
See
610 Electrical Component Locations.
Checking for spark
CAUTION-
If
a spark test is done incorrecth damage to the Engine Con-
trol Module
(ECM) or the ignition coils may result.
NOTE-
Spark plug replacement is covered in 020 Maintenance.
Check~ng for spark is d~fflcult on englnes wlth d~str~butorless
ignition systems.
Try removing the spark plugs and inspecting for differences between them.
A poor-firing plug may be wet with fuel and/or ~. - ~
black and sooty, but not always. If a coil is not operating, the
engine management system will electrically disable the fuel
injector to that cylinder. The key is to look for differences be-
tween cylinders.
Ignition coil assembly, testing and
replacing
C4 UTION-
Use a digital multimeter for the following tests. I
- Remove plastic engine cover from top of valve cover by pry-
ing off bolt covers and removing cover mounting bolts.
- Raise car slowly while constantly checking position of jack
and car.
- Disconnect harness connector from coil. Connect multimeter
between terminal 15
(+) in connector and ground.
4 Terminal identification are typically molded into connector. In
photo, terminals are from left to right: 1,
4a, 15.

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Battery, Starter, ~lternatorl
@ TO fuse & relay panel Battery Safety Terminal
A Battery Safety Terminal (BST) controlled by the Multiple
Restraint System (MRS) control unit was introduced for mod-
el year 1998
vehicles. The system will disconnect electrical
power to the engine compartment
in the event of a significant
impact. The MRS system fires an encapsulated pyrotechnic
device
in the positive (+) battery terminal that disconnects
power to the engine compartment, but maintains power to
the exterior lights and interior of the vehicle.
point
002125~1
Table a. Battery, alternator and starter troubleshooting
1-
/Starter motor or solenoid faulty. l~est starter.
Symptom
Engine does not crank
Engine cranks slowly or
not at all, solenoid
clicits
when starter is operated.
I I
Battery will not stay IShort circuit draining battery. l~est for excessive current drain with everything
Probable cause
Fault
in immobilizer system (EWS)
-Clean Battery cables loose, dirty or corroded.
Battery discharged.
Battery to body ground cable in trunk
loose,
dirty or corroded
Poor connection at starter motor terminal
30.
Corrective action
Try another ignition key. If problem persists, contact
your authorized BMW dealer.
or replace cables. See 020
~aintenance.
Charge battery and test. Replace if necessary.
inspect ground cable. Clean, tighten or replace if
necessary.
Checlc connections, test for voltage at starter. Test for
voltage at neutral safety or clutch
interloclc switch.
charged more than a few
days.
I~atter~ faulty. /Test battery and replace if necessary.
Short driving trips and high electrical drain
on
charging system does not allow battery to
recharge.
. I
I Battery cables loose, dirty or corroded. Iclean or replace cables. See 020 Maintenance.
Evaluate driving
style. Where possible, reduce
electrical
consumption when malting short trips.
Drive
belt@) loose, worn or damaged.
IAlternator or voltage regulator faulty. /Test alternator and voltage regulator.
Inspect
or replace ribbed
belt@). See 020
Maintenance.

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121-11
Battery, Starter, ~lternatorl
Alternator 1997 - 98 5281 1997 540i
/-- -----,
I'
-----------
F15 / 7.5A/ :
&.. .... , 30 1 Xi0015
Battery
Hol in run 61 E (D+) Alternator
and stsrt
lBL
(Generator)
1 .--------,charge , . I , indicator I xGoli i
I <"9,7,a,T
Alternator, basic
On 1997-1 998 6-cylinderand 1997 V-8 models, the charging
system indicator light is supplied voltage
(+) to one side of the
light bulb, and the other side of the bulb is connected to the
voltage regulator.
With the engine off and the key in the run position, voltage
from the ignition switch flows through the regulator to ground,
completing the circuit and illuminating the charge indicator
bulb.
When the vehicle is started and the alternator begins to pro-
duce voltage, the output of the diode trio increases and the
light is turned off.
Alternator with multi-function control
(MFR)
Alternator with multi-function control
(MFR)
The multi-function controlled alternator is used on:
* 1999-2002 6-cylinder models
* 1998-2002 V-8 models
4 On cars with multi-function control alternator, the charge in-
dicator lamp is activated by means of an electronic switch in-
tegrated in the alternator controller. This switch receives its
voltage supply from terminal
15 on the 3-pin connector at the
rear of the alternator. The controller measures internally the
voltage difference between terminal 30 and terminal
15 and
signals the DME ECM to turn the charge indicator lamp on.
The controller features integrated fault detection. The battery
charge indicator lamp will come on in the event of:
* Failure of belt drive
No charge due to an
electrical/electronic fault
Interruption in excitation circuit
Over-voltage due to a defective controller output stage Fault or break in charge line
No charge due to alternator fault

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Battery, Starter, ~lternatorl
Charging system quick-check
Use a digital multimeter to measure voltage across the bat-
tery terminals with key off and then again with engine running.
Battery voltage should be about 12.6 volts with key off and be-
tween 13.5 and 14.5 volts with engine running.
NOTE-
The regulated voltage (engine running) should be between
13.2 and 14.5, depending on temperature andoperating con-
ditions.
If the voltage is higher than 14.8, the voltage regula-
tor or
mulitfunction controller is most likely faulty
Check for clean and tight battery cables. Check ground cable
running from negative
(-) battery terminal to chassis and
ground cable running from engine to chassis. Check alterna-
tor drive belt condition and tension.
Charging system, checking
CAUTIOI\C
* Do not disconnect the battery while the engine is running.
Damage to the alternator and/or engine electronic systems
may result.
Only use a digital multimeter when testing charging
system components.
--7
4 Turn ignition key on. Check that battery warning light comes
on.
NOTE-
If the warning light does not come on, repair bulb or wiring
faults before continuing to checlc the charging system.
/ Charge indicator
502820805
4 6-cylinder engines only, remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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- -
/Battery, Starter, Alternator -- - -. - --I
< Check for battery voltage at alternator terminal 30 (B+) (ar-
row):
Pull back rubber insulating cover at terminal 30 at rear of
alternator.
Connect voltmeter between terminal 30 and ground and
check for battery voltage.
If voltage is not present, check
wiring for faults.
NOTE-
On V-8 engines, access to the rear of the alternator is limited.
Check for battery voltage between the jump start post on the
left cylinder head and ground.
r Disconnect harness connector from alternator. Turn ianition
on and check for battery voltage between terminal
lgand
ground. If voltage is not present, check wiring and fuses for
faults.
Reconnect connector to alternator.
Locate the blue wire coming from terminal
61E of the alter-
nator connector. Carefully connect the positive
(+) test lead
to the wire using a piercing test lead end.
Turn ignition key on and check for voltage. Voltage should be
less than 1.5 VDC and charge indicator lamp should light.
- Making sure all test equipment and tools are clear, start en-
gine. Voltage should increase to
8.0 VDC or higher. The
charge indicator light should go out.
If voltage does not increase and system is not charging,
the fault is in alternator.
- If voltage does not increase, but system is charging, inter- - roaate svstem for faults usina an appropriate BMW scan - .. . tool and'reset fault memory.
- If a load tester is not available, a quick alternator output test
can be done by running engine at about 2000 rpm and turn-
- -
ing on electrical loads (fans, lights, rear window defroster, -
- and wipers). With all accessories on, battery voltage should
be above 12.6
V.

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Battery, Starter, Alternator
- Installation is reverse of removal, noting the following:
Replace alternator rubber sealing O-ring.
* Fill and bleed cooling system as described in 170 Radiator
and Cooling System.
Tightening torques
Fan clutch to coolant pump
with
BMW special tool 11 5 040 30 Nm (22 ft-lb)
without
BMW special tool 11 5 040 40 Nm (29 ft-lb)
Terminal 30 (Bc) wire to alternator (ME) 13 Nm (10 ft-lb)
STARTER
Starter troubleshooting
Typical starter wiring terminal identification is shown. Large
wire at terminal
30 (not shown in photo) is direct battery volt-
age. Smaller wire at terminal
50 operates starter solenoid via
ignition switch.
If starter turns engine slowly when ignition is in start position:
Check battery state of charge.
Inspect starter wires, terminals, and ground
connectlons
for good contact. In particular, make sure ground connec-
tions between battery, body and
englne are completely
clean and tight.
If no faults are found, starter may be faulty and should be
replaced.
- If starter fails to operate, check EWS (drive-away protection
system). Try another ignition key.
If no faults can be found,
have the EWS system checked using
BMW scan tool equip-
ment.
Checkclutch pedal operated
starter lock-out switch or gear
position switch (automatic).
NOTE-
* A factory-installed drive-away protection system, also re-
ferred to as
EWS, is used on E39 cars. This system pre-
vents operation of the starter if a specially coded ignition
key is not used.
On cars with automatic transmission, the transmission
gear position switch signals
EWS to prevent the engine
from starting in gear positions other than PARK or NEU-
TRAL.
On cars with manual transmissions, a starter immobiliza-
tion switch
at the clutch pedal is used to prevent the starter
from operating unless the clutch pedal is pushed fully to
the floor.

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I Battery, Starter, Alternator
- Check for battery voltage at terminal 50 of starter motor with
key in start position. If voltage is not present, check wiring be-
tween ignition switch and starter terminal. Check the EWS
system and other inputs that disrupt terminal
56 to the start-
er. See ELE Electrical
Wiring Diagrams. If voltage is
present and no other visible wiring faults can be found, prob-
lem is most likely in starter motor.
Starter, removing and installing
(6-cylinder engine)
The starter is removed from below. Access to starter bolts is
difficult. Be sure to have the proper tools on hand before pro-
ceeding.
NOTE-
Access to the starter wiring is very limited. Forbetteraccess,
it may be necessary to remove the intake manifold.
- Disconnect negative (-) battery cable.
CAUTIOI\C
Prior to disconnecting the battern read the baltery discon-
nection cautions
in OOlGeneral Cautions and Warnings.
Remove complete air filter hous~ng:
Loosen intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw (D)
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.
Disconnect throttle cable.
Raise vehicle and support safely.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive
lift orjack stands designed for
the purpose. A
floorjaclc is not adequate support
- Working underneath car, remove engine splash shield
- Disconnect fuel lines and harness connectors from retaining
brackets, as necessary.

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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 lniection 1
Table b. Siemens MS 41.1 ECM pin assignments (continued)
Pin
lSiqnal 1 Componentlfunction / Notes I - I I
40 1 ground /Crankshaft position sensor /crankshaft position sensor control I - I I
41 1 ground /Camshaft position sensor (CMP) /shielding for CMP sensor I - I I
42 1 ground I~hrottie position sensor (TPS) /TPS ground
43
44
45
46
47
48
49
50
51 ground
output
output
output
outout
I I I
input
52 53
54
55
56 57
58
59
60
61
62
63
64
65
66 Camshaft position sensor (CMP)
Throttle position sensor (TPS)
Throttle position sensor (traction control)
Instrument cluster
Not used
Crankshaft position sensor (Hall effect)
I~ot used
I I I
Fuel pump relay control Camshaft
positionlrpm sensor control
Voltage
supply to TPS (5 vdc)
ABSIASC module
Instrument cluster, fuel reserve signal
Crankshaft position sensor control
Power supply (terminal 15)
Not used
Not used
output input
ground
ground
output
input
output
inputloutput
ground
output
input
input
input
I I
Battery voltage with key on or engine running
Oxygen sensor signal ground
67
Idle speed control valve
Power supply
Oxygen sensor heater (no. 2 in front catalytic
converter)
Ignition circuit
Knock sensor
(cyl. 1-3)
Knock sensor (cyl. 1-3)
Knock sensor
(cyl4-6)
Data linic connector (TxD)
Oxygen sensor heater (no. 2 behind catalytic
converter)
Secondary air injection
Knock sensor (cyl. 4-6)
Camshaft
positionlrpm sensor
Camshaft
positionlrpm sensor
Not used
Pulse ground with engine at normal temperature with
varying engine load
68 Pulsed ground-close signal (see
pin 26)
Battery voltage from main relay (terminal 87)
Oxygen sensor heater ground
Ignition circuit monitoring signal
Knock sensor
Knock sensor signal
Knock sensor
Diagnostic
TxD (transmit) signal to pin 18 in data link
connector
Oxygen sensor heater ground
Secondary air injection control
valve
Knocic sensor signal
Camshaft positionlrpm sensor control
Camshaft
positionlrpm sensor control
ground Oxygen sensor
(no.
1 in front of catalytic
converter)
output Evaporative purge
valve control