dme BMW 528i 1998 E39 User Guide

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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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130-2
/Fuel Injection
This repair group covers service and repair of the Bosch and
Siemens engine management systems used on
1997
through 2002 E39 models. Additional engine management
service and repair information may also be found in the fol-
lowing repair groups:
0 020 Maintenance
120 Ignition System
160 Fuel Tank and Fuel Pump
610 Electrical Component Locations
OBD On Board Diagnostics
NOTE-
Camshaft position sensor, crankshaft speed sensor and
knoclc sensors are covered in 120 Ignition System.
Table a. Engine management system applications
- - ~ ~
1 ~odellmodel year / Engine IDME system I - I
5281, 1997-1 998 IM52. 2.8 liter ISiemens MS 41 .I I 1
528i. 1999ZO00 1~52 TU, 2.8 liter ]siemens MS 42.0 I I
5251, 2001-2002 1~54, 2.5 liter 1 Siemens MS 43.0 I I
530i, 2001-2002 1~54, 3.0 liter ISiemens MS 43.0
5401 1999-2001 1~62 TU, 4.4 liter l~osch ME 7.2
I
OBI) II software and hardware is incorporated in the engine
management control systems. The
OED II system monitors
components that influence exhaust and evaporative emis-
sions. If a problem is detected, the
OED I1 system stores the
associated fault code and condition.
540i. 1997
4 If vehicle emission levels exceed 1.5 times Federally mandat-
ed criteria, the
OED II system illuminates a malfunction indi-
cator light
(MIL) in the instrument cluster.
For the
E39 cars covered by this manual, three different
MIL symbols were used, depending on year and model.
See illustration.
When faults arise, or if the malfunction indicator lamp (MIL) is
illuminated, begin troubleshooting by connecting BMW ser-
vice tester
DISplus, MoDiC, GTl or equivalent scan tool. The
capabilities of OBD
II software has the potential to save hours
540i. 1998 IM62, 4.4 liter /Bosch M5.2.1
M62, 4.4 liter Bosch M5.2

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Fuel Injection
Warnings and cautions
For personal safety, as well as the protection of sensitive
electronic components, adhere to the warnings and cautions
on the following pages.
WARNING-
Gasoline is highly flammable and its vapors are explosive.
Do not smoke or work on a car near heaters or other fire
hazards when diagnosing and repairing fuel system prob-
lems. Have a fire extinguisher available in case of an emer-
gency
Renew fuel system hoses, clamps and O-rings any
time they are removed.
When working on an open fuel system, wear suitable
hand protection, as prolonged contact
with fuel can
cause illnesses and skin disorders.
* The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when
working on a car with the ignition
switched on or the engine running.
CAUTION-
- Disconnecting the battery may erase fault code($ storedin
memory Check for fault codes prior to disconnecting the
battery cables. Read the battery disconnection cautions in
001 General Warnings and Cautions.
a Connect and disconnect the DME system wiring and
1 test equipment leads only when the ignition is switched
off.
Wait at least 1 minute after turning off the ignition be-
fore removing the engine control module (ECM) con-
nector. If the connector is removed before this time,
residualpower in the system relay may damage the
control module.
Fuel system cleaners and other chemical additives oth-
er than those specifically recommended by BMW may
damage the catalytic converter, the oxygen sensor or
other fuel supply components.
* Do not connect any test equipment that delivers a 12-
volt power supply to terminal 15 (+) of the ignition coil.
The current flow may damage the ECM. In general,
connect test equipment only as specified by BMW or
the equipment maker.
Only use a digital
multirneter for electrical tests. Only
use an LED test light for
quiclc tests.

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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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Fuel Injection I
Mass air flow (MAF) sensor,
checking and replacing
4 The hot film mass air flow (MAF) sensor (arrow) sends a
varying voltage (approx.
0.5 - 4.5 vdc) to the ECM represent-
ing the measured intake air. The air mass input signal is pro-
duced electronically by the
MAFsensorusing a heated metal
film in the air flow stream.
The ECM relay provides the operating voltage to the MAF
sensor. As air flows through the MAF sensor, the film is
-
cooled. To maintain the film at a constant temperature, addi-
tional heating current is necessary. It is this additional current
that is the basis for the input signal.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using throttle position and engine rpm in-
puts. A faulty MAF sensor illuminates the MIL.
A faulty MAF sensor can produce the following problems:
Difficult to restart when engine is hot.
Engine starts then stalls.
Engine starts and runs only with accelerator pedal de-
pressed.
Disconnect electrical harness connector from MAF sensor
(arrow).
- Turn ignition on and check for voltage and ground at connec-
tor.
There should be ground at pin
1 and battery voltage at pin
3.
If any faults are found, check for wiring breaks between
MAF sensor and ECM and between MAF sensor and ECM
relay.
NOTE-
Visually inspect the sensor for damage, missing or blocked
screens. The screens affect air flow calibration. Also inspect
the sealing O-rings where the sensor inserts into the air
filter
housing and intake boot. Ensure the pin connections are
clean and tight.
4 Connect a BMW-compatible scan tool or an OBD II generic
scan tool. Check air mass signal (load signal) with the engine
at idle. Raise idle speed and check that load signal changes
with rpm.
CA UTIOI\C
Be sure ignition is OFFbefore disconnecting or reconnecting r
1 DME svstem components. 1

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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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130-1 2
Fuel Injection
- Disconnect intake air boot from throttle housing. Unbolt throt-
tle housing and lay aside. It is not necessary to disconnect
throttle cable or electrical harness connectors from throttle housing.
- Remove electrical harness connector from IAT sensor.
- Unclip temperature sensor and remove from intake manifold.
- Installation is reverse of removal. Use a new gasket at throttle
housing.
Throttle position sensor (TPS),
testing and replacing
4 The throttle position sensor (arrow) is located on top of the
throttle valve housing and provides the ECM with a voltage
value that represents throttle position (angle) and rate of
movement.
TheTPS is non-adjustable. If the throttle position sensor is re-
placed, the previous 'learned' TPS settings must be cleared
from the ECM using a BMW-compatible scan tool.
If the throttle position sensor signal is defective, afault code is
stored and the
MILis illuminated when OBD II fault criteria are
exceeded. The ECM still operates the engine using the mass
air flow
(MAF) sensor and engine rpm inputs.
- Check throttle position sensor function by disconnecting har-
ness connector and checking continuity across terminals. If
test results are incorrect,
replace throttle position sensor. The
sensor is non-adjustable.
Throttle
~osition sensor testina values -
Terminals Test
values
1 and ground in harness 5 vdc (approx.)
connector, ltey on
1 and 3 at sensor 4.0 itR(appr0x.)
1 and 2 at sensor Throttle
plate rotated from idle to
lull throttle, continuously variable
from 1.0
- 4.0 1tR
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME svstem components. r

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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 Injection
- 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.
connector
CAUTION-
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
Checlc resistance of valve across valve terminals.
Idle speed control valve resistance
Terminals
1 and 2 20 i-2Q
Terminals 2 and 3 20 C2Q
Terminals 1 and 3 40 C4Q
The idle speed control valve is mounted under the intake
manifold. Accessing the valve is best accomplished by first
removing the air filter housing and the throttle housing.
< Disconnect intake air boot from throttle housing. Unbolt throt-
tle body and lay aside. Do not disconnect throttle cable or
electrical harness connectors to throttle body.
NOTE-
For additional worlcing room, unfasten and lift out the com.
plete air filter housing.
- Working under intake manifold, disconnect electrical harness
connector from idle speed control valve.
Unbolt dipstick tube
bracket (A) from intalte manifold.
- Remove two bolts (B) retaining idle speed control valve to un-
derside of intalte manifold. Remove valve from intalte mani-
fold. Remove hose clamp and disconnect hose.
- Installation is reverse of removal. Use new gaskets when in-
stalling.

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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.