sensor BMW 528i 2000 E39 Workshop Manual

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I Fuel lniection
varies as the coolant temperature (sensor resistance) chang-
es.
NOTE-
The ECT sensor is an NTC (negative temperature coeff-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
If the ETC sensor input is faulty or non-plausible, the MILis il-
luminated when OBD
II fault criteria are exceeded. The ECM
assumes a substitute value
(8OoC/176"F) to maintain engine
operation. The ignition timing is set to a
conservativelsafe ba-
sic setting.
4 Disconnect ECT sensor harness (A)
- Checlc ECT sensor resistance using a multimeter at sensor
terminals
3 and 4. Peel back protective boot (B) to ID termi-
nal numbers on connector housing.
/ ECT sensor resistance @l 2O" C (68°F) 2.2 - 2.7 kd
WARNING -
Due to risk of personal injug be sure the engine is cold be-
fore disconnecting ECT harness connector.
Sensor replacement: Disconnect ECT sensor harness (A).
- Unscrew ECT sensor from cylinder head and install new sen-
sor.
Use new copper sealing washers
when installing sensor.
Replace any lost coolant.
Tightening torque
ECT sensor to coolant flange 13 Nm (I0 it-lb)

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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.

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130-59
Fuel Injection
:-- -i. Evaporative emissions
1.
control diagram (M5.2.1)
i 1
i I @ 1. ECM r.=.:-:, 2. Purge valve
3. Leak detection pump (LDP)
4. Liquid vapor separator
5. Purge canister
6. Filter
Bosch M5.2 ECM pin assignments
(M62 up to 911997)
Tabled. Bosch M5.2 ECM pin assignments
I' 1- 1. . . -
4 1 output / Cyl. 4 fuel injection valve I Cyl. 4 fuel injection valve (cycled ground)
Pin
1
2
3
i I
I
7 / output I Cyl. 6 fuel injection valve I Cyl. 6 fuel injection valve (cycled ground)
Type
output
output
output
I I ,
8 1 output I Malfunction indicator light (MIL) (USA only) I lliumlnated for exhaust gas related diagnostic trouble code
5
Component/function
Oxygen sensor heater signal
Idle speed control -closing winding
Cvl. 1 fuel iniection valve Note
DME heated oxygen sensor
1 splice
idle speed control valve (cycled ground)
Cvl. 1 fuel iniection valve lcvcled around)
6 1 ground I Fuel injection valve ground 1 Ground
output
9
Not
used
Not used
11
12
13
Cyl. 5 fuel injection valve
10 1 input I Electronic immobilizer (EWS) / Electronic immobilizer (EWS) control unit
input
Heated oxygen sensor signal Cyl.
5 fuel injection
valve (cycled ground)
output
input
input
16
Start signal Starter relay
NC compressor signal
Terminal
50 signal
Knock sensor signal
17 1 ground I Hot film mass air flow (MAF) sensor ground I Hot film mass air flow (MAF) sensor ground
output Heating and
A/C control module
Ignition switch
Knock sensor
Intake air temperature intake air temperature sensor (voltage value)

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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
I 68 1 / Not used
Table
d. Bosch
M5.2 ECM pin assignments
I I I
69 1 input I AIC system standby signal (> 10 V) 1 Heating and AIC control module
Pin
57
58
59
60
61
62
63
64
65 66
67
Type
input
input
input
input
I 70
72
73
74
Componentlfunction
Not used
Not used
Heated thermostat (characteristic map, cooling)
Programming voltage input (voltage
value)
Signal input Evaporative emission valve
Not used
Fuel pump relay (ground)
Not used
Not used
Not used
Not used
75
76
77
78
79
80
Note
Characteristic map, cooling
Data
llnlc connector
Evaporative emission valve
Fuel pump relay
71 1 ground I Control module ground I Ground splice
input
input
81
input input
input
input
output Not used
I
Knock sensor signal
Not used
Not used
Coolant temperature
82 1 I Not used
83
I I
Knock sensor
Dual temperature
swltch
Not used
Heated oxygen sensor signal (voltage
0.1-1.0 V)
Heated oxygen sensor
signal (voltage 0.1-1.0 V)
Crankshaft position sensor signal (speed and
position, AC voltage)
Right rear wheel speed signal
TD signal (engine speed)
85
I I I
Heated oxygen sensor II behind catalytic converter
Heated oxygen sensor
I behind catalytic converter
Cranitshaft positionlrpm sensor
ABSIASC control module
TD signal splice
84 1 / Not used 1
output
88
86
1 input-output 1 CAN-Bus high I Transmission conlrol module (AGS)
input-output
Injection signal
input-output Integrated instrument cluster control
module (IKE)
CAN-Bus low Transmission control module (AGS)
Data
linlc TxD Data link connector

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130-62
Fuel Injection
Bosch M5.2.1
ECM pin assignments
(M62 from 911 997 to 911 998)
Table e. Bosch 5.2.1 ECM pin assignments
i I I
5 1 I Not used
I
I I
Note
I I I
7 lln~ut l~erminal 30 voltage supply I Fuse
F4
Description
Pin
Ground point right-hand drive
Ground connector
X6460
I I I
Signal
Connector
X60001
Ground 4 1
2
3 Ground
Ground point right-hand drive
Ground connector
X6460 6
8
9 1
2
3
4
5
Not used
Not used
Not used
-
6
7
8
9
10 11
12
Ground
Input
Connector
X60002
Output Input Input Output
Input Output
Grniind
. -
13
14
15
Ground
- .- -
Output
Ground
Ground
Ground
Ground
16
17
18
19
20
21 22
23
.
Terminal 87
Not used
Oxygen sensor heater
slgnal
Not used
CAN-Bus low
CAN-BUS high
Ground
Output Input
ln~ut
Fuse F1
Heater oxygen sensor II behind cataiytic converter
Back up light switch
Transmission control module (AGS)
Transmission control module
(AGS)
Ground connector X6480
Not used
Oxygen sensor heater signal
Oxygen sensor heater ground
Oxygen sensor heater ground
Oxygen sensor heater ground
Oxygen sensor heater ground
Not used
Input
Input
Output
Output
Output Heater oxygen sensor
I behind catalytic converter
Heater oxygen sensor
II behind catalytic converter
Heater oxygen sensor
1 in front of catalytic converter
Heater oxygen sensor
II in front of catalytic converter
Heater oxygen sensor I behind catalytic converter
Oxygen sensor heater ground
Oxygen sensor heater ground
Oxvqen sensor heater ground Heater oxygen sensor
iI in front
of catalytic converter
Heater oxygen sensor
II behind catalytic converter
Heater oxygen sensor
1 in front of catalytic converter . -
Oxygen sensor heater ground
Oxygen sensor heater ground
Signal, running losses
Oxygen sensor iieater ground
Not used
Not used
Not used
Terminal
85 control
Heater oxygen sensor II in front of catalytic converter
Heater oxygen sensor
I behind catalytic converter
Fuel changeover
(312 way valve) circuit
Heater oxygen sensor 1 in front of catalytic converter
Engine control module relay

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Fuel lnjection
Table e. Bosch 5.2.1 ECM pin assignments
Pin
Isignal 1 Description 1 Note
Connector
X60003
1
2
3
4
5
6
7 8
9 10
11
12
13
14
15
16
17
18
19
20
21
ate alr empe
Output
Output
Output
Ground
Ground
Output
Output Input
Input
Input
Ground
22
23
24
25
26
27
28
29
30
Injection signal
Injection signal
Signal, evaporative emission valve
Not used
Not used
Ground for electronic components
Not used
Not used
Hot film mass air flow sensor ground
Throttle position sensor voltage supply
Signal, engine coolant temperature sensor
Hot
film mass air flow sensor signal
Throttle position sensor slider voltage
Shield, throttle potentiometer (DK) Not used
Injection signal
Injection signal
Not used
Not used
Input
Input
Input
Ground
Output
Output Evaporative emission
valve
Ground point right-hand drive
Ground connector
X6460
Hot film mass air flow sensor
Throttle position sensor
Signal, secondary air injection pump valve
Terminal
30 voltage supply
Alternator
D+ (terminal 61) signal
injection signal
Injection
signal
Not used
Not used
Not used
Not used
Camshaft position sensor signal
Ground Dual temperature switch
Hot film mass air flow sensor
Throttle position sensor
Throttle position sensor
Cylinder
8 fuel injection valve
Cylinder
5 fuel injection valve
Secondary air injection pump
valve
Starter
Alternator (generator)
Cylinder
7 fuel injection valve
Cylinder 6 fuel injection valve
Camshaft position sensor (Hall effect) Dual temperature
switch

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-
Fuel Injection
Table e. Bosch 5.2.1 ECM pin assignments
Pin
I~iqnal 1 Description 1 Note
I I I
46 llnput ICrankshaft position sensor Icrankshaft positionlrpm sensor
38
39
40
41
42
43
44
45 Ground Input
Output
Output
Output
Output
Ground
47
48
49
50
51
Not used
I Not used
52
Shield, knock sensor
Oil level
- thermal
Injection signal
injection signal
Idle speed control - opening winding
Idle speed control - closing winding
Not used
Ground
Ground
-- Ground Input
Ground
Ground Not used Knock sensor
Oil level sensor
Cylinder
4 fuel injector
valve
Cylinder
1 fuel injector valve
Idle speed control valve
Idle speed control valve
Shield, crankshaft sensor
5
6
7
12 Not used
Ground
Intake air temperature sensor
Connector
X60004
8
9 10
11
14 1 1 Not used I
Shield, knock sensor
Shield, sensor
I
Shield, sensor 3
Shield, itnock sensor
Input
- Knoclc sensor
Knock sensor
Knock sensor
Knock sensor
Instrument cluster
Output
2 llnput l~erminal 30 voltage supply /Megrated instrument cluster control module (IKE)
Alt. charge indicator signal, terminal 61 1
Not used
Start signal terminal
50
Not used
15
16
17
18
Output
Ignition switch
Not used
Not used
Activation of relay for fuel pump
Not used
19
Fuel pump relay
Output Not used
I I I 20 loutput ICARB signal /Data link connector
Not
used
Not used
Engine speed signal output (TD)
Not used
Light module
21
Cruise control module (Tempomat)
22 llnput I Right rear wheel speed signal /ABS/ASC or ABSIDSC control module
Oulput
Washer
fluid level,
brake fluid level

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130-67
Fuel Injection /
ME 7.2 system overview
The Bosch ME 7.2 system is used on 1999 - 2002 540i mod-
els.
1 4 The ME 7.2 enaine control module (ECM). located on the
l and a combined total of 134 pins.
--__-- 1 I. 9 pin connector
12 3 4 5 2 24 pin connector
0lliC;nii, 3. 52 pin connector
4. 40 pin connector
5. 9 pin connector
The ME 7.2 system has the following functions or capabilities:
Electronic throttle control (EDK) integrates idle and cruise
control functions. ECM carries out all throttle and idle con-
trol functions directly via EDK system.
Leak diagnosis pump
(LDP) control and feedback monitor-
ing for evaporative system leak testing.
Batterylalternator charge logic (idle speed varies with bat-
tery state of charge).
CAN-Bus communications with instrument cluster.
EWS
111 (3.3) "rolling code" ISN interface.
Ignition
knock sensors.
DSC (dynamic stability control) torque reduction.
Monitoring and control of VANOS
(camshaft timing) with
active Hail sensor for camshaft position monitoring.
Integrated altitude sensor.
One touch engine start control
Single speed secondary air injection system.
Long life spark plugs.
IHKA auxiliary (electric) cooling fan control.
All emissions-related ME 7.2 electrical components are mon-
itored for faults. if driveability complaints are encountered or
the malfunction indicator
light (MIL) is illuminated, interrogate
fault memory using a compatible scan tool.
4 Use a break-out box for ME 7.2 system testing and diagnosis
at the control module
(break out box set: BMW special tool
90
88 6 121 300).
Electrically heated (characteristic
map) cooling system
DME Harness Connector thermostat.

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130-68
Fuel Injection
0
4 The ME 7.2 uses a non-return fuel rail. The fuel pressure reg-
ulator is integrated into the fuel filter.
I iY.,lii,in
4 The M62 TU engine uses a continuously variable VANOS
system at each intake camshaft. This system enhances en-
gine performance and reduces tailpipe emissions. Both cam-
shafts are adjusted simultaneously within
20" (maximum) of
the camshafts rotational axis. This equates to a maximum
span of
40°crankshaft rotation.
regulalor from luel pump
NOTE-
The fuel filter is available as a replacement part without the
fuel pressure regulator. When replacing the fuel filter, trans-
fer the fuel pressure regulator from the old
filter to the new fil-
ter.
Engine idle speed control is a function of the EDK. The M62
TU engine does not use a separate idle control valve.
Mmn CON,ROL
EML
< The M62 TU engine uses an electrically controlled throttle
valve called EDK. The throttle plate is positioned by a DC
gear reduction motor based on inputs signals to the ECM
from the pedal position sensor (PWG).
When the accelerator pedal is moved, the PWG provides a
change in the monitored signals. The ME
7.2 control module
compares the input signal to a programmed map and appro-
priately activates the EDK motor via proportional pulse width
modulated control signals. The control module self-checks its
activation of the EDK motor via the EDK feedbaclc
potentiom-
eters.