Fuel injectors BMW 528i 2000 E39 User Guide

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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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130-1 8
1 Fuel injection Secondary air injection
1. Secondary air pump (in right
front wheel housing)
2. Secondary air vacuum vent
valve solenoid (on intake mani-
fold)
3. Secondary air check valve
4. Intake manifold
5. Exhaust manifolds
6. Diverter valve (at exhaust mani-
fold)
Engine control module (ECM),
removing and installing
The ECM uses stored functions and processing programs to
process the input signals from the sensors. These input sig-
nals are used to calculate the control (output) signals to the
actuators
(e.g., ignition coils, injectors).
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
- Disconnect negative (-) battery cable. Wait approximately
one minute.
Prior to disconnecting the
battely, read the battery discon-
nection cautions in
001 General Warnings and Cautions.
Access engine control module (ECM):
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate air duct inward (arrow) to unloclc from bulk head
and remove duct.
Release spring lock
(C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
- If testing ECM or connected components, use breakout box
to allow tests to be made with connector attached to the
ECM. This prevents damage to small terminals in connector.

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130-40
Fuel Injection
Engine control module (ECM),
removing and installing
The ECM uses stored functions and processing programs to
process the input signals from the sensors. These input sig-
nals are used to calculate the control (output) signals to the
actuators
(e.g., ignition coils, injectors).
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
- Disconnect negative (-) battery cable. Wait approximately
one minute.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions
in 001 General Warnings and Cautions.
4 Access engine control module (ECM):
Release
interlor ventilation filter cover latch (A) and re-
move cover.
Release plastic loclting tab
(B).
Rotate air duct inward (arrow) to unloclt from bulk head
and remove duct.
Release spring lock
(C) to remove lower filter housing.
Slide
f~lter hous~ng away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
- If testing ECM or connected components, use breakout box
to allow tests to be made with connector attached to ECM.
This prevents damage to small terminals in connector.
- - As an alternative, harness connector housing can be sepa-
rated so that electrical checks can be made from
back of con-
nector.
4 If replacing ECM, disconnect control module harness con-
nector (arrow) by releasing fastener and pivoting connector
up and off ECM.

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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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Fuel Injection I
4 Release spring clips (arrows) from fuel injectors and pull in-
jector electrical loom straight up to remove.
4 Check that ECM signal is present at injector connectors.
- Connect digital voltmeter to fuel injector harness plug.
Operate starter and
check for voltage pulse.
* Repeat for each injector.
- Remove fuel injectors by removing retaining clips
- Installation is reverse of removal:
Fit new O-rings when installing injectors. For ease of instal-
lation, lightly lubricate all fuel system O-rings with assem-
bly lubricant.
Check that injector electrical connections are correctly fit-
ted and that
injectors are fully seated prior to installing iuel
rail mounting bolts.
Mass air flow sensor (MAF), replacing
The MAF sensor is provided with operating power from the
ECM relay. Based on calculated intake air mass, the MAF
generates
avarying voltage (approx. 0.5 - 4.5 vdc) as an input
signal to the ECM.
4 Remove MAF sensor:
Remove upper air filter housing locking clips.
Unscrew and remove MAF sensor harness
(A).
Disconnect intake air temperature sensor harness (B).
Loosen hose clamp (C).
Remove upper filter housing with sensor.
- Installation is reverse of removal

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130-72
Fuel Injection
I Oxygen sensors, replacing
4 Four Bosch oxygen sensors (2 precatalytic converter sen-
sors and
2 post-catalytic converter sensors) provide a vary-
ing voltage signal
[0.2 vdc (max. lean) to 0.8 vdc (max. rich)]
to the ME
7.2 ECM representing oxygen content in the ex-
haust gas.
WARNING-
Exhaust manifolds and pipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
- Using a special oxygen sensor socltet, remove the threaded
sensors from the exhaust system.
- If not already applied, coat the new oxygen sensor threads
with an anti-seize compound before installation. Do not get
compound on the sensor tip.
Tightening torque
Oxygen sensor to exhaust system
50 Nm (37 ft-lb)
Fuel injectors, removing and installing
The ME 7.2 system uses ball seat type fuel injectors. This de-
sign
prov:des precise seal'ng when the iniector is closed
therebv eiminalinq raw HC (unb~rned fue ) formalion in tne
intake.-~he fuel inkctors areswitched on and off by the ECM
at the ground side.
- Remove plastic cover from above fuel rail. See100 Engine
Removal and Installation.
- Disconnected battery negative (-) cable.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given at the front of this manual. See 001
General Warnings and Cautions.
- Remove both ignition coil covers.
Disconnect ignition coil connectors.
Remove left and right ignition coil ground wires,
4 Remove fuel injector loom boxes.
Loosen mounting fasteners
(A).
Disconnect electrical plugs (B and D).

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( Mass Air Flow Sensor
1" Intake air temp. (NTC)
Sensor qround
Reference voltage . . . -., f fitr mass signal I
Fuel Injection I
Release fuel injector locking clips (arrow).
- Remove fuel injector loom boxes and lay to one side.
- Remove 4 fuel rail mounting fasteners.
4 Disconnect fuel line at quick-disconnect. To disconnect,
press in plastic collar (arrow) and separate fuel line.
WARNING -
Fuel may be expelled underpressure. Do not srnol(e or work
near heaters or
other fire hazards. Keep a fire extinguisher
handy. Before disconnecting fuel hoses, wrap a cloth around
fuel hose
to absorb anv leakinq fuel. Plug all open fuel lines.
- Lifl fuel rail and injectors straight up to remove.
- lnstallation is reverse of removal. Use new injector seals and
clamps during installation.
Mass air flow (MAF) sensor,
removing and installing
4 The MAF sensor is provided with operating power from the
ECM relay. Based on intake air mass, the MAF sensor gen-
erates a varying voltage (approx. 0.5
- 4.5 vdc) as an input
signal
back to the ECM. A separate intalte air temperature
sensor is not used.
- Removing MAF sensor:
Remove upper air filter housing locking clips
Unscrew and remove sensor harness.
Disconnect air temperature sensor harness.
Loosen hose clamp.
Remove upper filter housing with sensor.
- lnstallation is reverse of removal

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Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit
(LDP or DMTL), removing . . -
and installing
- Raise rear end of car and support safely.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floor jack is not adequate support.
- Remove left rear wheel and inner fender panel
Remove carbon canisterlfuel tank leak detection unit
(V-8 model shown):
Disconnect electrical harness connector
(A) from fuel tank
leak detection unit.
Pinch and remove quick-disconnect fittings at intake line to
air filter housing
(5) and hose to expansion tank (C).
* Remove mounting clamp and lower canister with fuel tank
leak detection unit.
Installation is reverse of removal.
Tightening
torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp
13 - 16 rnm dia 3 Nm (27 in-lb)
Running losses (312-way) valve,
removing and installing
The running losses (312-way) valve is located under the car
beneath the driver's seat, just ahead of the fuel filter. A protec-
tive covershieldsfuel system components from road hazards
and dirt.
The engine control module
(ECM) controls the operation of
the 312-way valve (pulse-width modulated). On engine start
up, the valve solenoid is energized for 20 seconds in order to
supply full fuel volume to the fuel rail.
After20 seconds, the
solenoid is deactivated and sprung closed (the bypass is
opened). This reduces the amount of fuel circulating through
the fuel rail and diverts the excess to return to the fuel tank
through the fuel pressure regulator.
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.