throttle position sensor BMW 528i 2000 E39 User Guide

Downloaded from www.Manualslib.com manuals search engine
130-1
130 Fuel injection
General ........................... .I3 0.2
Tools and test equipment .............. .I3 0.3
Warnings and cautions ................ .I3 0.5
Fuel Supply ....................... .I3 0.6
Relieving system fuel pressure .......... .I3 0.6
Siemens MS 41 . 1. ................... 1 30-7
ECM relay. testing .................... .I3 0.7
Mass air flow (MAF) sensor.
checking and replacing
................ .I3 0.9
Engine coolant temperature (ECT) sensor.
testing and replacing
.................. 130-10
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.1 1
Throttle position sensor (TPS).
testing and replacing
.................. 130-1 2
ldle speed control valve.
checking and replacing
............... .I3 0.1 3
Fuel injectors. checking and replacing .... 130-15
Evaporative emissions. overview ....... .I3 0.1 6
Secondary air injection. overview ....... .I3 0-17
Engine control module (ECM).
removing and installing
................ 130-18
Siemens MS 41.1 ECM pin assignments . .I3 0.19
Siemens MS 42.0 and MS 43.0. ..... .I3 0.23
ECM relay. testing ................... .I3 0.27
Mass air flow (MAF) sensor.
checking and replacing
............... .I3 0.28
Engine coolant temperature (ECT) sensor.
testing and replacing
................. .I3 0.30
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.31
MS 42.0 throttle valve assembly. replacing . 130-32
MS 43.0 throttle valve assembly. replacing . 130-35
Throttle cable. adjusting (MS 42.0) ...... .I3 0.38
ldle speed control valve. checking
and replacing
....................... .I3 0.38
Evaporative emissions control diagrams . . 130- 39
Evaporative emissions control.
(MS
42.0 and MS 43.0). .............. .I3 0.39
Engine control module (ECM).
removing and installing
................ 130-40
Siemens MS 42.0 and MS 43.0
ECM pin assignments ................. 130-41
Bosch M5.2 (M62 up to 911997)
BOSC~ M5.2.1 (M62 911997 to 911998) 130-46
M5.2 system features ................. 130-47
M5.2.1 system features ............... 130-47
ECM relay. testing ................... 130-49
Oxygen sensors. checking ............. 130-51
Fuel injectors. checking and replacing .... 130-52
Mass air flow (MAF) sensor. replacing .... 130-53
ldle speed control valve. testing
and replacing
....................... 130-54
Throttle position sensor (TPS).
testing and replacing
................. 130-55
Engine coolant temperature (ECT) sensor.
testing and replacing
................. 130-55
Intake air temperature (IAT) sensor.
testing and replacing
................. 130-57
Auxiliary throttle valve (ADS) (M62 and
M62 TU engine). replacing ..... 130-57
Evaporative system pressure
leak diagnosis. overview
(5.2.1 only) ..... 130-58
Bosch 5.2 ECM pin assignments
(M62 UP to 911 997) ................... 130-59
~osch 5.2.1 ECM pin assignments
(M62 911 997 to 911 998) ............... 130-62
BOSC~ ME 7.2 ..................... 1 30-66
ME 7.2 system overview ............... 130-67
EDK adaptation ..................... 130-69
ECM relay. checking .................. 130-69
Engine coolant temperature
(ECT) sensor. testing
................. 130-71
Engine coolant temperature
(ECT) sensor. replacing
............... 130-71
Oxygen sensors. replacing ............. 130-72
Fuel injectors. removing and installing .... 130-72
Mass air flow (MAF) sensor.
removing and installing
................ 130-73
Evaporative system pressure
leak diagnosis. overview
............... 130-74
Secondary air injection. overview ........ 130-75
Bosch ME 7.2 ECM pin assignments .... 130-76

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
I Fuel Injection
Table b. Siemens MS 41.1 ECM pin assignments (continued)
Pin
l~iqnal I Componentlfunction 1 Notes I - I I
5 loutput I Fuel injector control, cyl. 2 I Pulsed ground (pulse width in ms), cyl. 2 I I I
6 loutput /Fuel injector control, cyi. 1 I Pulsed ground (pulse width in ms), cyl. 1
I I I
14 linput I Intake air temp. sensor (IAT) I Intake air temperature signal
- 7
8
9
10
11
12
13
ground
input
output
input
input
15
16
17 18
19
20
21
22
I - I I
35 loutput /Secondary air injection ISecondary air inj. pump relay control
25
26
27
28
29
30
31
32
33
36
/output I Engine speed output IEngine speed signal
Mass air flow sensor
Mass air flow sensor
instrument cluster
Engine coolant
temp.
(ECT) sensor
Not used
Throttle position sensor (TPS)
Not used
input
input
input
input
output
output
out~ut
37 1 - /Not used I
Mass air flow sensor signal
Mass air flow sensor signal
Fuel consumption signal
ECT signal
Throttle position signal
ground
input
output
ground
output
output
output
ground
output
Traction control (rear engine speed signal) Automatic climate control
Not used Electronic immobilizer control (EWS)
Auto. climate control
(AIC on input)
instrument
cluster
Camshaft actuator control (VANOS)
Fuel iniector control, cvl.
3
AES/ASC module
Automatic climate control instrument cluster (CARE signal)
Camshaft actuator (VANOS), switched ground
Pulsed ground (pulse width in
ms), cyl. 3
Oxygen sensor heater (no. 1 in front of catalytic
converter)
Power supply (terminal
30)
Idle speed control valve
Ground
Ignition coil control, cyl.
1
Ignition coil control, cyl. 3
Ignition coil control, cyl. 5
Ground Fuel injector control, cyl.
5
Oxygen sensor heater ground
Battery voltage
(E+) at all times
Pulsed ground-open signal (See pin
53)
Ground
Primary signal, ignition coil
1
Primary signal, ignition coil 3
Primary signal, ignition coil 5
Ground
Pulsed ground (pulse width in ms), cyl
5

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
- -.
Fuel Injection
SIEMENS MIS 42.0 AND 43.0
When system faults are detected, a diagnostic trouble code
(DTC) is stored in the engine control module (ECM). The MIL
also illuminates
if an emissions-related fault is detected.
When faults arise, or
if the malfunction indicator lamp (MIL) is
illuminated, begin troubleshooting by connecting BMW ser-
vice tester
DISplus, MoDiC, GTI or equivalent scan tool. The
capabilities of OBD
II software has the potential to save hours
of diagnostic time and to help avoid incorrect component re-
placement and possible damage to system components.
CAUTION-
* The tests in this section may set fault codes (DTCs) in tlie
ECM and illuminate the MIL. After all testing is completed,
access and clear DTC fault
memory using an OBD I/ or
BMW compatible scan tool. See
OBD On-Board Diag-
nostics.
Only use a
dgital multimeter for electrical tests.
Relay positions can vary. Be sure to confirm
relayposi-
tion by identifying the wiring in the socket using the wir-
ing diagrams found in
ELE Electrical Wiring
Diagrams.
NOTE-
- OBD I1 fault memory. (including an illuminated MIL! can
only be reset using the special 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
20-pin DLC is discontinued on models after
6/2000.
The 1 &pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
The MS
42.0 and MS 43.0 systems manage the following
functions.
- Air:
Idle speed valve
Electronic throttle
Hot film mass air flow (MAF) sensor
Resonance-turbulence intake control
- Fuel:
* Fuel supply
Running losseslnon return
Fuel injection

Downloaded from www.Manualslib.com manuals search engine
130-28
Fuel Injection
ECM Relay
4 Check for voltage at terminal 6 (30) at reiay socket
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 610 Electri-
cal
Component Locations.
- Reinstall relay and turn ignition on. Gain access to back side
of reiay socket and check for ground at terminal
4.
If ground is present continue testing.
If ground is not present, signal
from ECM is missing. Check
wire between ECM and relay.
- With ignition on and reiay installed, check lor battery voltage
at terminal
2.
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and
ail earlier tests are OK,
relay is faulty and should be replaced.
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.
Mass air flow (MAF) sensor, checking and
replacing
4 The hot f~lm mass air flow (MAF) sensor sends a varying volt-
age (approx. 0.5 - 4.5 vdc) to the ECM representing the mea-
sured
Intake air. The alr mass input signal is produced
electron~caily uslng an electrically heated metal fllm in the air
flow stream.
The ECM relay provides the operating voltage to the MAF
sensor. As air
flows through the sensor, the film is cooled. To
maintain the film at a constant temperature, additional current
is necessary. It is this additional current that is the basis lor
the input signal.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using the throttle position and engine rpm
inputs. A faulty MAF sensor illuminates the MIL.

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection
MS 43.0 throttle valve assembly, replacing
The electronic throttle valve assembly forthe MS43.0 system
is referred to as
EDK (electronic throttle valve). There is no
mechanical (cable) link between the accelerator pedal and
the throttle plate.
< The accelerator pedal module (PWG) at the pedal assembly
communicates the pedal position directly to the ECM. The
module provides two variable voltage signals (via two Hail
sensors) to the ECM for pedal position and rate of movement.
NOTE-
The EDK unit is non-adjustable and must be replaced as a
complete unit if found to be faulty
If replacing the
EDK unit, the adaptation values stored in
the
ECM must be cleared and the new unit initialized using
BMW special service tools.
CAUTIOIG
If the adaptation process is not completed correctk the en-
qine will not start
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
< Remove complete air filter housing:
- Disconnect electrical harness connector on mass air flow
sensor
(A).
Disconnect vacuum line at intake boot (6).
Loosen intaite air duct clamp (C).
Remove filter housing mounting screws.
Disconnect air duct and lift complete air filter housing and
MAF sensor out of engine compartment, pulling it forward
away from throttle housing.