Vol 2 BMW 528i 2000 E39 Service Manual

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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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130-1 0
Fuel Injection
Remove MAF sensor:
Release clips from air filter housing
(A).
Disconnect harness connector (B).
Loosen intake boot clamp (C) and remove MAF sensor.
Note large sealing O-rings.
Installation is reverse of removal.
No adjustment to MAF sensor is possible.
Check intake hoses for cracks and vacuum leaks.
Engine coolant temperature (ECT) sensor,
testing and replacing
R
1 -4 The ECT sensor is located below cylinder 1 intake port
The ECT sensor is a dual temperature sensor. One circuit
provides coolant temperature information to the ECM while
the other circuit provides coolant temperature information to
the instrument cluster.
The ECM determines the correct ignition timing and
airlfuel
mixture required for the engine by monitoring an applied volt-
age
(5 vdc) to the sensor. The voltage drop across the sensor
varies as the coolant temperature (sensor resistance) chang-
es.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
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 MIL is il-
luminated when
OED II fault criteria are exceeded. The ECM
assumes asubstitute value
(80°C1 176°F) to maintainengine
operation. The ignition timing is set to a
conse~ativelsafe ba-
sic setting.
- Check ECT sensor resistance using a multimeter at sensor
terminals.
-
WARNING -
Due to risk of personal injury, be sure the engine is cold be-
fore disconnecting or reconnecting ECT sensor.
ECT sensor resistance @ 20" C (68°F) 2.2 - 2.7
Temperature gauge sensor resistance @ 20°C (~B"F)( 6.7 k

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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 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.

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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

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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

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/Fuel injection
Table b. Siemens MS 41.1 ECM pin assignments (continued)
85
86
87
88 CAN-Bus low
CAN-Bus high
Power supply
Diagnostic connector
(TxD)
inputloutput
inpuWoutput
input
input output Automatic transmission control module (AGS)
Automatic transmission control module (AGS)
Battery voltage from main relay terminal 87
Diagnostic TxD signal to pin 17 in data link connector

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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.