Electrical component locations BMW 528i 2000 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
100-6
( Engine-General
The main grounds for the fuel and ignition circuits of the DME
system are illustrated below; see 610 Electrical Component
Locations for additional ground and component locations.
4 Ground for engine management system in right rear of en-
gine compartment on E-box bulkhead (arrow).
6-cylinder models: Grounds
for ignition coils (arrows)
4 V-8 models: Grounds for ignition coils, at cylinders 3
(arrow) and 7.
4 Fuel pump ground (arrow) below right tail light in luggage
compartment.
NOTE-
Ground location for sedan shown, wagon models may
differ.

Downloaded from www.Manualslib.com manuals search engine
Cylinder Head Removal and Installation
4 If applicable, remove secondary air injection pump:
Disconnect hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
Disconnect electrical harness from bottom of secondary
air injection pump.
Remove mounting bracket from strut tower.
4 Remove ignition coils:
* Disconnect ignition coil harness connectors.
Remove coil mounting fasteners.
Remove coils.
* Remove ground straps.
CA UTIOI\C
Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.
Set coil harness to side of engine compartment
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
ltets should be reinstalled in their original locations. Male
note of their arrangement during removal.
- Remove spark plugs
4 Remove oil baffle cover from above intake camshaft.

Downloaded from www.Manualslib.com manuals search engine
.-
ignition System
Disabling ignition system
The ignition system operates in a lethal voltage range and
should be disabled any time engine service or repair work is
being done that requires the ignition to be switched on.
The engine management system can be disabled by remov-
ing the DME main relay. The relay is located in the electronics
box (E-box) in the left rear of the engine
compartment, be.
neath the interior microfilter housing.
CAUTION- Relay locations may
vary. Use care when identifying relays.
See
610 Electrical Component Locations.
Checking for spark
CAUTION-
If
a spark test is done incorrecth damage to the Engine Con-
trol Module
(ECM) or the ignition coils may result.
NOTE-
Spark plug replacement is covered in 020 Maintenance.
Check~ng for spark is d~fflcult on englnes wlth d~str~butorless
ignition systems.
Try removing the spark plugs and inspecting for differences between them.
A poor-firing plug may be wet with fuel and/or ~. - ~
black and sooty, but not always. If a coil is not operating, the
engine management system will electrically disable the fuel
injector to that cylinder. The key is to look for differences be-
tween cylinders.
Ignition coil assembly, testing and
replacing
C4 UTION-
Use a digital multimeter for the following tests. I
- Remove plastic engine cover from top of valve cover by pry-
ing off bolt covers and removing cover mounting bolts.
- Raise car slowly while constantly checking position of jack
and car.
- Disconnect harness connector from coil. Connect multimeter
between terminal 15
(+) in connector and ground.
4 Terminal identification are typically molded into connector. In
photo, terminals are from left to right: 1,
4a, 15.

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
-
Fuel Injection
ECM relay, testing
The engine control module (ECM) relay is energized via the
ECM and supplies battery positive
(Bc) power to many of the
engine management components and subsystems. If this re-
lay is faulty, the engine will not start.
NOTE-
The ECM relay is also referred to as the DME main relay
ECM relay powers:
ECM
Ignition coils
* Fuel injection
Evaporative leak detection pump
Idle air actuator
- Camshaft sensors Evaporative emissions valve
Hot film mass air flow sensor
Fuel pump relay
Oxygen sensor heaters
4 Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate duct inward (arrow) to unlock 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.
With ignition off, remove ECM relay (arrow) in electronics
box (E-box) at rear of engine compartment, right side.
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.

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 Tank and Fuel pump]
Remove fuel pump
relay (arrow).
4 Connect relay socitet terminal 6 (redlviolet wire) to relay
socket terminal
2 (whitelblue wire) with a fused jumper wire.
After completing tests, remove jumper harness.
CA
UTIOG
Relay locations may vary Use care when identifying relays
and making electrical checks at
the fuse/relay panel. See
610 Electrical Component Locations for additional re-
lay information.
The fuel pump relay has a 1.5
md red/violet wire at
terminal
6 in the relay socket. Terminal2 has a 2.5md
white/blue wire. See ELE Electrical Wiring Diagrams
for additional wiring information.
NOTE-
* The fuel pump will run as soon as the jumper wire Is at-
tached.
The jumper wire should be 1.5
md (14 ga.) and include
an in-line fuse holder with a 15A fuse. To avoid
fuse/relay
panel damage from repeated connecting and disconnect-
ing, also include a toggle switch in the jumper harness.
- If pump does not run with jumper installed, fault could be in
fuel pump, fuses
F31 or F22 1 F54, or wiring to pump. Check
pump, fuses and its wiring as described below.
Fuel pump electrical circuit, testing
- The test given below assumes that the fuel pump relay circuit
is functioning correctly as described earlier. Access to the
pump is from below the rear seat bottom cushion.
- Remove rear seat lower cushion by lifting front edge off left
and right catches.

Downloaded from www.Manualslib.com manuals search engine
250-7
Gearshift ~inka~el
Automatic shiftlock, checking function (automatic transmission)
The automatic shiftlock uses an electric solenoid to lock the
selector lever in Park or Neutral. Depressing the foot bralte
with the ignition on energizes the solenoid, allowing the lever
to be moved into a drive gear. The solenoid is energized only
when the engine speed is below 2,500 rpm and the vehicle
speed is below
3 mph (5 kph). The solenoid is mounted in the
right side of the selector lever housing.
... nir r
Shiftlock
4 Automatic shiftlock prevents drive gear selection until brake
pedal is depressed.
With engine running and car stopped, place selector lever
in Park or Neutral.
Without depressing bralte pedal, check that selector lever
is
loclted in position (Parlt or Neutral).
Depress brake pedal firmly. Solenoid should click audibly.
Check that selector lever can now be moved out of
Parlt or
Neutral.
parking
brake on and with extreme caution.
solenoid
0012713
With selector
lever in Park or Neutral and bralte pedal de-
pressed, raise engine above 2,500
rpm. Check that selec-
tor lever cannot be moved out of Park or Neutral.
If any faults are found check the electrical operation of the
shiftloclt solenoid and checlt for wiring faults to or from the
transmission control module (TCM). See
610 Electrical
Component Locations and ELE Electrical Wiring
Dia-
grams.
NOTE-
NOTE-
The solenoidis controlled via the TCM, using brake pedalpo-
sition, engine speed, and road speed as controlling inputs.
The
next test should be performed in an open area with the

Downloaded from www.Manualslib.com manuals search engine
Hood, raising to service position
CAUTION-
Do not switch on the windshield wipers with the engine
hood raised. As a precaution, remove the wiper
motor
fuse. See 610 Electrical Component Locations.
The
hoodis heavy Before removing the hoodsupports,
be sure to have an assistant help support the hood.
< Open hood fully. With the help of a partner, support hood and
remove retaining clips (arrow) on upper end of pressurized
lifting struts. Pull struts off hood.
< Raise hood to service position and loclc in position by placing
bolts (arrow) in right and
left hinges.

Downloaded from www.Manualslib.com manuals search engine
51 5-2
/Central Locking and Anti-Theft
This section covers repair information for door, trunk and car-
go compartment locks, central locking, electronic
immob~liza-
tion (EWS) and anti-theft alarm (DWA).
€39 cars are equipped with sophisticated self-diagnostic elec-
trical systems. When experiencing malfunctions relating to
central locking. EWS or anti-theft systems, start the diagnosis
process using the
BMW service tester DIS, GT 1, MoDiC or
equivalent scan tool. An advanced diagnostic scan tool can
usually pinpoint electrical faults quickly and safely.
Additional electrical information can be found in:
610 Electrical Component Locations
ELE Electrical Wiring Diagrams
Central locking in E39 vehicles controls the door
locks, trunk
or tailgate lock and fuel filler flap lock. The control module for
the Central Body Electronics system (ZKE
Ill), lknown as the
General Module (GM
Ill), controls central locking.
ZKE
Ill manages the following central locking related func-
tions:
Central locking
* Keyless entry
Key memory
Power trunk release
Electric opening of tailgate
DWA alarm system
Diagnosis
General Module
4 The General Module (GM) (arrow) is responsible for the op-
eration of central body electronics. The GM is located behind
the glove compartment.
Based on input information, the GM uses internal transistors
to switch current flow (providing voltage or ground) through
circuits and actuators. Actuators are the final controlling de-
vices used by GM to operate or control various output func-
tions such as relays and motors.
The accompanying schematic, Central locking inputs and
outputs, illustrates the GM central locking system.