Obd BMW 540i 1998 E39 Owner's Manual

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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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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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- -.
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

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Fuel Injection
- Ignition:
Direct ignition
Knock control
4 Primary1 secondary ignition monitoring
- Emissions:
OBD II compliance
Secondary air injection
Pre- and post-catalyst oxygen sensors
0 Electrically heated DME-mapped thermostat
Misfire detection
Evaporative emission control and
leak detection
Malfunction indicator light (MIL)
Performance controls:
Dual VANOS control
Output of injection signal (TI) for fuel economy gauge
Output of engine rpm (TD) for tachometer
AIC compressor control
0 Electric radiator cooling fan
CAN-Bus communication
Stability and traction system
(ABSIASCIDSC) interlace
Electronic immobilizer (EWS)
Cruise control
ECM programming

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Fuel Injection
- Installation is reverse of removal:
Use new copper sealing washers when installing sensor.
Replace any lost coolant.
Tightening torque
Temperature sensor to cylinder head
13 Nm (10 ft-lb)
Intake air temperature (IAT) sensor,
testing and replacing
4 The intake airtemperature (IAT) sensor, located at the top of
I the intake manifold, adapts (fine tunes) the fuel mixture and i
T engine timing based on varying intake air temperatures.
i If the intaite air temperature signal is implausible, a fault code
! is set and the MIL is illuminated when OBD I1 fault criteria are
I exceeded. The ECM then operates the engine using the ECT
i sensor sional inout as a back uo.
type sensor. In other words,
a> the temperature rises, resis-
tance through the sensor decreases.
lid I The IATsensor can be tested using a multimeter:
/IAT sensor resistance at 20'C (68°F) 2.2 - 2.7 kd
Remove engine cover by prying off plastic trim caps (arrows)
and removing nuts below caps.

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130-46
Fuel Injection
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
OED 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.
CA UTIOiU-
The tests in this section may set fault codes (DTCs) in the
ECM and illuminate the MIL. After ail testing is completed,
access and clear DTC fault
memory using an OED I/ or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
Only use a digital
multimeter for electrical tests.
Relay positions can vary. Be sure to confirm relay
posi-
. tion by identifying the wiring in the socket using the wir-
ing diagrams-found in ~~~~lectrical Wiring
Diagrams.
NOTE-
OED 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 link connector
(DLC) is in the right rear of the engine compartment.
The 16-pin OBD
I1 diagnostic connector (arrow) is located
inside the car on
the lower left dash panel.

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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
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, GTl 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.
CA UTIOI\C
The tests in this section may set fault codes (DTCs) in the
ECM and illuminate the MIL. After all testing is completed,
access and clear DTC fault memory using an OBD
I1 or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
. Only use a digital multimeter for electrical tests.
Relay positions can vary. Be sure to confirm relay posi-
tion by identifying the wiring in the
socket using the wir-
ing diagrams found in ELE Electrical Wiring
Diaqrams.
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.
0 The BMW-dedicated 20-pin diagnostic link connector
(DLC) is in the right rear of the engine compartment. The
20-pin DLC was eliminated on models after
6/2000.
The 16-pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.

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Fuel Injection I
Engine coolant temperature (ECT) sensor,
testing
The ECT sensor is located on the front of the engine in the
coolant~thermostat flange. The ECT sensor is a dual temper-
ature sensor. One circuit provides coolant temperature infor-
mation 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. Thevoltage 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 OBD
II fault criteria are exceeded. The ECM
assumes a substitute value
(80" C/ 176°F) to maintain engine
operation. The ignition timing is set to a
conse~ativelsafe ba-
sic setting.
Disconnect harness from
ECTsensor (A) at coolant flange at
front of engine.
- Check 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.
I ECT sensor resistance @ 20" C (68°F) I 2.2 - 2.7 lkCi
Engine coolant temperature (ECT) sensor,
replacing
I WARNING-
/ Due to risk ofpersonal injury, be sure the engine is cold be- I
I fore replacin~~~~sensor. -
-
I
- Disconnect ECT sensor harness.
- 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 (10 it-lb)

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Fuel Injection I
Connector X60004 (continued)
8 10
11
12
13
14
15
16
9
Output 0
Input
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
llnput lsignal l~oolant outlet temperature sensor
Output
Output
Ground
Input
Output
I I - I
40 /output Istart signal Istarter relay
Pedal position sensor (PWG), signal
Output Input
Output
input
Input
Input
Input
Input
Input
input
Input
Output
Input/-output
Input/-output
37
Connector X60003
Pedal position sensor
Fuel pump relay, activation
Oil pressure indicator Pedal position sensor (PWG), ground
Pedal position sensor (PWG), signal
Pedal position sensor (PWG), power supply
Not used
Not used Fuel
pump relay
Instrument cluster
Pedal position sensor
Pedal position sensor
Pedal position sensor
Engine speed signal output (TD)
Not used
Signal
back-up light
DM-TL (diagnostic module,
tank leakage)
Signal oil level sensor
Right rear wheel speed, signal
Clutch pedal position switch, signal
Brake light switch, signal
Not used
Voltage supply, terminal
15
Data link, MFL (multi-function steering wheel)
Brake light test signal
AJC compressor signal
DM-TL (diagnostic module, tank
leakage)
Not used
Diagnosis signal
TxD
Communication link (EWS)
Not used
Not used
CAN-BUS hiqh
38 1 Ground l~round I Coolant outlet temperature sensor
OED II plug
Integrated instrument cluster control module (IKE)
Light module
ABSIDSC control module
Clutch pedal position switch
Brake light switch
Fuse
F14
Airbag contact coil spring
Brake light switch
Heating and
A/C control module
OBD
II plug
Electronic immobilizer (EWS)
CAN-Bus link
CAN-Bus link
Input/-output CAN-Bus low