light BMW X5 2002 E53 M62TU Engine Workshop Manual

TABLE OF CONTENTS
SubjectPage
M62TU Engine . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
Vanos Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IHKA System Auxilary Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DME-ME 7.2 Engine Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IPO ME 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Integral Electronic Throttle System (EML). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Input Signal/Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Camshaft Position Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hot Film Air Mass Sensor (HFM 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Integrated Ambient Barometeric Pressure Sensor. . . . . . . . . . . . . . . . . . .21
Radiator Outlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DSC III Road Speed Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Accelerator Pedal Sensor (PWG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EDK Throttle Position Feedback Signal. . . . . . . . . . . . . . . . . . . . . . . . . . 24
MFL Cruise Control Data Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Brake Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Can Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Output Control Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .27
E-Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Secondary Air Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Auxiliary Fan Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Electric Throttle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DM-TL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 31
Leak Diagnosis Test Precondition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

18
PWG SIGNAL MONITORING & PWG FAILSAFE OPERATION:
• As a redundant safety feature the PWG provides two separate signals from two integral
potentiometers (Pot 1 and Pot 2) representing the driver’s request for throttle activation.
• If the monitored PWG potentiometer signals are not plausible, ME 7.2 will only use the
lower of the two signals as the driver’s pedal request input providing failsafe operation.
Throttle response will be slower and maximum throttle position will be reduced.
• When in PWG failsafe operation, ME 7.2 sets the EDK throttle plate and injection time
to idle (LL) whenever the brake pedal is depressed.
• When the system is in PWG failsafe operation, the instrument cluster matrix display will
post “Engine Emergency Program” and PWG specific fault(s) will be stored in memory.
EDK FEEDBACK SIGNAL MONITORING & EDK FAILSAFE OPERATION:
• The EDK provides two separate signals from two integral potentiometers (Pot 1 and Pot
2) representing the exact position of the throttle plate.
• EDK Pot 1 provides the primary throttle plate position feedback. As a redundant safe-
ty feature, Pot 2 is continuously cross checked with Pot 1 for signal plausibility.
• If plausibility errors are detected between Pot 1 and Pot 2, ME 7.2 will calculate the
inducted engine air mass (from HFM signal) and only utilize the potentiometer signal that
closely matches the detected intake air mass.
- The ME 7.2 uses the air mass signalling as a “virtual potentiometer” (pot 3) for a
comparative source to provide failsafe operation.
- If ME 7.2 cannot calculate a plausible conclusion from the monitored pots (1 or 2
and virtual 3) the EDK motor is switched off and fuel injection cut out is activated
(no failsafe operation possible).
• The EDK is continuously monitored during all phases of engine operation. It is also
briefly activated when KL 15 is initially switched on as a “pre-flight check” to verify it’s
mechanical integrity (no binding, appropriate return spring tension, etc). This is accom-
plished by monitoring both the motor control amperage and the reaction speed of the
EDK feedback potentiometers. If faults are detected the EDK motor is switched off and
fuel injection cut off is activated (no failsafe operation possible). The engine does how-
ever continue to run extremely rough at idle speed.
• When a replacement EDK is installed, the ME 7.2 adapts to the new component
(required amperage draw for motor control, feedback pot tolerance differences, etc).
This occurs immediately after the next cycle of KL 15 for approximately 30 seconds.
During this period of adaptation, the maximum opening of the throttle plate is 25%.

24
EDK THROTTLE POSITION FEEDBACK SIGNALS
The EDK throttle plate position is monitored by two integrated potentiometers. The poten-
tiometers provide DC voltage feedback signals as input to the ME 7.2 for throttle and idle
control functions.
Potentiometer signal 1 is the primary signal, Potentiometer sig-
nal 2 is used as a plausibility cross-check through the total
range of throttle plate movement.
EDK FEEDBACK
SIGNAL MONITORING & FAILSAFE OPERATION:
• If plausibility errors are detected between Pot 1 and Pot 2, ME 7.2 will calculate the
inducted engine air mass (from HFM signal) and only utilize the potentiometer signal that
closely matches the detected intake air mass.
- The ME 7.2 uses the air mass signalling as a “virtual potentiometer” (pot 3) for a
comparative source to provide failsafe operation.
- If ME 7.2 cannot calculate a plausible conclusion from the monitored pots (1 or 2
and virtual 3) the EDK motor is switched off and fuel injection cut out is activated
(no failsafe operation possible).
• The EDK is continuously monitored during all phases of engine operation. It is also
briefly activated when KL 15 is initially switched on as a “pre-flight check” to verify it’s
mechanical integrity (no binding, appropriate return spring tension) by monitoring the
motor control amperage and the reaction speed of the EDK feedback potentiometers.
If faults are detected the EDK motor is switched off and fuel injection cut off is activat-
ed (no failsafe operation possible). The engine does however continue to run extreme-
ly rough at idle speed.

25
MFL CRUISE CONTROL DATA SIGNAL
The ME 7.2 control module provides the FGR cruise control function. Throttle activation is
provided by ME 7.2 automatic control of the EDK and monitoring of the throttle plate posi-
tion feedback potentiometer signals.
All of the familiar driver requested cruise control function requests are provided to the ME
7.2 control module via the MFL control module on a single FGR data signal wire.
BRAKE LIGHT SWITCH
The Electronic Brake Switch (Hall effect) provides brake pedal position status to the ME 7.2.
The control module monitors both the brake light and a separate brake light test switch cir-
cuits for plausibility.
When the brake pedal is pressed the brake light segment of the switch provides a ground
signal. Simultaneously, the brake light test switch (located in the same housing) provides a
high signal.

28
SECONDARY AIR INJECTION
Secondary air injections required to pre-heat the catalytic converters for OBD II compliance.
The system consists of the same components as previous systems with V8 specific loca-
tions.
The DME ME7.2 control unit controls the vacuum vent valve and the secondary air injec-
tion pump relay separately but simultaneously.
The secondary air pump operates at a start temperature of between 10°C and 40°C. It con-
tinues to operate for a max. of 2 minutes at idle speed.
ME 7.2 contributes an additional correction factor for secondary air “on” time with the addi-
tional input from the integral ambient barometric pressure sensor.
This sensor provides a base value to calculate the air mass being
injected into the exhaust system. This helps to “fine tune” the sec-
ondary air injection “on” time, optimizing the necessary air flow
into the exhaust system which reduces the time to catalytic con-
verter light-off.
VACUUM
VACUUM
VENT VALVENONPUMP/MOTOR
AIR PUMP SUPPLY HOSE
AIR DELIVERY TUBE WITH O RING
CONNECTIONS TO CYLINDER HEADS
VACUUM
CONTROL TO
NON RETURN
VA LV E

29
AUXILIARY FAN CONTROL
The Auxiliary Fan motor incorporates an out-
put final stage that activates the fan motor at
variable speeds.
The auxiliary fan is controlled by ME 7.2. The
motor output stage receives power and
ground and activates the motor based on a
PWM signal (10 - 100 Hz) received from the
ME 7.2.
Similar to the aux fan in the E46 with MS 42.0
control, the fan is activated based on the fol-
lowing factors:
• Radiator outlet temperature sensor input exceeds a preset temperature.
• IHKA signalling via the K and CAN bus based on calculated refrigerant pressures.
• Vehicle speed
• Battery voltage level
When the over temperature light in the instrument cluster is on (120
OC) the fan is run in the
overrun function. This signal is provided to the DME via the CAN bus. When this occurs
the fan is run at a frequency of 10 Hz.
FAN MOTOR MODULE
POWER, GROUND & SIGNAL WIRES