1998 BMW 528i diagnosis

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
. .
Fuel Injection
Check resistance of valve across valve terminals
Idle speed control valve coil resistance
Terminals
1 and 2 20 i2.0.
Terminals 2 and 3 20 i2.0.
Terminals 1 and 3 40 i4.0.
CAUTIOIG
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
- To remove valve, remove cable bracket mounting bolt and
idle speed control valve mounting bracket bolts from front of
throttle housing and remove idle speed control valve with at-
tached bracket.
NOTE-
When installing idle speed control valve, remove intake boot
sealing ring from valve and install into intake air boot. Then
install valve info sealing
ring.
Evaporative emissions control diagrams
MS 42.0 (LDP) ,-a"-
Evaporative emissions control,
(MS 42.0, MS 43.0)
E39 models with MS 42.0 or MS 43.0 engine are equipped
with a fuel system evaporative pressure leak diagnosis sys-
tem. The main component of this system is the leak diagnosis
pump (LDP or DM-TL). The function of either system is to
pressurize the fuel tank and the evaporative emission system
for the purpose of detecting leaks.

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection
M5.2 system features
The Bosch M5.2 system used on 1997 540i models uses an
88-pin control unit. The
M5.2 system has the following func-
tions and capabilities:
Fully sequential cylinder-individual fuel injection.
Integrated adaptive knock control.
Oxygen sensor fuel mixture control.
0 Self-diagnosis and emergency operation characteristics.
CAN-Bus link.
0 OED II functions (misfire detection, catalytic converter
monitoring, oxygen sensor monitor, and fuel tank ventila-
tion system).
Electronic vehicle immobilization via EWS.
One-touch starter function.
Control of characteristic map thermostat.
M5.2.1 system features
The Bosch M5.2.1 system is used on 1998 540i models. The
M5.2.1 control module utilizes the SKE (standard shell con-
struction housing) with 5 connectors and a combined total of
134 pins.
The M5.2.1 systefn has
tile following functions or capabilities:
Separate power supply relay for ignition coils. Leak diagnosis pump (LDP) control and feedback
rnonitor-
ing for evaporative system leak testing.
Fuel evaporative system providing ORVR (on-board refuel-
ing vapor recovery) compliancy.
Batterylalternator charge logic (idle speed varied with the
battery state of charge).
CAN-Bus communications with the instrument cluster
EWS
Ill "rolling code" ISN interface.
More sensitive ignition
knock sensors.
Pulse width modulated (P-W-M) Heating and
AIC (IHKA)
status signal.
Running loss (312-way) solenoid valve.

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection Evaporative fuel system pressure leak
diagnosis, overview
(M5.2.1 only)
1998 540i models are equipped with an evaporative fuel sys-
tem pressure leak diagnosis system. The main component of
this system is the leak diagnosis pump (LDP). The function of
the LDP is to pressurize the fuel tank and the evaporative
emission system for the purpose of detecting
leaks. This sys-
tem is capable of detecting a leak as small as 0.5 mm.
The LDP, located in the left rear wheel housing, is a unitized
component that contains the following:
Vacuum chamber. Pneumatic pump chamber.
DME activated vacuum solenoid
Reed switch (provides switched voltage
feedback signal to
ECM).
The vacuum supply line is in the wiring harness from the en-
gine compartment and runs down the driver's side of the vehi-
cle.
The canister vent valve is integrated into the LDP, which is
electrically controlled by the ECM. The canister vent valve is
opened to provide fresh air entry into the fuel system only dur-
ing purge operation.
- Purge operation characteristics:
Off idle through full throttle: purge valve opened by pulse
width modulated (PWM) control of the ECM. PWM duty cy-
cle varies by engine operating conditions
(e.g. warm idle,
purge valve opened slightly; cold
idleldecel with engine
temp
< 67" C, purge valve always closed).

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection
Table Pin
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
2
3
4
5
6
7
8
9
e. Bosch 5.2.1
Signal
Input
Input
Ground
Output Input- output
Output
Input- output
Input- output
Output
Connector
X60005
Output
Output
Output
Output
Ground
Output
Output
Output
Output
ECM pin assignments
Description
Not used
Not used
Voltage supply, terminal
15
Not used
Not used
Compressor ON signal from engine control module
(DME)
Ground
Not used
Diagnosis signal TXD
Communication
link (EWS)
Signal, leak diagnosis pump
Not used
CAN-Bus high
CAN-Bus low Not used
Not used
Start
signal
Terminal 1 signal
Terminal
1 signal
Terminal
1 signal
Terminal
1 signal
Ground
Terminal
1 signal
Terminal
1 signal
Terminal
1 signal
Terminal 1 signal Note
Fuse
F14
Heating
and AIC control module
Lealtage diagnosis pump
Data
iinit connector
Electronic immobilizer (EWS)
Leakage diagnosis pump (LDP)
CAN link
CAN link
Starter relay
Cylinder
7 ignition coil
Cylinder 8 ignition coil
Cylinder
2 ignition coil
Cylinder
3 ignition coil
Ground point
Cylinder
1 ignition coil
Cylinder
4 ignition coil
Cylinder 5 ignition coil
Cylinder
6 ignition coil

Downloaded from www.Manualslib.com manuals search engine
130-67
Fuel Injection /
ME 7.2 system overview
The Bosch ME 7.2 system is used on 1999 - 2002 540i mod-
els.
1 4 The ME 7.2 enaine control module (ECM). located on the
l and a combined total of 134 pins.
--__-- 1 I. 9 pin connector
12 3 4 5 2 24 pin connector
0lliC;nii, 3. 52 pin connector
4. 40 pin connector
5. 9 pin connector
The ME 7.2 system has the following functions or capabilities:
Electronic throttle control (EDK) integrates idle and cruise
control functions. ECM carries out all throttle and idle con-
trol functions directly via EDK system.
Leak diagnosis pump
(LDP) control and feedback monitor-
ing for evaporative system leak testing.
Batterylalternator charge logic (idle speed varies with bat-
tery state of charge).
CAN-Bus communications with instrument cluster.
EWS
111 (3.3) "rolling code" ISN interface.
Ignition
knock sensors.
DSC (dynamic stability control) torque reduction.
Monitoring and control of VANOS
(camshaft timing) with
active Hail sensor for camshaft position monitoring.
Integrated altitude sensor.
One touch engine start control
Single speed secondary air injection system.
Long life spark plugs.
IHKA auxiliary (electric) cooling fan control.
All emissions-related ME 7.2 electrical components are mon-
itored for faults. if driveability complaints are encountered or
the malfunction indicator
light (MIL) is illuminated, interrogate
fault memory using a compatible scan tool.
4 Use a break-out box for ME 7.2 system testing and diagnosis
at the control module
(break out box set: BMW special tool
90
88 6 121 300).
Electrically heated (characteristic
map) cooling system
DME Harness Connector thermostat.

Downloaded from www.Manualslib.com manuals search engine
130-74
I Fuel Injection
Evaporative system pressure leak
diagnosis, overview
The M62 TU engine is equipped wlth an evaporative fuel sys-
tem pressure leak diagnosis system. The main component of
this system is the leakdiagnosis pump (LDP). The function of
the LDP is to pressurize the fuel tank and the evaporative
emission system for the purpose of detecting leaks.
This system iscapable of detecting a
lealcas small as0.5 mm.
The LDP, located in the left rear wheel housing, contains the
following:
Vacuum chamber. Pneumatic pump chamber
DME activated vacuum solenoid
Reed switch (provides switched voltage
feedback signal to
DME).
The vacuum supply line is in the wiring harness from the en-
gine compartment and runs down the driver's side of the vehi-
cle.
The canister vent valve is
~ntegrated into the LDP, which IS
electrically controlled by the ECM. The canister vent valve is
opened to provide fresh air entry into the fuel system only dur-
ing purge operation.
- Purge operation characteristics:
Off idle through full throttle: purge valve opened by pulse
width modulated (PWM) control of the ECM. PWM duty cy-
cle varies by engine operating conditions
(e.g. warm idle,
purge valve opened slightly; cold
idleldecel with engine
temp
< 67" C. purge valve always closed).

Downloaded from www.Manualslib.com manuals search engine
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