2000 BMW 528i Speed sensor

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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.

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130-54
I Fuel Injection ldle speed control valve,
testing and replacing
ldle speed is maintained by the ECM through the idle speed
control valve. The idle control function compensates for en-
gine load and engine operating conditions. ldle speed is
adaptive through the ECM and no adjustments can be made.
Before checking valve, confirm that throttle position sensor is
working correctly.
NOTE-
The test given below is an electrical check only. It does not
check the mechanical operation of the valve. If the valve is
sticking, hanging up or is sluggish in operation, substituting a
Inown good valve is the best way to check it.
With engine running, check that idle speed control valve is
buzzing.
Turn on
AIC or shift car into drive. ldle should remain steady
or increase slightly.
If valve is not buzzing, or if idle decreases in step above, stop
engine and disconnect harness connector from valve.
4 Check resistance of valve across its terminals. Test values
are listed below.
ldle speed control valve coil resistance
Terminals
1 and 2 20 +2%
Terminals 2 and 3 20 +2Q
Terminals 1 and 3 40 +4%
NOTE-
If you suspect an intermittent fault, lightly tap the valve while
testing resistance.
With valve harness connector disconnected, check for bat-
tery voltage at redlwhite wire in connector with ignition on.
If . ~~ ~~
there is no voltage, check wiring between connector and 7 ECM relay. See ELE Electrical Wiring Diagrams.
NOTE- - The idle speed control valve receivespositive (+) battery volt-
age from the ECM (DME main) relay

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Fuel Injection
- If voltage is present as described above, check wiring be-
tween ECM and valve. If no wiring faults are found, check
ECM signal to valve.
- When replacing idle speed control valve, clean and inspect
all sealing areas.
. Inspect sealing ring in throttle body and replace if neces-
sary.
Throttle position sensor (TPS),
testing and replacing
The throttle position sensor (arrow) is mounted on the side
of the primary throttle housing and is directly connected to
the throttle valve shaft. The ECM sends a voltage signal to
the potentiometer-type sensor and monitors the voltage that
comes back. Resistance decreases (voltage increases) as
the throttle opens.
NOTE-
Do not confuse the TPS on the primary throttle housing with
the throttle switch on the
ASC secondary throttle housing.
4 Check throttle position sensor function by disconnecting har-
ness connector and checking across terminals. If any faults
are found, replace throttle position sensor.
Engine coolant temperature (ECT) sensor,
testing and replacing
Throttle position sensor (M62 engine)
The ECT sensor is located on the front of the engine in the
coolanVthermostat flange.The ECTsensor is a dual tempera-
ture 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. The voltage drop across the sensor
Test
value
5 vdc (approx.)
4.0 kR(approx.)
Continuously variable
from
1.0 to 4.0 kR
without interruption
Test
conditions
Harness connector
disconnected, ignition on
Harness connector
disconnected,
ignition on
Throttle plate rotated from idle to
full throttle position Test Terminal
Term.
1 at
harness
connector and ground
Term.
1 and term. 3 at
sensor
Term.
1 and term. 2 at
sensor

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130-59
Fuel Injection
:-- -i. Evaporative emissions
1.
control diagram (M5.2.1)
i 1
i I @ 1. ECM r.=.:-:, 2. Purge valve
3. Leak detection pump (LDP)
4. Liquid vapor separator
5. Purge canister
6. Filter
Bosch M5.2 ECM pin assignments
(M62 up to 911997)
Tabled. Bosch M5.2 ECM pin assignments
I' 1- 1. . . -
4 1 output / Cyl. 4 fuel injection valve I Cyl. 4 fuel injection valve (cycled ground)
Pin
1
2
3
i I
I
7 / output I Cyl. 6 fuel injection valve I Cyl. 6 fuel injection valve (cycled ground)
Type
output
output
output
I I ,
8 1 output I Malfunction indicator light (MIL) (USA only) I lliumlnated for exhaust gas related diagnostic trouble code
5
Component/function
Oxygen sensor heater signal
Idle speed control -closing winding
Cvl. 1 fuel iniection valve Note
DME heated oxygen sensor
1 splice
idle speed control valve (cycled ground)
Cvl. 1 fuel iniection valve lcvcled around)
6 1 ground I Fuel injection valve ground 1 Ground
output
9
Not
used
Not used
11
12
13
Cyl. 5 fuel injection valve
10 1 input I Electronic immobilizer (EWS) / Electronic immobilizer (EWS) control unit
input
Heated oxygen sensor signal Cyl.
5 fuel injection
valve (cycled ground)
output
input
input
16
Start signal Starter relay
NC compressor signal
Terminal
50 signal
Knock sensor signal
17 1 ground I Hot film mass air flow (MAF) sensor ground I Hot film mass air flow (MAF) sensor ground
output Heating and
A/C control module
Ignition switch
Knock sensor
Intake air temperature intake air temperature sensor (voltage value)

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130-60
/Fuel lniection
Tabled. Bosch M5.2 ECM pin assignments
Note
Pin
21
20 I output / Crankshaft position sensor (speed and position) I Crankshaft positionlrpm sensor
23
I - I I 29 1 output I Idle speed control - opening winding I Idle speed control valve (cycled ground)
Type
22
1 output I Cvl. 6 ignition signal (primary signal) I Cyl. 6 ignition coil (RZV adapter)
output
25
26
27
28
Component/function
24 1 outout I Cvl. 7 iqnition siqnal (primary signal) I Cyl. 7 ignition coil (RZV adapter)
output
4 outbut I' I - I Cyl. 3
fuel injection valve I Cyl. 3 fuel injection valve (cycled ground)
Camshaft position
sensor (cylinder reference)
output input
output
oround
30
31
32
ground Hall effect camshaft position sensor
Cyl. 3 ignition signal (primary signal)
output
I
Cyl. 3 ignition coil (RZV adapter)
. - . .. . .
Cyl. 2 ignition signal (primary signal)
Terminal 30
Engine control module relay
Ground for electronics and sensor shield
output
output
outout
Remaining output stages ground
(not iclnition and fuel iniection valves) Cyl.
2 ignition coil (RZV adapter)
Fuse carrier, engine electronics
Engine control module relay
Ground splice ,
Cyl. 2 fuel injection valve
Oxygen sensor heater signal
Cyl. 5
fuel injection valve
Cvl. 8 fuel iniection valve
AIC comuressor relav sianal
Heated oxygen sensor I in front of catalytic converter,
Heated oxygen sensor
iI in front of catalytic converter
Cyl.
5 fuel injection valve (cycled ground)
Cvl. 8 fuel iniection valve (cycled ground)
. -
Not used Ground point
Cyl.
2 fuel injection valve (cycled ground)
Heatinq and AIC control module (ground - compressor OFF)
38 Not used
40 39
1 I Not used
I'
I . I
I' I -. I
46 1 ground I Heated oxygen sensor signal (voltage 0.1-1.0 V) I Oxygen sensors
41
1 inuut I Knock
sensor signal I Knock sensor
input
I
I I
Instrument cluster
I' I I 55 1 ground I Ignition ground I Ground point
Knock sensor signal
43
1 I Not used I
Fuel reserve signal
42
Throttle position sensor
47
48
49
50
51
52
53
54
Knoclc sensor
input
45
1 outout I Hot film mass air flow sensor signal (0-5 V) I Hot film mass air flow sensor
Throttle position sensor signal
(0.4-4.2 V) 44
input
output
output
output
output
output
inout
I - I
Not used
Not used
Cyl. 1 ignition signal (primary signal)
Cyl. 5 ignition signal (primary signal)
Cyl. 4 ignition signal (primary signal)
Cyl. 8 ignition signal (primary signal)
Throttle position sensor
(c 5 V voltage supply)
Terminal 87
f> 10 V)
ignition switch
56
Cyl. 1 ignition coil (RZV adapter)
Cyi. 5 ignition coil (RZV adapter)
Cyi.
4ignition coil (RZV adapter)
Cyl. 8 ignition coil (RZV adapter)
Throttle position sensor
Fuse
F1
input Terminal 15 (> 10 V)

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-. -
Fuel Injection
I 68 1 / Not used
Table
d. Bosch
M5.2 ECM pin assignments
I I I
69 1 input I AIC system standby signal (> 10 V) 1 Heating and AIC control module
Pin
57
58
59
60
61
62
63
64
65 66
67
Type
input
input
input
input
I 70
72
73
74
Componentlfunction
Not used
Not used
Heated thermostat (characteristic map, cooling)
Programming voltage input (voltage
value)
Signal input Evaporative emission valve
Not used
Fuel pump relay (ground)
Not used
Not used
Not used
Not used
75
76
77
78
79
80
Note
Characteristic map, cooling
Data
llnlc connector
Evaporative emission valve
Fuel pump relay
71 1 ground I Control module ground I Ground splice
input
input
81
input input
input
input
output Not used
I
Knock sensor signal
Not used
Not used
Coolant temperature
82 1 I Not used
83
I I
Knock sensor
Dual temperature
swltch
Not used
Heated oxygen sensor signal (voltage
0.1-1.0 V)
Heated oxygen sensor
signal (voltage 0.1-1.0 V)
Crankshaft position sensor signal (speed and
position, AC voltage)
Right rear wheel speed signal
TD signal (engine speed)
85
I I I
Heated oxygen sensor II behind catalytic converter
Heated oxygen sensor
I behind catalytic converter
Cranitshaft positionlrpm sensor
ABSIASC control module
TD signal splice
84 1 / Not used 1
output
88
86
1 input-output 1 CAN-Bus high I Transmission conlrol module (AGS)
input-output
Injection signal
input-output Integrated instrument cluster control
module (IKE)
CAN-Bus low Transmission control module (AGS)
Data
linlc TxD Data link connector

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-
Fuel Injection
Table e. Bosch 5.2.1 ECM pin assignments
Pin
I~iqnal 1 Description 1 Note
I I I
46 llnput ICrankshaft position sensor Icrankshaft positionlrpm sensor
38
39
40
41
42
43
44
45 Ground Input
Output
Output
Output
Output
Ground
47
48
49
50
51
Not used
I Not used
52
Shield, knock sensor
Oil level
- thermal
Injection signal
injection signal
Idle speed control - opening winding
Idle speed control - closing winding
Not used
Ground
Ground
-- Ground Input
Ground
Ground Not used Knock sensor
Oil level sensor
Cylinder
4 fuel injector
valve
Cylinder
1 fuel injector valve
Idle speed control valve
Idle speed control valve
Shield, crankshaft sensor
5
6
7
12 Not used
Ground
Intake air temperature sensor
Connector
X60004
8
9 10
11
14 1 1 Not used I
Shield, knock sensor
Shield, sensor
I
Shield, sensor 3
Shield, itnock sensor
Input
- Knoclc sensor
Knock sensor
Knock sensor
Knock sensor
Instrument cluster
Output
2 llnput l~erminal 30 voltage supply /Megrated instrument cluster control module (IKE)
Alt. charge indicator signal, terminal 61 1
Not used
Start signal terminal
50
Not used
15
16
17
18
Output
Ignition switch
Not used
Not used
Activation of relay for fuel pump
Not used
19
Fuel pump relay
Output Not used
I I I 20 loutput ICARB signal /Data link connector
Not
used
Not used
Engine speed signal output (TD)
Not used
Light module
21
Cruise control module (Tempomat)
22 llnput I Right rear wheel speed signal /ABS/ASC or ABSIDSC control module
Oulput
Washer
fluid level,
brake fluid level

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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.