2001 BMW 525i 20 pin

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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.

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130-76
Fuel Injection
Bosch
ME 7.2 ECM pin assignments
Bosch ME 7.2 ECM connectors
X60001
X60002
X60003
X60004
X60005
Table e. Bosch ME 7.2 ECM pin assignments
Connector
X60001
I I I
8 1 lnput [Terminal 87 voltage supply I Fuse F1
9-pin, Black
24-pin, Black
52-pin, Black
40-pin, Black
9-pin,
Blaclc
I I I
9 I NO^ used I
Notes
Ground connector
X6460
Ground connector X6460
Pin 1
2 3
4
5
Connector X60002
Ground connector X6460 6
Pin
/Type I Descriptionlfunction 1 Notes
Type
Ground
Ground
7 llnput l~errninai 30 voltage supply I Fuse F4
Descriptionlfunction
Not used
Not used
Not used
Ground Ground
Ground Ground
1
2
3
4
5
6
7
8
9
10
11
12
13
. . - Ground Input
Input/
output
input/
Output
Ground
Ground
Ground
Ground
Ground
Ground Heated oxygen sensor, heater ground
Back-up
light signal
CAN-BUS Low
CAN-Bus High
Not used Not used
Heated oxygen sensor, heater ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Not used
Heated oxvaen sensor, heater
ground
Heated oxygen sensor II behind catalylic converter
Baclcup light switch
Automatic transmission control module (AGS)
Automatic transmission control module (AGS)
Heated oxygen sensor
I behind catalytic converter
Heated oxygen sensor
II behind catalytic converter
Heated oxygen sensor I in front of catalytic converter
Heated oxygen sensor
II in front of catalytic converter
Heated oxygen sensor
I behind catalytic converter
Heated oxygen sensor
Ii in front of catalytic converter

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Fuel lnjection
I 1- I
4 /output l~em~erature signal. E-box fan I E-box fan
Connector
X60002 (continued)
14
15
16
17
18
19
20
21
22
23
24
5
6
7
8
9
10
11
12
13
14
15
16
Input
Input
Input
Input
Ground
Output Heated
oxygen sensor signal
Heated oxygen sensor signal
Heated oxygen sensor signal
Heated oxygen sensor signal
Not used
Heated oxygen sensor, heater ground
Not used
Not used
Not used
Terminal 85 control
Not used Heated oxygen sensor
II behind catalytic converter
Heated oxygen sensor
I in front of catalytic converter
Heated oxygen sensor
I1 in front of catalytic converter
Heated oxygen sensor
I behind catalytic converter
Heated oxygen sensor I in front of catalytic converter
Engine control module relay
Connector
X60003
Ground
Output Input
Ground
Output
Input
Input
Output
Output
Input
Pin 1
2
3
Not used
Ground for electronic components
Voltage supply for hot
film mass air flow sensor
Signal EDK (electric throttle actuator) Hot film mass air flow sensor, ground
Electric throttle actuator
Not used
Voltage signal, terminal 30h
Alternator
D+ (terminal 61) signal
Injection signal
Injection signal
VANOS valve, signal
Type
Output
Output
Output
Ground connector
X6460
Hot film mass air flow sensor
Electric throttle actuator
Hot film mass air flow sensor
Electric throttle actuator, voltage supply
Starter
Alternator (generator)
Cylinder
7 fuel injection valve
Cylinder 6 fuel injection valve
VANOS valve, cylinder
5-8
Descriptionlfunction
Injection signal
Injection signal
Signal evaporative emission valve Notes
Cylinder 2 fuel injector valve
Cylinder 3 fuel injector valve
Evaporative emission valve

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I Fuel Injection
Connector X60003 (continued) Electric throttle actuator
25
- 27 28
29
30
31
32
33
I I I
36 jlnput I Knoclc sensor 2, signal 1 Knock sensor
I I I
Input
26
Output
Output
input
Output
Input
I ' I . I
43 1 ln~ut I Electric throttle actuator, signal (Electric throttle actuator
Ground, electric throttle actuator
1 Not
used
Hot film mass air flow sensor
34
- 37
38
39
40
41
42
injection signal
Injection
signal
VANOS valve, signal
Not used
Thermostat characteristic map, signal
Crankshaft position sensor, signal
Not used
35 l~round I~nock sensor, shield 1 ~nock sensor
Cylinder
8 fuel injection valve
Cylinder
5 fuel injection valve
VANOS valve, cylinders
1-4
Characteristic map
Crankshaft positionlrpm sensor
input
input
Ground
Input
Output
Output
Innut
Hot film mass air flow sensor, signal
I
44
45 46
47
48
49
50
51
52
Connector )(GO004
Knock sensor 4, signal
Knock sensor, shield
Oil
level (thermal)
Injection, signal
Injection, signal
Electric throttle actuator, signal
Not used
Ground
Crankshaft position sensor, signal
Not used
Knoclc sensor, shield
Knock sensor
1, signal
Knock sensor
3, signal
Knock sensor, shield
Secondary air injection pump valve, signal
'
Ground
Input
Ground
input Input
Ground
Input
I' I ... I . ~
Knock sensor
Knocic sensor
Oil level sensor
Cylinder
4 fuel injection valve
Cylinder
1 fuel injection valve
Electric throttle actuator
Crankshaft sensor shield
Crankshaft
positionlrprn sensor
Knock sensor
Knock sensor
Knock sensor
Knock sensor
Secondary air injection pump valve
Notes
Instrument cluster
Integrated instrument cluster control
Secondary air injection pump
relay
Pin
1
2
3
Electric (auxiliary) cooling fan 4
Type
Output
Output
Outout
Descriptionlsignal type
Charge indicator signal (terminal
61)
Voltage signal, terminal 30h
Secondam air pump relay, activation
Input
5
Signal, electric (auxiliary) cooling fan, signal
I~ot used

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.-- -
/ Fuel Tank and Fuel Pump - .. -. -- 1
Fuel pump fuse and relay
Troubleshooting of any fuel pump fault should begin with
checking the fuel pump fuse and the fuel pump relay. The
DME main relay should also be checked. The fuel pump relay
is located behind right side luggage compartment interior
panel.
I Fuel pump relay
BLU =blue ERN = blo$,m GRN =groan GRY = grsy ORG =orange PNI< =pink RED =red VIO =violel WHT = wlilte
rk-; I I 1 ECM
I I I 31 8 ,._--___.I
NOTE-
Special tools are required for some of the tests described
here.
4 Fuel pump circu~t is fuse-protected.
0 6-cylinder models with Siemens DME MS41 .I, MS42, V-8
models with Bosch DME M5.2, M5.2.1 englne manage-
ment: Fuse
F54,15A (luggage compartment fuse panel)
6-cylinder models with Siemens DME MS43 engine man-
agement: Fuse
F22,25A (glove compartment fuse panel)
V-8 models with Bosch DME M7.2: Fuse F54,25A (lug-
gage compartment fuse panel)
- Fuse 31 in glove compartment fuse panel supplies power to
coil side of fuel pump relay. Engine control module (ECM)
supplies switched ground to relay. During starting, fuel pump
runs as long as ignition switch is in START position and con-
tinues to run once engine starts. If electrical system fault in-
terrupts power to fuel pump, engine will not run.
. .
Operating fuel pump for tests
- To operate fuel pump for testing purposes without having to
run engine, bypass fuel pump relay to power pump directly.
< To run fuel pump, open luggage compartment and release
right side trim panel.

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Fuel Tank and Fuel Pump
Fuel pressure gauge, installing
(V-8 models)
Remove engine cover by pressing down on pins (arrows) to
release cover locks.
4 Disconnect and remove fuel supply line from lefl side of fuel
rail by sliding
loclting collar in (arrows) and pulling lines
apart.
NOTE-
* ME2 TU and MS43 vehicles (1999 and later models) use a
non-return fuel line with only one line to the fuel
rafl.
BMW uses three styles of fuellfne connections; a one-use
clamp, a locking fitting that uses
BMWspeclal tool 16 1 050
to release, and a quick release sleeve (above) that discon-
nects the line when depressed.
WARNING -
* Fuel In fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
lealiing fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before workina on the tank or lines.
< Install inline fuel pressure gauge.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from coming loose underpressure.
NOTE-
The fuel pressure gauge should have a minimum range of 0
to 5 bar (0 to 75 psi).

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Fuel Tank and Fuel Pump
4 Relieve system pressure and attach a fuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING-
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or
worlc near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before
working on the tank or lines.
- Operate fuel pump as described in Operating fuel pump for
tests. Compare fuel pressure to specifications in accompa-
nying table.
Fuel pressure specification
All E39 vehicles 3.5 +0.2 bar (50.76 i2.9 psi)
- If pressure is low, repeat test while gradually pinching off re-
turn hose to fuel tank. Pressure should rise rapidly. If not, fuel
pump is most likely faulty. If pressure rises, the fuel pressure
regulator is most
likely faulty.
- If pressure is too high, checlc return line from pressure regu-
lator to tank. Check for
ltinks in hose. If no faults can be
found, pressure regulator is most likely faulty.
CAUTION-
The fuel pump is capable of developing a higher pressure
than that regulated by the pressure regulator. In the event the
fuel pump checlc valve is faulty (stuck closed), male sure the
I fuel pressure does not rise above 6.0 bar (87psi). Damage
to the fuel lines or fuel system components could result.
- Reassemble engine, noting the following:
Remove fuel pressure gauge and fittings.
Replace schraeder valve, if removed
Replace fuel pump relay.
Replace fuel filler cap.
Residual pressure, testing
For quick restarts and to avoid vapor lock when the engine is
hot, the fuel injection system retains fuel pressure after the
engine is shut off. This residual pressure is primarily
rnain-
tained by the fuel pressure regulator and a checlc valve at the
fuel pump
outlet.

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. .
I Fuel Tank and Fuel Pump I
4 Relieve system pressure and attach afuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines
- Start engine allow it to run for approximately one minute.
Note fuel pressure reading.
- Observe fuel pressure reading after approximately 20 mln-
utes. The pressure should not drop more than 0.5 bar from
system pressure listed in fuel pressure specifications in ac-
companying table.
Fuel pressure specification
Ail
E39 vehicles 3.5 i-0.2 bar (50.76 i2.9 psi)
- When finished, disconnect pressure gauge and fitting, and
replace schraeder valve, if removed.
- If fuel system does not maintain pressure:
Visually check for leaks in fuel lines and unions,
Check for leaking
injector(s).
Check for faulty fuel pump check valve.
- To test fuel pump check valve:
Repeat residual pressure test.
Immediately aftershutting off engine, pinch off fuel delivery
line using a fuel hose pinch clamp (BMW
13 3 010 or
equivalent).
If pressure is now maintained, fault is most likely at fuel
pump check valve.
If pressure again drops below specifications, fault is most
likely in fuel pressure regulator.