2001 BMW 525i Injector

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Fuel Tank and Fuel Pump
Fuel delivery,
testing
Checitino fuel delive~ is a fundamental oart of troubleshoot- .. ing and diagnosing thk DME system. ~ukl pressure directly
influences
fuel delivery. An accurate fuel pressure gauge will
be needed to make the tests.
There are two significant fuel deliveryvalues to be measured:
* System pressure - created by fuel pump and maintained
by pressure regulator
Residual pressure
- pressure maintained in closed sys-
tem after engine and fuel pump are shut off
if proper system pressure and residual pressure are present,
also check for problems in fuel delivery volume, which can be
affected by restrictions such as clogged fuel filter or fuel pick-
up port in the fuel tank.
System pressure, testing
1. Fuel pressure regulator outer seal
4 System pressure is created by the fuel pump and maintained
2. Vacuum line connection.
3. Fuel pressure regulator Inner seal.
4. Fuel flow back to fuel tank.
5. Fuel flow from fuel pump.
Fuel pressure
regulator
Fuel pressure regulator locations
M52 In fuel injector rail, in engine
compartment
M52 TU In 312 way valve, below vehicle under
driver seat
by the pressure
regulator. System pressure is not adjustable.
M54 In fuel filter
M62 to 9/97 In fuel injector rail, in engine
compartment
M62 from 9/97 to 9/98 In 312 way valve, below vehicle under
driver seat
M62 TU from 9/98 In fuel filter, below vehicle under driver
seat

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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.

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Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit
(LDP or DMTL), removing . . -
and installing
- Raise rear end of car and support safely.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floor jack is not adequate support.
- Remove left rear wheel and inner fender panel
Remove carbon canisterlfuel tank leak detection unit
(V-8 model shown):
Disconnect electrical harness connector
(A) from fuel tank
leak detection unit.
Pinch and remove quick-disconnect fittings at intake line to
air filter housing
(5) and hose to expansion tank (C).
* Remove mounting clamp and lower canister with fuel tank
leak detection unit.
Installation is reverse of removal.
Tightening
torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp
13 - 16 rnm dia 3 Nm (27 in-lb)
Running losses (312-way) valve,
removing and installing
The running losses (312-way) valve is located under the car
beneath the driver's seat, just ahead of the fuel filter. A protec-
tive covershieldsfuel system components from road hazards
and dirt.
The engine control module
(ECM) controls the operation of
the 312-way valve (pulse-width modulated). On engine start
up, the valve solenoid is energized for 20 seconds in order to
supply full fuel volume to the fuel rail.
After20 seconds, the
solenoid is deactivated and sprung closed (the bypass is
opened). This reduces the amount of fuel circulating through
the fuel rail and diverts the excess to return to the fuel tank
through the fuel pressure regulator.
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.

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OBD-14
I On-Board Diagnostics
I Engine diagnostic trouble codes: M52 engine (continued) - - -
P-code IBMW-FC ~DTC Definition
PO133
PO134
PO135
PO136
PO136
PO136
PO139
PO141
I I
PO150 1155 102 Sensor Circuit (Bank 2 Sensor 1)
I
I
229
186
25
156
157
215
220 61
PO150 02
Sensor Circuit
Slow Response (Banlc 1 Sensor 1)
02 Sensor Circuit No Activity Detected
(Bank 1 Sensor 1)
02 Sensor Heater Circuit (Bank 1 Sensor 1)
02 Sensor Circuit
(Banlc 1 Sensor 2)
02 Sensor Circuit (Bank 1 Sensor 2)
02 Sensor Circuit (Bank 1 Sensor 2)
02 Sensor Circuit Slow Response
(Bank 1 Sensor 2)
02 Sensor Heater Circuit
(Bank 1 Sensor 2)
PO153
PO154
PO155
PO156
PO156
PO156
PO150 1154 102 Sensor Circuit (Bank 2 Sensor 1)
153
PO159
PO161
PO170
02
Sensor Circuit (Banic 2 Sensor 1)
230
187
55
159
160
21 6
p~-~~--~ PO173
PO201
PO202
PO203
PO204
PO205
PO206
02 Sensor Circuit Slow Response (Banlc 2 Sensor 1)
02 Sensor Circuit No Activity Detected (Bank 2 Sensor
1)
02 Sensor Heater Circuit (Bank 2 Sensor 1)
02 Sensor Circuit (Bank 2 Sensor 2)
02 Sensor Circuit (Banlc 2 Sensor 2)
02 Sensor Circuit (Banlc 2 Sensor 2)
221
79
202 02
Sensor Circuit Slow Response (Banic 2 Sensor 2)
02 Sensor Heater Circuit
(Banic 2 Sensor 2)
Fuel Trim
(Banic 1)
203
6
5
22
24
33
23
Fuel Trim (Banic 2)
injector
Circuitlopen -Cylinder 1
injector
Circuitlopen - Cylinder 2
injector
Circuitlopen -Cylinder 3
Injector
Circuitlopen - Cylinder 4
injector
Circuitlopen - Cylinder 5
lniector
CircuitlOpen - Cvlinder 6

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/ On-Board Diagnostics
Po202
PO203
PO204
PO205
PO206
PO221
PO222
5
22 24
33
23 119
113 Injector CircuiVOpen -Cylinder
2
Injector
CircuiVOpen -Cylinder 3
lnjeclor CircuiVOpen -Cylinder 4
Injector
CircuiVOpen - Cylinder 5
Injector CircuiVOpen - Cylinder 6
ThrotileiPedal Position SensorISwiich 'B' Circuit RangeIPeriormance
ThrottleIPedal Position SensorISwitch 'B' Circuit Low

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On-Board ~ia~nosticsl
Engine diagnostic trouble codes: M54 engine (continued) I -.
P-code BMW-FC Explanation
PO223 113 ThrottlelPedal Position SensorlSwitch '0' Circuit High
PO261 / Cylinder 1 Injector Circuit Low
PO271 Cylinder 4 Injector Circuit High
PO273 Cylinder 5 Injector Circuit Low
Cylinder 2 Injector Circuit High
Cylinder 3 Injector Circuit
Low
Cylinder 3 Injector Circuit High
Cylinder 4
iniector Circuit Low
PO265
PO267
PO268
PO270
, I
PO277 1 23 1 Cylinder 6 Injector Circuit High
5
22
22
24
I I
PO274
PO301
PO302
PO303
PO304
PO276 1 23 I Cylinder 6 Injector Circuit Low
33
I
I -
I I
PO31 3 1 240 I Misfire Detected with Low Fuel Cylinder 5 Injector Circuit High
238
239
240
241
PO305
I I
Cylinder 1 Misfire Detected
Cylinder 2 Misfire Detected
Cylinder 3 Misfire Detected
Cylinder 4 Misfire Detected
PO313
PO306 1 243 I Cylinder 6 Misfire Detected
242
PO313
PO313
PO31 3
PO327
Cylinder 5 Misfire
Detected
PO31 3 1239 I Misfire Detected with Low Fuel
238
PO332
PO335
PO339 - PO340
Misfire Detected with Low Fuel
241
242
243
57
PO344
PO365
PO369
PO41 3
PO414
PO420
Misfire Detected with Low Fuel
Misfire Detected with Low Fuel
Misfire Detected with Low Fuel
Knock Sensor 1 Circuit Low
(Banlc 1 or Sinale Sensor)
59
83
83
65
-
Knoclc Sensor 2 Circuit Low (Banlc 2)
Crankshaft Position Sensor
'A' Circuit
Crankshaft Position Sensor
'A' Circuit Intermittent
Camshaft Position Sensor 'A' Circuit (Bank 1 or Single Sensor)
65
18
18
62
62
233 Camshaft Position Sensor
'A' Circuit Intermittent (Bank 1
or Single Sensor)
Camshaft Position Sensor
'B' Circuit (Banlc 1)
Camshaft Position Sensor 'B' Circuit Intermittent (Bank 1)
Secondary Air Injection System Switching Valve A Circuit Open
Secondary Air
Injection System Switching Valve A Circuit Shorted
Catalyst System Efficiency Below Threshold (Bank 1)

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1 On-Board ~iaanosticsl
I Engine diagnostic trouble codes: M62 engine (continued) -.
P-code I BMW-FC 1 Explanation I I
PO134 / 10 1 02 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
PO135
PO136
PO1 37
PO138
POI 39
PO140
PO141
PO150
PO151
- - . - . . . . - -. - - 02 Sensor Circu I Slow Response (Bann 2 Sensor 2) .. -- .- -- .- -- . - . . . -. . - ... - . - - - PO160 02 Sensor Circ~ t No Actv ly Delecleo (Bank 2 Sensor 2)
13
PO152
PO153
PO154
PO155
PO156
PO1 57
POI 58
-- 12
12
12
17
12
14
18
18 02
Sensor Circuit (Bank 1 Sensor 2)
02
Sensor Circuit Low Voltage (Bank 1 Sensor 2)
02
Sensor Circuit High Voltage (Bank 1 Sensor 2)
02
Sensor Circuit Slow Response (Bank 1 Sensor 2)
02
Sensor Circuit No Activity Detected (Bank 1 Sensor 2)
02
Sensor Heater Circuit (Bank 1 Sensor 2)
02
Sensor Circuit (Bank 2 Sensor 1)
02 Sensor Circuit Low Voltage (Bank 2 Sensor 1)
18
21 18
5
20
20
20
PO161
PO171
PO171
PO172
PO172
PO174
PO174
I I
PO201 1150 I Injector CircuiVOpen - Cylinder 1
02 Sensor Circuit High Voltage (Bank 2 Sensor 1)
02
Sensor Circuit Slow Response (Bank 2 Sensor 1)
02
Sensor Circuit No Activity Detected (Bank 2 Sensor 1)
02
Sensor Heater Circuit (Bank 2 Sensor I)
02 Sensor Circuit (Bank 2 Sensor 2)
02
Sensor Circuit Low Voltage (Bank 2 Sensor 2)
02
Sensor Circuit Hiqh Voltage (Bank 2 Sensor 2)
I I.
4
24
26
24
26
25
- 27
PO175
02 Sensor Heater Circuit (Bank 2 Sensor 2)
System Too Lean (Bank 1)
System Too Lean (Bank 1)
System Too Rich (Bank 1)
System Too Rich (Bank 1)
System Too Lean (Bank 2)
1
PO202
PO203
PO204
PO205
PO206
PO207
PO175 1 27 I System Too Rich (Bank 2) 1
25
I I'
System Too Rich (Bank 2)
157
155
152
151
154
156
Injector CircuiVOpen - Cylinder 2
Injector CircuiVOpen - Cylinder 3
Injector CircuiVOpen - Cylinder 4
Injector CircuitIOpen -Cylinder 5
Injector CircuiVOpen - Cylinder 6
lniector CircuiVOpen - Cylinder 7
injector CircuiVOpen - Cylinder 8 PO208 153

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan