2001 BMW 540i turn signal

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Fuel Injection I
- As an alternative, harness connector housing can be sepa-
rated so that electrical
checlts can be made from backof con-
nector.
4 If replacing ECM, disconnect control module harness con-
nector (arrow) by releasing fastener and pivoting connector
up and
off ECM.
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
- Remove ECM from retaining brackets and lift off holder.
- Installation is reverse of removal.
- Before attempting to start engine, use BMW service tester
DISplus, MoDiC, GTI or equivalent:
- Code replacement ECM with application information (i.e.
engine code, transmission type, etc.).
Align ECM to EWS (electronic immobilizer).
Siemens MS 41.1 ECM pin assignments
ECM pin assignments are given in Table b. For engine man-
agement system schematics, see ELE Electrical Wiring
Di-
agrams.
CAUTION-
a Always wait at least one minute after turning off the ignition
before removing the connector from the
ECM. If the con-
nector is removed before this time, residual power
in the
system relay may damage the
ECM.
Always connect or disconnect the control module con-
nector and meter probes with the ignition
off
When malting checks at the ECM itself, a breakout box
should be used to allow tests to be made with the connector
attached to the ECM. This also prevents damage to the small
terminals in the connector. As an alternative, the harness
connector housing can be separated so that electrical checlts
can be made from the back of the connector.
Table b. Siemens MS
41.1 ECM pin assignments
Pin
1
2
3
4
Signal
output
output
output
qround Componenfffunction
Ignition coil control, cyl. 2
Ignition coil control, cyl. 4
ignition coil control, cyl. 6
Ground Notes
Primary signal,
ignition
coil 2
Primary signal, ignition coil 4
Primary signal, ignition coil 6
Ground

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130-28
Fuel Injection
ECM Relay
4 Check for voltage at terminal 6 (30) at reiay socket
If battery voltage is present continue testing.
if battery voltage is not present, check fuse 109 (80-amp
fusible link) under passenger seat carpet. See 610 Electri-
cal
Component Locations.
- Reinstall relay and turn ignition on. Gain access to back side
of reiay socket and check for ground at terminal
4.
If ground is present continue testing.
If ground is not present, signal
from ECM is missing. Check
wire between ECM and relay.
- With ignition on and reiay installed, check lor battery voltage
at terminal
2.
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and
ail earlier tests are OK,
relay is faulty and should be replaced.
NOTE-
If no faults are found during testing but power is not reaching
the ECM or other components, check the fuses
in the fuse
carrier
X8680 in the E-box.
Mass air flow (MAF) sensor, checking and
replacing
4 The hot f~lm mass air flow (MAF) sensor sends a varying volt-
age (approx. 0.5 - 4.5 vdc) to the ECM representing the mea-
sured
Intake air. The alr mass input signal is produced
electron~caily uslng an electrically heated metal fllm in the air
flow stream.
The ECM relay provides the operating voltage to the MAF
sensor. As air
flows through the sensor, the film is cooled. To
maintain the film at a constant temperature, additional current
is necessary. It is this additional current that is the basis lor
the input signal.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using the throttle position and engine rpm
inputs. A faulty MAF sensor illuminates the MIL.

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Fuel Injection
A faulty MAF sensor can produce the following problems:
Difficult to restart when engine is hot
Engine starts then stalls
* Engine starts and runs only with accelerator pedal de-
pressed
4 Disconnect electrical harness connector from MAF sensor
(B).
- Turn ignition on and checlc for voltage and ground at connec-
tor.
There should be ground at pin
1 and battery voltage at pin
3.
- If any faults are found, checlc for wiring breaks between
MAF sensor and ECM and between MAF sensor and main
DME relay.
NOTE-
Visually inspect the sensor for damage, missing or blocked
screens. The screens affect air flow calibration. Also inspect
the sealina
0-rinas where the sensor inserts into the air filter - - housing and intake boot. Ensure the pin connections are
clean and tight.
4 Connect a BMW-compatible scan tool or an OED II generic
scan tool.
Checlc air mass signal (load signal) with the engine
at idle. Raise idle speed and
checlc that load signal changes
with rpm.
CAUTION-
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
Remove MAF sensor:
Loosen intake boot clamp
(A).
Disconnect harness connector (6).
* Release clip from air filter housing (C) and remove sensor.
- Installation is reverse of removal.
No adjustment to MAF sensor is possible.
Check intake hoses for cracks and vacuum
lealts.

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130-50
Fuel Injection
Bosch M5.2
ECM relay
1 HoL al ail iirnel XOL a1 ail limes
i--[-----i F109 (BOA) electronics I L.$.....: .I:
ECM relay . . . . . . . . . ,
8,s
:,
6 1 .. ... ~~.~~. . ...... .-, Engine control ii~~-~.~~..~ ........ ~~~~~~.~~~~:. module relay -;I
Of?
,c,;,,,
< With ignition off, remove ECM relay (arrow) in electronics
box (E-box) at right rear of engine compartment.
NOTE-
Relay locations can vary. Conh relay identification by
matcliing wiring colors and terminal numbers.
4 Check for voltage at terminal 6 of main relay socket (30-red
wire). On M5.2 cars also check for battery voltage at terminal
8.
. . . . . . . . . ,
If battery voltage is present, continue testing
.
If battery voltage is not present, check large red wire(s) in
relay socltet. See
ELE Electrical Wiring Diagrams.
%P,,tt
- Reinstall relay and turn ignition on. Gain access to underside
of relay socket and
checlc for ground at terminal 4 (85-brown
wire).
. . . . . . . . . . . . - - - - - - - - - . - - - . . l ,,-. ; Engine i f .: , ; Fuse carrier .,A . :engine /;is? /control L.!.!! .... 1.: ...... !.::..! I lij :module electronics If
ground is present, continue testing
If ground is not present, signal from ECM is missing. Checic
wire between ECM and relay.
4 With ignition on and relay installed, check for battery voltage
at terminal
2 (87-redlwhite wire). On M5.2.1 cars also checlc
for battery voltage at terminal 5.
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and all earlier tests are OK,
relay is faulty and should be replaced.

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130-51
Fuel Injection
Oxygen sensors, checking
The oxygen sensor provides an input voltage signal [0.2 vdc
(lean) to 0.8 vdc (rich)] to the
ECM based on the oxygen con-
tent in the exhaust gas. To generate voltage, the sensor tem-
perature must exceed 575"
F (300" C). Therefore the sensor
is electrically heated.
NO JE -
The test given below is not a conclusive test of oxygen sen-
sor efficiency and does not test how the oxygen sensor re-
acts to changing conditions. Pin numbers and wire colors
can vary Always check the wiring diagrams to confirm wire
color and pin assignment.
0 The oxygen sensorconnectorplugs are locatednext to the
catalytic converters.
With connector attached to sensor, connect digital voltmeter
between
A and B wires in connector.
WARNING -
Exhaust manifolds andpipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
NOJE-
Connector style may vary depending on system application.
Consult wiring diagram for system-specific wiring. See
ELE
Electrical Wiring Diagrams.
Start engine.
A fluctuating voltage signal should show on the
meter.
If voltage is incorrect, turn engine off and check pre-
heater circuit as described below.
NOJE-
To check sensor response to lean and rich mixtures, create
an air leak.
Oxygen sensor
voltage at idle
- Connect digital voltmeterbetween sensor heaterwires (white
wires,
C and D). Start engine and check for battery voltage.
If voltage is not present, check oxygen sensor heater fuses.
0.2 to 0.8 vdc fluctuating
NOJE-
The oxygen sensor heater is powered via fusedpositive (+)
battery voltage and a switchedground from the ECM. See
ELE Electrical Wiring Diagrams for specific circuit informa-
tion.
- The ground side of the oxygen sensor heater circuit is pulsed
on and off by the
DME control module.

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Fuel Injection
Intake air temperature
([AT) sensor,
testing and replacing
Disconnect harness connector from intake air temperature
sensor
(A) at air filter housing.
Turn ignition on. Using a digital voltmeter, check for
5 volts
between supply voltage wire in connector and ground.
If volt-
age is not present, test ECM
inputs/outputs as described lat-
er.
With harness connector disconnected, test resistance across
sensor terminals. If any faults are found, replace IAT sensor.
IAT test resistance
0 lV *lac (50" i-2°F) 7-1 1.6 k.0.
020' kl°C (68' 322°F) 2.1-2.9 it.0.
080" ?lac (176" i-2°F) 0.27-0.40 itn
Auxiliary throttle valve (ADS)
(M62 and M62 TU engine), replacing
ADS components 540i models with ASC and DSC are fitted with a motor-driv-
en auxiliary throttle valve and housing ahead of the standard Throttle position switch throttle housing. The ADS throttle valve controls engine throt-
tle intervention based on signals from the DME control mod-
ule if road conditions, such as slipping driven wheel, warrant
reduced engine power.
ADS throttle housing
Bowden cable NOTE-
Before replacing the ADS throttle housing, read DME fault
ADS lhroltle actualor codes.
- ADS throttle housing replacement:
Switch off ignition and disconnect electrical connector on
ADS throttle body.
Remove hose from idle control valve.
Loosen hose clamps and remove throttle housing air in-
take boot.
Disconnect cable from ADS throttle body.
- Unscrew 3 bolts and remove ADS throttle body.
Installation is reverse of removal.
- Adjust cable so that no free play is present.

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130-68
Fuel Injection
0
4 The ME 7.2 uses a non-return fuel rail. The fuel pressure reg-
ulator is integrated into the fuel filter.
I iY.,lii,in
4 The M62 TU engine uses a continuously variable VANOS
system at each intake camshaft. This system enhances en-
gine performance and reduces tailpipe emissions. Both cam-
shafts are adjusted simultaneously within
20" (maximum) of
the camshafts rotational axis. This equates to a maximum
span of
40°crankshaft rotation.
regulalor from luel pump
NOTE-
The fuel filter is available as a replacement part without the
fuel pressure regulator. When replacing the fuel filter, trans-
fer the fuel pressure regulator from the old
filter to the new fil-
ter.
Engine idle speed control is a function of the EDK. The M62
TU engine does not use a separate idle control valve.
Mmn CON,ROL
EML
< The M62 TU engine uses an electrically controlled throttle
valve called EDK. The throttle plate is positioned by a DC
gear reduction motor based on inputs signals to the ECM
from the pedal position sensor (PWG).
When the accelerator pedal is moved, the PWG provides a
change in the monitored signals. The ME
7.2 control module
compares the input signal to a programmed map and appro-
priately activates the EDK motor via proportional pulse width
modulated control signals. The control module self-checks its
activation of the EDK motor via the EDK feedbaclc
potentiom-
eters.

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130-70
Fuel Injection
ECM relay
--
CAUTION-
Relay positions can vary Be sure to confirm relay position by
identifying the wiring in the
socl(et using the wiring diagrams
in ELE Electrical Wiring Diagrams.
Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate duct inward (arrow) to unlock from bulk head and
remove duct.
Release spring
loclt (C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
4 With ignition off, remove main relay (arrow) in electronics
box (E-box) at right rear of engine compartment.
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.
4 Check for voltage at terminal 6 of main relay socket (30-red
wire).
If battery voltage is present, continue testing.
If battery voltage is not present, check large red wire in re-
lay socltet. See ELE Electrical Wiring Diagrams.
- Reinstall relay and turn ignition on. Gain access to underside
of relay socket and check for ground at terminal
4 (85-brown
wire).
If ground is present, continue testing.
If ground is not present, switched ground signal from ECM
is missing. Check wire between ECM and relay.
- With ignition on and relay installed, check for battery voltage
at terminal
2 (87-redlwhite wire).
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and all earlier tests are OK.
relay is faulty and should be replaced.