Engine Controls - System & Component Testing: Diagnosis BMW 5 series E39 facelift

Ignition System Testing (Siemmens 2003)

If there is a fault in the secondary ignition, testing should include primary ignition and evaluation of secondary oscilloscope patterns. See BASIC DIAGNOSTIC PROCEDURES article.

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

1. Using DISplus/GT1, read out fault memory in Digital Motor Electronics (DME). Remove sound absorption hood or ignition coil cover as necessary. Open control unit box. Unlock plug fastener of ignition coil. (Scheme 178) Detach plug in direction of arrow. Pull out ignition coil toward top. (Scheme 179)
2. Install Adapter Lead (127050) between spark plug and rod-type ignition coil. (Scheme 180) Connect clip-on trigger sensor of DIS Tester to adapter lead. (Scheme 181) Perform following procedure on DIS tester: Select MEASUREMENT. Select PRESET MEASUREMENT. Select SECONDARY IGNITION SIGNAL. Connect TD cable to diagnostic head. Select STATIONARY IGNITION DISTRIBUTOR SYSTEM. Select CYLINDER NUMBER. For subsequent procedure, follow DIS instructions.
3. Primary Measurement: Connect 26-pin pin box with Adapter Lead (121301) to connector of DME module. On DIS tester, perform following procedure: Select MEASUREMENT. Select PRESET MEASUREMENT. Select IGNITION SIGNAL TERMINAL. For subsequent procedure, follow DIS instructions. Ignition signal is a multiple spark ignition. (Scheme 182) NOTE: Ignition oscillogram applies to engines with multiple spark ignition from a production date of 4-2001 and after. Depending on engine temperature of about -4 to 211°F (-20 to 100°C) and engine speed (less than 2000 RPM), some ignition voltage peaks (about 1-5 ignition peaks) can occur before the typical ignition voltage characteristic. The additional ignition peaks play a role in diagnosis. The last ignition peak on the oscillogram is decisive. (Scheme 183) The display of the ignition voltage peak is about 20-25 percent lower than the real value. It is not the height of the ignition voltage peaks but rather the uniformity of all the cylinders that is important. Differences of 3000-4000 volts are permitted.

Leak Diagnosis Test - X5

Note. For leak detection (Scheme 184)and (Scheme 185).

Scheme 184

Scheme 185

Checking Fuel Tank & Tank Venting System For Leaks With Tank Leakage Diagnosis Module (DM-TL) - Z3

1. A fault is indicated by CHECK ENGINE indicator light in instrument cluster lighting up. This may indicate a leak in the tank venting system. Information on this is provided by the fault memory of the DME control unit. Read out fault memory of DME control unit and carry out diagnosis in accordance with faults stored. A leak test with the DM-TL module is then carried out if: The components of the DM-TL module are okay. An error is stored in the DME fault memory (tank leak detected).
2. Adhere to following conditions in order to carry out a correct leak test: Ensure content of fuel tank is greater than 90 percent. Ensure reserve indicator light is off. Leave car in workshop for at least 2 hours so that fuel temperature equals workshop temperature as closely as possible (ideal fuel temperature is about 50-68°F (10-20°C). Do not under any circumstances fill up car with fresh fuel. Check that tank cap is correctly seated. WARNING: During leak test, under no circumstances apply external pressurization through tank filler neck as this may cause incorrect readings.
3. Clear DME fault memory. Using Diagnosis and Information System (DIS), go to FUNCTION AND COMPONENT SELECTION page by selecting COMPLETE VEHICLE, DRIVE, ENGINE MANAGEMENT, TANK SYSTEM TEST, DIAGNOSIS MODULE TANK LEAKAGE (DMTL). Adopt test module in test schedule. Switch to test schedule and implement tank leakage diagnosis module. Leakage test is carried out. If fault is recorded again in DME fault memory (tank leak detected), go to next step and carry out leak test. CAUTION: On vehicles with Tank Leak Diagnosis Modules (DM-TL), do not work with external pressurization as the tank venting system will leak under this condition. Because of emerging fuel vapors, carry out all work in well ventilated rooms, or use a suitable extractor system. NOTE: Following procedure is only applicable to vehicles with tank leak diagnosis module (DM-TL).
4. To conduct leak test on fuel tank and tank ventilation system, in Diagnosis and Information System (DIS), go to FUNCTION AND COMPONENT SELECTION page by selecting: SERVICE FUNCTIONS, DRIVE, DIGITAL MOTOR ELECTRONICS AND ACTIVATION DMTL PUMP ADOPT TEST MODULE in test schedule. Switch to test schedule and implement ACTIVATION DMTL PUMP test module.
5. Tank leak diagnosis pump pressurizes fuel tank and tank venting system. Carry out leak test. Terminate test module after completing leak test. Tank leak diagnosis pump is automatically shut down after about 15 minutes due to risk of overheating. Allow pump to cool down for at least 15 minutes, then continue procedure. Leak test can be carried out with a leak detector. Follow leak test manufacturer's operating instructions. Possible causes of leaks are: Tank cap leaking (check tank cap pressure relief valve). See «FUEL CAP PRESSURE RELIEF VALVE TEST»(ref-151726-S39329810192004012800000) under FUEL EVAPORATION. Tank venting lines leaking (fuel tank, carbon canister, or tank venting valve). Tank ventilation valve leaky (engine compartment). Fuel level sensor flange on tank leaking.

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. Do not work with external pressurization as tank venting system will leak. Because of escaping fuel vapors, these tasks should only be carried out in well ventilated rooms or with a suitable extractor facility provided. Using BMW Diagnosis and Information System (DIS), go to FUNCTION AND COMPONENT SELECTION page by selecting: SERVICE FUNCTIONS, DRIVE, DIGITAL MOTOR ELECTRONICS, ACTIVATION DMTL PUMP and ADOPT TEST MODULE in test schedule. Switch to test schedule and implement ACTIVATION DMTL PUMP TEST MODULE VENTING. (Scheme 186)- (Scheme 189).
2. Tank leak diagnosis pump pressurizes fuel tank and tank venting system. Carry out leak test. Terminate test module after completing leak test. Tank leak diagnosis pump will automatically shut down after about 15 minutes due to risk of overheating. Allow pump to cool down for at least 15 minutes, then continue procedure. Leak test can be carried out with a leak detector. Follow manufacturer's operating instructions. Possible causes of leaks are: Tank cap leaking. See «FUEL CAP PRESSURE RELIEF VALVE TEST»(ref-151726-S39329810192004012800000) under FUEL EVAPORATION. Tank vent line leaking (fuel tank-carbon canister). Tank vent line leaking (engine compartment). Sealing ring on fuel filter leaking.

Checking Fuel Tank & Tank Venting System For Leaks With Tank Leakage Diagnosis Module (DM-TL) - Z8

1. For vehicles without tank leak diagnosis module, go to step 3 . For vehicles with tank leak diagnosis module, go to next step. CAUTION: On vehicles with tank leak diagnosis modules (DM-TL), do not work with external pressurization as the tank venting system will leak under this condition.
2. Select 4 EXPERT MODE function on Diagnosis and Information System (DIS). From menu, 2 ACTIVATE COMPONENTS, select function 127 ACTIVATION DMTL PUMP. DMTL PUMP appears in display. Pump is activated. Tank leak diagnosis pump pressurizes fuel tank and tank venting system.
3. On vehicles without tank leak diagnosis module, pressurize tank through filler neck. When leak-testing with a leak detector, follow manufacturer's operating instructions. On account of emerging fuel vapors, carry out all operations in well ventilated rooms, or use a suitable extractor system.
4. Possible causes of leaks may be: Tank cap leaking (check tank cap pressure relief valve). See «FUEL CAP PRESSURE RELIEF VALVE TEST»(ref-151726-S39329810192004012800000) under FUEL EVAPORATION. Tank venting lines leaking (fuel tank, EVAP carbon canister or tank venting valve). Tank venting valve leaking (engine compartment). Fuel level sensor flange on tank leaking.

Checking Fuel Tank & Tank Venting System For Leaks With Tank Leakage Diagnosis Module (DM-TL) - 3-Series (E46)

1. Remove screws and panel. Remove expansion rivet and panel. (Scheme 190) Unlock line and detach line from dust filter. (Scheme 191) Seal dust filter with special tool. Remove tank filler cap and connect Special Tool (16 1 150) to tank filler neck. (Scheme 192) Screw in rear towing eye and hook Special Tool (16 1 150) into it. Connect special tool to workshop compressed air system of 116-145 psi (8-10 bar) with compressed air hose. (Scheme 193) Connect pressure sensor with measuring range of 0-51 psi (0-3.5 bar). NOTE: Ensure pressure regulator on Special Tool (16 1 150) is set completely in "-" direction and non return cock between pressure regulator and pressure sensor is closed. Select MEASURING TECHNOLOGY function on Diagnosis Information System (DIS).
2. Set measuring range in accordance with pressure sensor to 0-51 psi (0-3.5 bar). Open non return cock on Special Tool (16 1 150) and increase pressure in tank system by.72 psi (.050 bar) with the pressure regulator. WARNING: Do not increase pressure by more than 1.45 psi (.100 bar), as damage to fuel tank and tank ventilation system is possible.
3. Close non return cock. Wait about 20 seconds for system to settle. Read off pressure value, then wait 60 seconds. Read off final pressure value and compare with starting pressure value. If pressure drop is within range of.116-1.7 psi (.008-.12 bar), measurement must be repeated to obtain a confirming result. If pressure drop in 60 seconds is greater than.145 psi (.010 bar), system is leaking.
4. Leak test can be carried out with a leak detector. Possible causes may be fuel filler cap leaking, tank ventilation line leaking (fuel tank-activated carbon canister-tank ventilation valve), tank ventilation valve leaking (engine compartment), tank sensor on fuel tank leaking or activated carbon canister non return valve leaking (spare wheel recess).

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Checking Fuel Tank & Tank Venting System For Leaks With Tank Leakage Diagnosis Module (DM-TL) - 5-Series (E39) 6-Cylinder

1. If a leak in the tank ventilation system is indicated by CHECK ENGINE indicator lamp in the instrument cluster, a leak test must be carried out. First, fault memory of DME control unit must be read out and diagnosis conducted. If sensors are okay, then begin leak test. Following conditions must be observed to obtain plausible measuring results: Ensure contents of fuel tank are 25-75 percent. Park vehicle in workshop at least 2 hours before test so fuel temperature is about that of workshop temperature. Ideal fuel temperature is 50-68°F (10-20°C). Never refuel the vehicle directly prior to leak test due to strong gas emission by fresh fuel.
2. To conduct leak test, remove luggage compartment mat and spare tire. Remove battery cover. Remove hexagon nut and plastic nut. (Scheme 194) Remove cover of activated carbon canister upward.
3. Disconnect electrical connector of activated carbon canister non return valve. (Scheme 195) Connect Special Tool (12 6 410/411) to activated carbon canister non return valve and vehicle battery. (Scheme 196) Activated carbon canister non return valve is closed by applying 12 volts. Ensure voltage is sufficient and do not reverse terminals. Remove tank filler cap and connect special tool (16 1 150) to tank filler neck. (Scheme 192)
4. Screw in rear towing eye and hook Special Tool (16 1 150) into it. Connect special tool to compressed air system of 116-145 psi (8-10 bar) with compressed air hose. (Scheme 193) Connect pressure sensor with measuring range of 0-51 psi (0-3.5 bar). WARNING: Ensure pressure regulator on Special Tool (16 1 150) is set completely in "-" direction and non return cock between the pressure regulator and pressure sensor is closed.
5. Select MEASURING TECHNOLOGY function on Diagnosis Information System (DIS). Set measuring range in accordance with pressure sensor to 0-51 psi (0-3.5 bar). Open non return cock on Special Tool (16 1 150) and increase pressure in tank system by.72 psi (.050 bar) with pressure regulator. WARNING: Do not increase pressure by more than 1.45 psi (.10 bar), as damage to fuel tank and tank ventilation system is possible.
6. Close non return cock. Wait for about 20 seconds for system to settle. Read off pressure value, then wait 60 seconds. Read off final pressure value and compare with starting pressure value. If pressure drop is in area between.116-1.7 psi (.008-.012 bar), measurement must be repeated to obtain a confirming measurement. If pressure drop in 60 seconds is greater than.145 psi (.010 bar), system is leaking.
7. Leak test can be carried out with a leak detector. Possible causes may be fuel filler cap, tank ventilation line (fuel tank-activated carbon canister-tank ventilation valve), tank ventilation valve (engine compartment), tank sensor on fuel tank or activated carbon canister non return valve (spare tire recess).

Scheme 194

Scheme 195

Scheme 196

Checking Fuel Tank & Tank Venting System For Leaks With Tank Leakage Diagnosis Module (DM-TL) - 5-Series (E39) V8

1. Remove left rear wheel. Remove left rear wheel housing trim. Remove leak diagnosis pump air cleaner from retaining bracket of activated carbon filter from below. (Scheme 197) Using hose clamp, seal with Special Tool (16 1 161).
2. Remove tank filler cap and connect Special Tool (16 1 150) to tank filler neck. (Scheme 192) Screw in rear towing eye and hook Special Tool (16 1 150) into it. Connect special tool to compressed air system of 116-145 psi (8-10 bar) with compressed air hose. Connect pressure sensor with measuring range of 0-51 psi (0-3.5 bar). (Scheme 193) WARNING: Ensure pressure regulator on Special Tool (16 1 150) is set completely in "-" direction and non return cock between pressure regulator and pressure sensor is closed.
3. Select MEASURING TECHNOLOGY function on Diagnosis and Information System (DIS). Set measuring range in accordance with pressure sensor to 0-51 psi (0-3.5 bar). Open non return cock on Special Tool (16 1 150) and increase pressure in tank system by.72 psi (.05 bar) with pressure regulator. WARNING: Do not increase pressure by more than 1.45 psi (.10 bar) as damage to fuel tank and tank ventilation system is possible.
4. Close non return cock. Wait for about 20 seconds for system to settle, read off pressure value, then wait for 60 seconds. Read off final pressure value and compare with starting pressure value. If pressure drop is.116-1.7 psi (.008-.12 bar), measurement must be repeated to obtain a confirming result. If pressure drop in 60 seconds is greater than.145 psi (.010 bar), system is leaking.
5. Leak test can be carried out with a leak detector. Possible causes may be fuel filler cap leaking, tank ventilation line leaking (fuel tank-activated carbon canister-tank ventilation valve), tank ventilation valve leaking (engine compartment), tank sensor on fuel tank leaking or activated carbon canister non return valve leaking (spare wheel recess).

Scheme 197

Scheme 198

Scheme 199

1. An OBD fault is indicated by CHECK ENGINE light in instrument cluster. This may indicate a leak in the tank venting system. Information on this is provided by the fault memory of the DME control unit. Read out fault memory of DME control unit and carry out diagnosis in accordance with faults stored. (Scheme 198)and (Scheme 199). A leak test with the DM-TL module is then carried out if: The components of the DM-TL module are okay. A error is stored in the DME fault memory (tank leak detected).
2. To carry out a correct leak test, ensure content of fuel tank is less than 90 percent and reserve indicator lamp is off. Leave car in workshop for at least 2 hours so that fuel temperature comes into line with workshop temperature. Ideal fuel temperature is approximately 50-68°F (10-20°C). Do not under any circumstances fill up car with fresh fuel as there is a strong exhalation of fresh fuel. Check that tank cap is correctly seated. WARNING: During leak test, under no circumstance apply external pressurization through the tank filler neck as this may cause an incorrect reading.
3. Clear DME fault memory. In Diagnosis and Information System (DIS), go to FUNCTION AND COMPONENT SELECTION page. Carry out tank leakage diagnostic module. If a fault is stored again in DME fault memory (tank leak detected), carry out leak testing. Go to «CONDUCTING LEAK TEST ON FUEL TANK & TANK VENTILATION SYSTEM»(ref-151726-S10983440092004051100000).

Conducting Leak Test On Fuel Tank & Tank Ventilation System

1. For vehicles without tank leak diagnosis module, go to next step. For vehicles with tank leak diagnosis module, on Diagnosis and Information System (DIS), select CONTROL UNIT FUNCTIONS for DME MOTOR ELECTRONICS ME9 control unit. Select COMPONENT ACTIVATION from FUNCTIONS column. From SUBFRAMES column, select TANK LEAK DIAGNOSIS MODULE: ACTIVATE PUMP function. Press ACTIVATE button. Tank leak diagnosis pump pressurizes the fuel tank and tank venting system for 30 seconds. If pressure is required for longer than 30 seconds, you must press the ACTIVATE button again after 30 seconds. Go to step 3 .
2. For vehicles without tank leak diagnosis module, pressurize through filler neck. When leak testing with a leak detector, follow manufacturer's operating instructions. Observe country-specific accident prevention and occupational safety regulations. Go to next step.
3. Possible causes of tank leakage may be tank cap leaking (check tank cap pressure relief valve), tank venting lines leaking (fuel tank, carbon canister or tank venting valve), tank venting valve leaking (engine compartment), or fuel level sensor flange on tank leaking.

See also:
• PIN VOLTAGE CHARTS