Fuel System - Repair BMW M3 E46

13 00 002 Checking Function Of Digital Engine Electronics (DME)

Diagnostic Connector In Engine Compartment

Connect up MoDiC or BMW DIS.

Interrogate DME fault memory.

Note down fault messages stored in memory.

Further information on troubleshooting in line with DIS or MoDiC instructions.

Scheme 12

OBD Socket (1) In Driver's Footwell

Same procedure as above.

Scheme 13

13 31 ... Notes On Fuel Pressure Check (Reference Pressure: Intake Manifold Pressure)

Feature Of This Version With Intake Manifold Pressure

1. The connection for the vacuum hose of the fuel pressure regulator is located in the intake manifold after the throttle.

Test Precondition

The correct fuel pressure regulator is fitted.

1. Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted: Connect test adapter, Refer to «CHECKING FUEL PUMP DELIVERY PRESSURE (S54)»(/bmw/m3/e46-1999-2006/remont/fuel-system/#fuel-system-repair__13-31-029-checking-fuel-pump) .

Description Of Operation: Fuel Pressure Regulator

Depending on requirements, the fuel pressure regulator regulates a low or high fuel pressure. This requirement is set with the help of the pressure regulator.

Depending on the engine's operating state, less or more fuel is needed

1. At idle speed, less fuel.
2. At full load, considerably more fuel.

The injection rate is precision-adjusted by means of the injection time; the injection time is controlled by the DME.

The partial vacuum in the intake manifold serves as engine load information for pressure regulation. The diaphragm of the pressure regulator is actuated with this partial vacuum.

A partial vacuum builds up in the intake manifold during idling operation or in overrun mode. Depending on the partial vacuum value, the fuel pressure decreases starting out from the nominal value. The nominal value is stamped in the fuel pressure regulator housing.

At full load, the partial vacuum in the intake manifold is approximately equal to zero. The fuel pressure regulator regulates the fuel pressure to the nominal value stamped in the housing.

Description Of Operation: Fuel Pump

The control function of the fuel pressure regulator must be ensured in all operating states. The fuel pump must therefore always be able to generate a higher fuel pressure than the pressure regulated by the pressure regulator.

Description Of Operation: Fuel Return Line

When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure regulator is at zero pressure.

Description Of Operation: Pressure Retaining Function

The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel pressure in the delivery line is retained over an extended period. A non-return valve closes in the fuel pump. These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.

Complaint: Drive Characteristic Faults, Lack Of Power

1. Run engine at idle speed and measure fuel pressure.
2. In order to simulate "full load" state: Disconnect vacuum hose from fuel pressure regulator and measure fuel pressure. The measured value must increase by 0.4 to 0.7 bar depending on the engine. Note down measured value. If the measured value does not increase: Replace vacuum hose and measure fuel pressure again. If the measured value still does not increase: Replace pressure regulator.
3. Measure fuel pressure again and note down measured value.
4. Compare the measured value with the nominal value stamped in the pressure regulator housing. If the specified measured value is still not achieved, you must carry out the following checks depending on the measured value.

If The Measured Value Is Less Than The Nominal Value - 0.2 Bar

1. The cross-sections in the fuel feed line are contracted or the fuel filter is clogged, or
2. The fuel pump voltage supply is not O.K., e.g. due to high contact resistance (corrosion) in the plug connection between wiring harness and fuel pump.

If The Measured Value Is Greater Than The Nominal Value + 0.2 Bar

1. Switch off engine and then observe measured value.
2. If the measured value drops to the nominal value, the cross-sections in the fuel return line are contracted or clogged.
3. Check the fuel lines for kinks.

If no kinks are visible

1. Replace return lines.

If the measured value remains too high, the pressure regulator is most probably faulty.

1. As a precaution, have a cleaning cloth ready and collect and dispose of any escaping fuel.
2. Replace the return line but not the pressure regulator.

Complaint: Starting Problems

1. Run engine briefly at idle speed and switch off.
2. Note measuring value when engine is stationary.
3. Read off measured value again after approx. 20 to 30 minutes with engine stopped.

The special tool 13 3 010 (hose clip) is needed for the following check.

If The Measured Value Has Dropped By More Than 0.5 Bar

1. Start engine and wait briefly for a stable pressure increase.
2. Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the special tool 13 3 010.
3. Note down measured value.
4. Read off measured value again after approx. 20 to 30 minutes with engine stopped.

If The Measured Value Has Now Dropped By Less Than 0.5 Bar, The Following Faults May Be Present

1. Fault in delivery lines.
2. Fault in in-tank delivery hose.
3. Faulty pressure-holding non-return valve in fuel pump. Check components. Replace faulty components.

If The Measured Value Has Again Dropped By More Than 0.5 Bar

1. Replace pressure regulator.

Note. All the fuel hoses and hose clips which were detached within the framework of the checks must be replaced. Fault messages may be stored in the fault memory of the DME control unit if the vehicle is operated in the intervening period. The fault messages "Incorrect lambda control" or "Lambda control at stop" must be cleared after the check is completed: Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Now clear the fault memory.

13 31 029 Checking Fuel Pump Delivery Pressure (S54)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46) .

Special Tools Required

1. 13 5 220
2. 13 5 221
3. 13 5 222
4. 61 3 050

Switch off ignition.

Release screw connections (1).

Remove cover (2) on floor plate on left.

Scheme 14

Installation

Ensure seal (1) is in correct installation position.

Scheme 15

Remove dust cap (1).

Scheme 16

Connect special tool kit 13 5 220 (comprising 13 5 221 and 13 5 222) to pressure sensor of DIS Tester.

Connect pressure sensor to DIS Tester.

Scheme 17

Attach special tool kit 13 5 220 to housing of pressure regulator and tighten knurled nut until hand-tight.

Screw out check valve (1) so that valve in pressure regulator housing is closed.

Start engine.

Screw in check valve (1) until a pressure reading is indicated on DIS Tester.

Scheme 18

Measuring fuel pressure.

1. Select Measurement.
2. Multimeter function appears.
3. Select Pressure test.
4. Read off value of fuel pressure.

Compare actual value of test pressure with specified value. Refer to FUEL SYSTEM - TECHNICAL DATA .

Switch off engine.

Checking Fuel Pump

Remove fuel pump relay. Refer to 13 63 590 REPLACING FUEL PUMP RELAY .

Connect special tool 61 3 050 to terminals 87 and 30.

Press button and read off fuel pump delivery pressure on DIS Tester.

Compare actual value with setpoint value of delivery pressure. Refer to FUEL SYSTEM - TECHNICAL DATA

Scheme 19

Note. For further test procedures, refer to 13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: INTAKE MANIFOLD PRESSURE) . Removing special tool kit 13 5 220: Switch off engine. Screw out check valve fully again. Remove special tool kit 13 5 220 from pressure regulator housing. Catch and dispose of escaping fuel.

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 31 035 Replacing Fuel Line (S54)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46) .

Special Tools Required

1. 12 1 120

Interrogate fault memory of DME control unit. Switch off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Remove starter motor. Refer to 12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (S54) .

Recycling

Fuel emerges when fuel line is detached. Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Scheme 20

Unlock connector strip with special tool 12 1 120 in sequence 1 to 6.

Scheme 21

Release upper screw of fuel line (2) from return line. Unclip vacuum line from holders on fuel line.

Scheme 22

Release lower screw of fuel line (2) from engine block.

Follow instructions for unlocking fuel line. Refer to 13 53 540 REPLACING, SEALING FUEL HOSES .

Unlock fuel feed line and detach from fuel line (2).

Scheme 23

Detach retainer (1).

Pull fuel line out of fuel injector rail and remove.

Scheme 24

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 32 051 Replacing Fuel Filter (S54)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46) .

Special Tools Required

1. 13 3 010

Turn off ignition.

Release screws (1).

Remove cover (2).

Scheme 25

Installation

Ensure seal (1) is in correct installation position.

Scheme 26

Seal all fuel hoses on fuel filter with special tool 13 3 010.

This prevents excessive discharge of fuel from the fuel lines.

Scheme 27

Follow instructions for detaching fuel lines with integral unlocking facility. Refer to 13 53 540 REPLACING, SEALING FUEL HOSES .

Recycling

Fuel escapes when fuel lines are detached. Have a drip tray ready.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Unlock fuel hoses (1) and detach from fuel filter (2).

Detach vacuum hose (3) from fuel pressure regulator.

Release clamp (4) and detach fuel hose (5) from fuel filter (2).

Release screw connection of holder on body.

Remove fuel filter horizontally towards bottom.

Allow fuel to drain out of fuel filter into a drip tray.

Scheme 28

13 51 630 Replacing Fuel Pressure Regulator (S54)

Turn off ignition.

Release screws (1).

Remove cover (2).

Scheme 29

Installation

Ensure seal (1) is in correct installation position.

Scheme 30

Detach vacuum hose (1).

Remove snap ring (2).

Recycling

Catch and dispose of escaping fuel.

Pull out fuel pressure regulator (3).

Installation

Note. installation position of fuel pressure regulator (3).

Scheme 31

Installation

Snap lugs of snap ring into place in openings on fuel pressure regulator housing.

Scheme 32

Installation

Apply a thin coat of anti-friction rubber coating (e.g. petroleum jelly) to O-rings (1).

Scheme 33

13 41 100 Removing And Installing/Replacing Supplementary Air Line (S54)

Necessary Preliminary Tasks

1. Remove microfilter housing

This operation is described in 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD .

Press locks.

Detach engine ventilation hose.

Scheme 34

M3 CSL Only

Open clamp (1) and detach hose (2).

Unfasten plug connection (3) and disconnect.

Replacement Only

Release screws (4) and remove pressure sensor.

Scheme 35

Detach vacuum hose (5) from supplementary air line (4).

Note. For purposes of clarity, this operation is shown on the removed engine.

Scheme 36

Press lock together and detach air hose (1) from supplementary air line (2).

Note. Illustration shows intake air manifold removed.

Scheme 37

Release threaded connection for fuel injector rail and supplementary air line on left and right.

Pull out supplementary air line together with pipe neck towards top.

Note. Illustration shows intake air manifold removed

Scheme 38

Installation

Check O-rings of pipe necks for damage, replace if necessary.

Coat all O-rings with petroleum jelly or with SAE 90 gear oil.

Scheme 39

13 41 500 Replacing Idle-Speed Control Valve (S54)

Interrogate fault memory of DME control unit.

Turn off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Release hose clamps (1) and detach hoses from idle-speed control valve (2).

Unlock plug (3) and detach from idle-speed control valve (2).

Release nuts.

Remove holder (4) together with idle-speed control valve (2).

Installation

If necessary, install holder (4) with rubber damper on new idle-speed control valve.

Scheme 40

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

Refer to 13 51 630 REPLACING FUEL PRESSURE REGULATOR (S54) .

Refer to 13 31 035 REPLACING FUEL LINE (S54) .

Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

13 53 540 Replacing, Sealing Fuel Hoses

Recycling

1. Catch and dispose of escaping fuel.
2. Observe country-specific waste-disposal regulations.

Version With Hose Clamps

Release hose clamps.

Remove hoses (1) and (2).

Installation

1. Fuel hoses and hose clamps must be replaced each time they are removed!

Scheme 41

Version With Compressed Air Connection

Blow fuel back into tank with a short blast of compressed air (max. 3 bar) at compressed air connection (1).

Scheme 42

Version, Fuel Hoses Without Integrated Unlocking Facility

Unlock fuel hoses with special tool 16 1 050 and detach hoses.

Installation

1. Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.
2. Coat O-ring for assembly with anti-friction agent.

Scheme 43

Version, Fuel Hoses With Integrated Unlocking Facility

Press fuel hose (1) downwards and keep pressed.

Scheme 44

Press unlocking ring (2) upwards, keep pressed and detach fuel hose (1).

Installation

1. Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.
2. Coat O-ring for assembly with anti-friction agent.

Scheme 45

Installation Instruction 1

1. Always replace fuel hose (1) and hose clamps once they have been removed.

Scheme 46

Seal Off Fuel Hoses

Fuel hoses with hose clamps

Seal hoses with special tool 13 3 010.

Installation

1. Fuel hoses and hose clamps must be replaced each time they are removed!

Scheme 47

Fuel Hoses With Quick-Release Couplings

Seal fuel hoses (1) with special tool 13 5 281.

Seal fuel lines (2) with special tool 13 5 282.

Installation

1. Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.
2. Coat O-ring for assembly with anti-friction agent.

Scheme 48

13 64 501 Removing And Installing/Replacing A Fuel Injector (S54)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46) .

Special Tools Required

1. 12 1 120

Remove heater bulkhead. Refer to 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD .

Release screw.

Remove cable (1) from holder.

Scheme 49

Detach wiring harness (1) for fuel injector rail from holder (2).

Scheme 50

Scheme 51

Unlock connector strip with special tool 12 1 120 in sequence 1 to 6.

Lay connector strip to one side.

Scheme 52

Detach retainer (1). Pull fuel line out of fuel injector rail.

Recycling

Catch and dispose of escaping fuel.

Scheme 53

Release screw connection of fuel injector rail and air pipe on left and right.

Pull out fuel injector rail towards top.

Recycling

Catch and dispose of escaping fuel.

Scheme 54

Lever out retainers (1) and remove fuel injectors (2) from injection pipe.

Scheme 55

Installation

Check O-rings, replace if necessary.

When fitting, coat all O-rings with lubricant SAE 90.

Scheme 56

Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

13 54 010 Adjusting Basic Throttle Setting (S54)

Interrogate fault memory of DME control unit. Switch off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Scheme 57

Checking Basic Throttle Setting

To ensure that the basic throttle setting at the 6th throttle assembly can be properly checked, you must remove protective cap (1).

Release nuts.

Remove protective cap (1) of throttle.

Scheme 58

Remove idle-speed control valve (1) to facilitate access to throttle assembly 2.

Release nuts, remove idle-speed control valve (1) together with holder from assembly and place to one side.

Scheme 59

Gap between stop screw (1) and actuating lever (2) must be less than 0.05 mm.

To check gap, use a feeler gauge with a thickness of 0.05 mm.

Checking gap

1. Pull rod of throttle actuator in opening direction of throttles.
2. Slide feeler gauge (3) between stop screw (1) and actuating lever (2).
3. Return throttles slowly to stops.

Scheme 60

Press lever (1) on throttle actuator in closing direction of throttles. In so doing, compress overload spring (2) in pull rod (3).

Release lever (1) again.

When correctly adjusted, feeler gauge will jam between stop screw (1) and actuating lever (2) and will not fall out.

Perform check on each throttle assembly.

Scheme 61

Adjusting Basic Throttle Setting

A readjustment must be made if the gap is larger than 0.05 mm at one or more throttle assemblies.

Remove auxiliary air line. Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

Note. In order to ensure correct throttle setting, you must slacken all the screw connections on the actuating levers with the actuating shaft except at throttle assembly 1. It is not necessary to adjust the throttle at throttle assembly 1 because the actuating lever (1) on throttle assembly 1 is connected via set screw (3) to the actuating shaft (2). Also do not slacken screw connection of actuating lever of long pull rod with actuating shaft.

Scheme 62

To release screw connection of actuating lever with actuating shaft, only turn nut (2) and grip screw (1).

Slacken screw connections of actuating levers with actuating-j shaft on throttle assemblies 2, 3, 4, 5 and 6.

Scheme 63

Adjusting Throttle Assembly 2

Move actuating lever (1) of second throttle assembly downwards until actuating lever (2) rests without play against stop screw (3).

Scheme 64

Tighten down screw connections of actuating levers with actuating shaft again. Observe the following instructions in so doing

1. Use screws and nuts only once.
2. Only turn nut (2) and grip screw (1).
3. To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on the actuating lever; such torque would impair the quality of adjustment.
4. Retighten nut to tightening torque of 7 N.m.

Installation

If necessary, carry out adjustment with a second person.

Scheme 65

Adjusting Throttle Assemblies 3,4, 5 And 6

To adjust throttle assemblies 3, 4, 5 and 6, follow the same procedure as for adjusting throttle assembly 2. Carry out adjustment of throttle assemblies 3, 4, 5 and 6 in sequence.

Carry out checking of basic throttle setting.

If necessary, carry out adjustment of basic throttle setting again.

Adjusting Full-Load Stop

Activate servomotor via DIS Tester or MoDiC until throttles are fully open and stop screw (1) rests on detent lug.

Follow instructions featured in DIS Tester or MoDiC.

Scheme 66

Carry out measurement at throttle of first throttle assembly (cylinder 1).

Adjust measurement (A) = 24.66 mm +/- 0.2 mm by turning stop screw.

Activate servomotor several times and check whether measurement (A) is in tolerance range.

Scheme 67

1. Service functions.
2. DME system checks.
3. Function test.

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 54 030 Removing And Installing/Sealing Throttle Assembly (S54)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46) .

Special Tools Required

1. 12 1 120

Note. Interrogate fault memory of DME control unit. Turn off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Press lock together and detach air hose (1) from air pipe (2).

Scheme 68

Release nuts, remove idle-speed control valve (1) together with holder from assembly and place to one side.

Scheme 69

Detach wiring harness (1) for fuel injector rail from holder (2).

Detach hose (5) from air pipe (4).

Detach protective cap (3) from holder (2) towards top.

Note. J For a better overview, this work step is shown on an engine that 1 has been removed.

Scheme 70

Release nut and remove cable (1) from holder.

Scheme 71

Unlock plug (1) and detach from throttle potentiometer (2).

Scheme 72

Scheme 73

Unlock connector strip with special tool 12 1 120 in sequence 1 to 6.

Scheme 74

Recycling

Fuel escapes when fuel lines are detached. Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Detach retainer (1).

Recycling

Catch and dispose of escaping fuel.

Scheme 75

Release screw connection of fuel injector rail and air pipe on left and right.

Pull out fuel injector rail towards top.

Recycling

Catch and dispose of escaping fuel.

Scheme 76

Installation

1. Check O-rings, replace if necessary.

When fitting, coat all O-rings with lubricant SAE 90.

Scheme 77

Remove pulse generator for inlet camshaft. Refer to 12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (S54) .

Unclip pull rod (1) for throttle actuator on throttle side.

Scheme 78

Release screw connection of throttle assemblies.

Remove throttle assemblies.

Scheme 79

Installation

Clean sealing surfaces (1). Note correct position of adapter sleeves (2).

Note. For a better overview, only a removed throttle assembly is shown.

Scheme 80

Installation

Clean sealing surfaces on cylinder head.

Replace all O-rings (1) in cylinder head.

Scheme 81

1. Service functions.
2. DME system checks.
3. Function test.

Installation

Read out fault memory of control unit of Digital Motor Electronics (DME).

Check stored fault messages.

Rectify faults.

Now clear the fault memory.

13 54 045 Removing And Installing/Sealing A Throttle Assembly (S54)

Note. Interrogate fault memory of DME control unit. Turn off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Remove fan cowl. Refer to 17 11 031 REPLACING FAN COWL (S54) .

Release nuts, remove idle-speed control valve (1) together with holder from assembly and place to one side.

Scheme 82

If throttle assembly 1 is to be removed, remove throttle potentiometer. Refer to 13 63 555 REPLACING THROTTLE POTENTIOMETER (S54) .

If throttle assembly 6 is to be removed, remove pulse generator of inlet camshaft. Refer to 12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (S54) .

Remove fuel injector rail. This operation is described in 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54) .

Remove auxiliary air line. Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

Removal

Removal of a throttle assembly is described separately from its installation.

Unclip pull rod (1) for throttle actuator on throttle side (long pull rod).

Scheme 83

Unclip pull rods (1) on all throttle assemblies.

Scheme 84

Release screw connection of actuating lever on long pull rod.

Always grip screw (2) and turn nut (1) in so doing.

Scheme 85

Release screw connection of actuating lever with actuating shaft on all throttle assemblies.

Always grip screw (2) and turn nut (1) in so doing.

Scheme 86

Detach lock washer (1) from actuating shaft.

Scheme 87

Withdraw actuating shaft (1) in direction of arrow from throttle assemblies.

Note. If actuating shaft cannot be withdrawn, turn actuating lever to left or right.

Scheme 88

Support actuating lever (2) when withdrawing actuating shaft (1).

Scheme 89

Release screw connection of corresponding throttle assembly.

Remove throttle assembly.

Scheme 90

Installation

Removal of a throttle assembly is described separately from its installation.

Clean sealing faces (1). Note correct position of adapter sleeves (2).

Scheme 91

Clean sealing face of cylinder head.

Replace O-ring (1) in cylinder head.

Scheme 92

Position actuating lever (1) in such a way that it is flush with mount (2) for connecting pipe.

Hold actuating lever (2) and insert throttle assembly until it rests against engine block.

Scheme 93

Tighten down screw connection of corresponding throttle assembly.

Scheme 94

Push actuating shaft into bearings of throttle assemblies. Start on throttle assembly 1.

Feed out actuating lever (3) when pushing actuating shaft (1) into bearings of throttle assemblies (2).

Scheme 95

Insert fitting screw (1) as illustrated into actuating lever of throttle assembly 1.

Scheme 96

Tighten down screw connection of actuating lever with actuating shaft. Observe the following instructions in so doing

1. Use screws and nuts only once.
2. Only turn nut (2) and grip screw (1).
3. To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
4. Retighten nut to tightening torque of 7 N.m.

Scheme 97

Note. Actuating lever (1) of throttle assembly 3 and actuating lever (2) of pull rod for throttle actuator are offset approx. 180° to each other.

Ball ends are turned to each other.

Scheme 98

Insert fitting screw (1) as illustrated into actuating lever (2) of pull rod.

Observe position of actuating lever (2) to actuating lever (3).

Scheme 99

Tighten down screw connection of actuating lever on long pull rod. Observe the following instructions in so doing

1. Use screws and nuts only once.
2. Only turn nut (2) and grip screw (1).
3. To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
4. Retighten nut to tightening torque of 7 N.m.

Scheme 100

Insert screw (1) in all other actuating levers and fit nut (2).

Note. Do not tighten down nuts (2).

Scheme 101

Clip in pull rod (1) for throttle actuator on throttle side (long pull rod).

Scheme 102

Clip in pull rods (1) on all throttle assemblies.

Scheme 103

Carry out basic throttle adjustment. Refer to 13 54 010 ADJUSTING BASIC THROTTLE SETTING (S54) .

Assemble engine.

1. Service functions.
2. DME system checks.
3. Function test.

Installation

Read out fault memory of control unit of Digital Motor Electronics (DME).

Check stored fault messages.

Rectify faults.

Now clear the fault memory.

13 54 250 Replacing Intake Hose (S54)

Release hose clamps (1).

Detach intake hose (2) first from intake filter housing and then from intake air manifold.

Installation

Check sealing rings for damage, replace if necessary.

Check that suction pipe is correctly seated.

Scheme 104

13 62 560 Removing And Installing/Replacing Air-Mass Flow Sensor (S54)

Turn off ignition.

Unlock plug (2) and detach from air-mass flow sensor (1).

Release screws (3).

Withdraw air-mass flow sensor (1) from intake pipe.

Installation

Check O-ring for damage, replace if necessary.

Scheme 105

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 62 530 Replacing Transmission Fluid Temperature Sensor (SMG)

Note. After completing work: Check transmission fluid level.

Failure to comply with this requirement will result in serious damage to the transmission.

Remove rear underbody protection.

Detach cable plug (1) on transmission fluid temperature sensor.

Scheme 106

Release transmission temperature sensor (2).

Tightening torque, refer to 13 62 2AZ in FUEL SYSTEM - TIGHTENING TORQUES .

Remove transmission fluid temperature sensor (2).

Scheme 107

13 62 531 Replacing Coolant Temperature Sensor (S54)

Interrogate fault memory of DME control unit.

Switch off ignition.

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Unlock plug (1) and detach from idle-speed control valve.

Unlock plug (2) and detach from temperature sensor (3).

Unscrew temperature sensor (3).

Tightening torque, refer to 13 62 2AZ in FUEL SYSTEM - TIGHTENING TORQUES .

Installation

Check coolant level, top up coolant if necessary.

Scheme 108

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

Refer to 13 62 560 REMOVING AND INSTALLING/REPLACING AIR-MASS FLOW SENSOR (S54) .

13 63 555 Replacing Throttle Potentiometer (S54)

Interrogate fault memory of DME control unit.

Turn off ignition.

Unlock plug (1) and detach from throttle potentiometer (2).

Release screws (3).

Remove throttle potentiometer (2) from throttle assembly of cylinder 1.

Scheme 109

1. Service functions.
2. DME system checks.
3. Function test.

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 63 590 Replacing Fuel Pump Relay

Turn off ignition.

Remove glovebox on right. Refer to 51 16 360 REMOVING AND INSTALLING RIGHT GLOVEBOX .

Unclip glovebox light (1) in opening (2).

Disconnect plug connection of glovebox light and remove light.

Scheme 110

Release screws (1) and pin (2).

Remove insert (3) downwards.

Scheme 111

Feed out wire (1) for glovebox light from guides (2).

Scheme 112

Disconnect plug connections (1 and 2) on general module.

Scheme 113

Pull fuel pump relay (1) out of pin base.

Scheme 114

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

For additional instructions on troubleshooting, refer to DIS.

Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

Refer to 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54) .

13 71 000 Removing And Installing Intake Filter Housing (S54)

Turn off ignition.

Lever out expansion rivets (1).

Remove intake hood (2) with intake pipe (3) towards top.

Scheme 115

Release hose clamp (1).

Unlock plug (2) and detach.

Open retainer (3).

Rotate upper section of intake filter housing (4) towards top left. Detach intake hose from intake air manifold.

Remove upper section of intake filter housing (4).

Installation

Check seal between intake hose and intake air manifold for damage, replace if necessary.

Scheme 116

Installation

Insert retaining lugs (1) in openings (2).

Scheme 117

If necessary, remove control unit for left xenon headlamp. Refer to 63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT (M3) .

Note. Release only screw connection of control unit to body.

Detach screw connection of intake filter housing on body.

Remove air cleaner element (1).

Remove lower section of intake filter housing (2) towards top.

Scheme 118

Installation

Insert intake pipe (1) in intake hose (2).

Scheme 119

Installation

Install guide rail (1) on intake filter housing on rubber mount (2).

Scheme 120

13 72 001 Replacing Air Cleaner Element (S54)

Release hose clamp (1).

Unlock plug (2) and detach from air-mass flow sensor.

Release clips (3).

Rotate upper section of intake filter housing (4) in direction of arrow and remove.

Scheme 121

Installation

Check seal between intake hose and intake air manifold for damage, replace if necessary.

Installation

Insert retaining lugs (1) in openings (2).

Scheme 122

Withdraw air cleaner element and replace.

Installation

1. Clean lower section of intake filter housing before installing new air cleaner element.

Scheme 123

13 90 500 Replacing Tank Venting Valve (S54)

Turn off ignition.

Note. Tank venting valve is fitted at front under intake air manifold.

Remove upper section of intake filter housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54) .

Unlock plug (2) and detach from tank venting valve (1).

Press locking bar (4) and detach vent hose (3).

Detach hose (5) from tank venting valve (1).

Detach tank venting valve (1) with rubber holder together with intake air manifold.

Scheme 124

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

See also:
• FUEL SYSTEM - SPECIAL TOOLS - 3-SERIES (M54/E46)
• 12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (S54)
• 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD
• 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54)
• 12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (S54)
• 17 11 031 REPLACING FAN COWL (S54)
• 51 16 360 REMOVING AND INSTALLING RIGHT GLOVEBOX
• 63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT (M3)
• CHECKING FUEL PUMP DELIVERY PRESSURE (S54)
• 13 63 590 REPLACING FUEL PUMP RELAY
• 13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: INTAKE MANIFOLD PRESSURE)
• 13 53 540 REPLACING, SEALING FUEL HOSES
• 13 51 630 REPLACING FUEL PRESSURE REGULATOR (S54)
• 13 31 035 REPLACING FUEL LINE (S54)
• 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54)
• 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54)
• 13 63 555 REPLACING THROTTLE POTENTIOMETER (S54)
• 13 54 010 ADJUSTING BASIC THROTTLE SETTING (S54)
• 13 62 560 REMOVING AND INSTALLING/REPLACING AIR-MASS FLOW SENSOR (S54)
• 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54)
• 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54)