Engine Electrical System - Repair BMW M3 E46

12 00 Contents of Engine Electrical System General

CONTENTS OF ENGINE ELECTRICAL SYSTEM GENERAL

12 00 ... Instructions For Disconnecting And Connecting Battery

Observe safety instructions for handling vehicle battery. Refer to 61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before Disconnecting Battery

Switch off ignition.

Note. If the ignition is not turned off when the battery is disconnected, fault memories may be set in some control units.

General Notes On Disconnecting Battery

1. Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
2. Cars with IBS on battery negative terminal: Do not under any circumstances pull/lever off pole shoes by force. Do not under any circumstances release socket-head cap screw of IBS.
3. Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery negative terminal(s) and secure.
4. When work is carried out on the electrical system, faults may be caused in the fault memories of some control units when the battery is connected.
5. When fitting terminal for battery negative lead: Tightening torque, refer to 61 21 1AZ «ENGINE ELECTRICAL SYSTEM TIGHTENING TORQUES»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-tightening-torques) .

After Connecting Battery

Example

1. Activate sliding sunroof, refer to «54 0. NOTES ON STEEL AND GLASS SLIDE/TILT SUNROOFS (INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE)»(/bmw/m3/e46-1999-2006/remont/sun-rooft-topconvertible-top/#slidetilt-roof-repair__54-0-notes-on-steel) .
2. Vehicles with AFS only: activate steering angle.
3. If necessary, activate power windows.
4. If necessary, activate mirror with compass.

For further information and instructions on vehicle-specific activation, please refer to PROCEDURE FOR INITIALIZATION .

Vehicles With A Two-Battery System

Starter And Equipment Batteries

A two-battery system has a starter battery circuit and an equipment battery circuit. A secondary control unit monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from the secondary control unit via an isolating relay.

Two AGM batteries are used as a storage battery.

Receiving/Giving Starting Assistance Via Jump Start Terminal

The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of the engine compartment.

Note. The starter battery is isolated from the alternators when the engine hood/bonnet is open.

Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when the engine hood/bonnet is open.

Charging Starter And Equipment Batteries Via Jump Start Terminal

The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included in the charging operation. The secondary control unit automatically detects a charging operation at a charging voltage at the starter battery of +/= 13.5 V. The isolating relay is closed and thus the equipment battery is connected in parallel. Both batteries are now charged.

Prerequisite

1. Terminal 61 inactive.
2. Terminal 15 inactive.

If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and again only the starter battery is charged.

Note. When the engine hood is open, the isolating relay is also opened in normal operation when the engine is running. A special mode can be set by means of diagnosis for workshop/garage operation. The isolating relay is closed from terminal R in this operating mode. This mode is automatically reset once a distance of 5 km has been driven.

Trickle Charging

Increased closed-circuit current consumption can be compensated with the aid of the battery trickle charger (special tool 61 2 410) via the jump start terminal.

12 13 Notes On Checking Ignition System

NOTES ON CHECKING IGNITION SYSTEM

12 00 ... Information On Working On Ignition System

Safety Instructions

1. Always switch off ignition before working on ignition system.
2. Use only test leads which have been approved and belong to the testing instruments (e.g. DIS Tester).
3. Comply with operating instructions of the respective testing instrument used.
4. Comply with the country-specific safety regulations.
5. Never touch components conducting current with engine running!
6. Comply with instructions of DIS tester.
7. Do not connect any suppression capacitors or inspection lamps to terminal 1 on the ignition coil.
8. Terminal 1 of ignition coil must not be connected to ground or battery positive lead.
9. If an alarm system is subsequently installed, lead of terminal 1 must not be used for start prevention.
10. When working on ignition system, always disconnect supply leads to ignition coils.

High Voltage! - Mortal Danger!

12 00 ... Instructions For Removing And Installing Electronic Control Units

12 00 ... Instructions For Welding Work (Overload Protection Of Control Units)

When performing welding work on installed control units, to avoid any defects in the electronic control units, observe the following steps

1. Observe instructions for disconnecting and connecting battery. See «12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-00-instructions-for-disconnecting) .
2. Detach terminal of battery negative lead from car battery and second battery if fitted. Cover negative terminal posts.
3. If welding is to be performed near the battery/batteries, first remove battery/batteries from vehicle (flying sparks - combustion of explosive gas).
4. Fit return clamp on welding unit as close as possible to welding point (maximum distance approx. 1 m).
5. Never connect return clamp to ground pin on body which has ground wires attached!

12 00 ... Instructions For Connecting And Disconnecting Test Units

When connecting and disconnecting

1. Service Tester.
2. Testing devices.
3. Test leads.
4. When replacing control units.

It Is Essential To Turn Off The Ignition!

Follow instructions for removing and installing electronic control units, refer to 12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS .

Follow operating instructions for testing devices.

Make sure that connected test leads cannot make contact with rotating parts (e.g.: fans, ribbed V-belts, etc.).

12 00 ... Instructions On Component Inspection

Note. During all inspections and work on engine electrics and electronics, always observe safety regulations and accident prevention specifications. Always disconnect connectors of control units or components before checking electric wires.

Testing Aids

1. Schematics, refer to Diagnosis Information System (DIS).
2. Only ever use test lines, adapters, terminals and test tips manufactured by specialists, refer to Diagnosis Information System.
3. The inspection values for component testing are located in the Diagnosis Information System (DIS).
4. For further technical information, refer to «ENGINE ELECTRICAL SYSTEM - TECHNICAL DATA»(ref-201330) .

12 00 ... Instructions On Starting Aid

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting engine with starting cable

1. Ensure that jump lead wires are to appropriate cross-section size.
2. Only use fuse-protected jump leads.
3. Check whether the current supplying battery has 12 V voltage.
4. If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of both vehicles.

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed.

Carrying Out

Always conform with the procedures to avoid injury to persons or damage to parts

1. On automatic transmission, select "P" setting, apply handbrake.
2. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect positive terminals of both batteries with one jump lead (red).
5. Use positive connection point in engine compartment for vehicles with one battery in trunk.
6. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started.

12 13 ... Fault In Fuel Injection System

Evaluation of ignition voltage peaks in response to sudden accelerator loads. (Scheme 2)

Scheme 2

1. Beginning of dying-out process is not much higher than ignition voltage peak. Ignition system is OK.
2. Beginning of dying-out process is considerably higher than ignition voltage peak. Fault in injection system: Lean Mixture. Defective Injection Valve. Low Compressions.

12 13 ... Spark-Plug Faults

Evaluation of sparking period at idling speed.

1. Normal ignition voltage peak. Spark plug is OK.
2. Low ignition voltage peak. Small electrode gap.
3. High ignition voltage peak. Large electrode gap.

Scheme 3

Evaluation of sparking period at idling speed

Scheme 4

1. Normal combustion period: Spark plug is OK

Long combustion period

1. Small electrode gap.

Short sparking period

1. Large electrode gap.

12 13 ... Ignition Coil Faults

Evaluation of ignition voltage peaks and attenuation process at idling speed

1. Beginning of attenuation processes with normal peaks upwards and downwards.
2. Beginning of attenuation processes strongly shortened. Ignition coil is defective.
3. Absence of initial downwards attenuation. Ignition coil is defective. NOTE: Higher ignition voltage peak is not always available.

Evaluation of sparking voltage line at idling speed

1. Normal combustion period.
2. Normal attenuations to sparking voltage line. Ignition coil is OK.

1. Shorter sparking period.
2. Attenuation to sparking voltage line is only slight. Ignition coil is defective.

1. Much shorter sparking period.
2. Attenuations to sparking voltage line absent. Ignition coil is defective.

No sparking voltage line. Ignition coil is defective.

Scheme 5

Evaluation of combustion voltage line at raised engine speeds approx. 1500 Min (1)

1. Normal combustion period.
2. Normal attenuations to sparking voltage line. Ignition coil is OK.

1. Shorter sparking period.
2. Attenuation to sparking voltage line is only slight. Ignition coil is defective.

1. Normal combustion period.
2. Attenuations to sparking voltage line absent. Ignition coil is defective.

12 13 ... Further Fault Patterns With Evaluation

Evaluation of sparking period and ignition voltage peaks at idling speed

1. Normal combustion period.
2. Normal ignition voltage peak. Ignition system is OK.

Long sparking period (1) with low ignition voltage peak (2). Indicates low compression.

Fluctuating sparking period: Indicates contamination on spark plug (shunt).

Scheme 6

Short sparking period (1) with high ignition voltage peak. Constant but short sparking period: Indicates defective ignition lead.

Scheme 7

Note. The sparking-voltage line could sometimes be missing completely and the ignition voltage peak could rise very high.

IGNITION VOLTAGE TOO HIGH

IGNITION VOLTAGE TOO LOW

12 13 ... Additional Fault Notes For Troubleshooting

Use the primary voltage test adapter, Special Tool 12 7 020 to troubleshoot the primary side of a separate ignition coil.

Scheme 8

Note. If terminal 1 signal is not present on pin 1 in the diagnosis connector, the external trigger signal for the BMW Service Tester can be prepared with the help of Special Tool 12 7 020.

Connect BMW SERVICE TESTER.

Select Engine Test Step 05.

Enter number of cylinders (four).

Connect universal adapter to tester.

Connect brown clip to vehicle earth.

Connect black clip to terminal 1 of Special Tool 12 7 020.

Note. If trigger signal is missing from diagnosis box on 6-cylinder engine, preselect two cylinder settings on BMW SERVICE TESTER.

The red inductive clip is not used as only the cylinder is being tested. For this reason, the engine speed display will be too low by factor 4.

Connect Special Tool 12 7 020 to the ignition coil being tested and the vehicle wiring harness.

Produce a stationary signal on the oscilloscope by pressing key R.

Scheme 9

Note. The sparking voltage line on the oscilloscope will be very nervous, as the fuel/air mixture swirl of a 4-valve engine will be greater than that of a 2-valve engine.

12 13 ... Normal Oscillogram (M, S, W Engines Only)

1. Start Of Ignition Voltage Peak.
2. Level Of Ignition Voltage.
3. Level Of Combustion Voltage.
4. Period Of Combustion.
5. Combustion Curve Characteristics.
6. Start Of Decay Process.
7. Termination Oscillations.

Secondary voltage patterns, beside one another: Evaluation of ignition voltage peaks at idle speed (this example shows an engine with 4 cylinders). Note: The display of ignition voltage spikes is approx. 20-25% lower than the real value. The uniformity of all cylinders to each other is more important than the height of ignition voltage peaks. Differences of 3000-4000 V are permitted. In event of greater differences, refer to FURTHER FAULT PATTERNS WITH EVALUATION .

Scheme 10

Evaluation of ignition voltage peaks at increased speed of approx. 2000 RPM (this example shows an engine with 4 cylinders).

Scheme 11

Secondary voltage diagrams, superimposed: Evaluation of combustion characteristics curve and decay characteristics at idle speed (this example shows a 4-cylinder engine).

Scheme 12

Secondary voltage diagrams, consecutive: Note: Only the major differences in the ignition voltage patterns are revealed by this method of comparison. The identified fault must be allocated to the relevant cylinder using the secondary voltage representation forms next to/on top of each other.

Scheme 13

12 13 ... Oscillograms Of Ignition Coils From Different Manufacturers

Evaluation Of Ignition Voltage Peaks And Decay Characteristics At Idle Speed.

Make: Bremi

1. 1. Normal ignition voltage spikes (6000-9000 V).
2. 2. Normal start of attenuation processes.

Make: Beru

1. 3. Normal ignition voltage peak.
2. 4. High initial level of attenuation processes.

Make: May & Christe

1. 5. Normal ignition voltage peak.
2. 6. Low initial level of attenuation processes.

Make: Bosch

1. 7. Low ignition voltage peak.
2. 8. Normal start of attenuation processes.

Note

At high speeds, the ignition voltage peak falls very markedly relative to the peaks on units from other ignition coil manufacturers.

Scheme 14

Evaluation Of Combustion Voltage Characteristics At Raised Engine Speed Of Approx. 2500 RPM.

Make: Bremi

1. 1. Normal oscillation of the combustion. voltage curve
2. 2. Normal combustion period.
3. 3. 3 to 4 attenuations.

Make: Beru

1. 1. Normal oscillation of the combustion. voltage curve
2. 2. Normal combustion period.
3. 3. At least 3 decay oscillations.

Make: May & Christe

1. 1. No oscillation on combustion voltage curve.
2. 2. Normal combustion period.
3. 3. At least 5 decay oscillations.

Make: Bosch

1. 1. Normal oscillation of the combustion voltage curve.
2. 2. Long combustion period.
3. 3. At least 3 decay oscillations.

12 13 ... Checking Secondary Signal For Stationary Ignition Distribution

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

1. 12 7 030

Engine Test Step 10

Remove ignition coil. Clip Special Tool 12 7 030 on relevant ignition coil to be tested. Clip high tension clip around ignition lead.

Scheme 15

Connect earth lead of adapter to vehicle earth and ignition coil.

Connect up diagnosis connector.

If trigger signal is not present (terminal 1), connect black clip of universal adapter cable to pin 1 of primary adapter cable.

Scheme 16

Produce a stationary signal by pressing key R on the tester.

NOTE: Neighboring ignition leads could produce interference on the screen of the oscilloscope.

Refer to the fault memories of engine control units for additional troubleshooting.

Interrogate fault memory and its fault reports, refer to appropriate article.

Scheme 17

12 12 011 Replacing All Spark Plugs (S54)

Switch off ignition.

Remove ignition coils. Refer to 12 13 511 REPLACING IGNITION COIL (S54) .

Unscrew and remove spark plugs with special tool 12 1 171.

Installation

1. Using special tool 12 1 171 in conjunction with special tool 12 1 172, tighten spark plugs.

If special tool 12 1 172 is not used, observe tightening torque, refer to 12 12 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 18

Refer to 12 13 NOTES ON CHECKING IGNITION SYSTEM .

Refer to 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION DISTRIBUTION .

Refer to NORMAL OSCILLOGRAM (M, S, W ENGINES ONLY) .

12 13 009 Checking Ignition Coils (Secondary Coil)

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

1. 12 7 040
2. 12 7 041
3. 12 7 042
4. 12 7 043
5. 12 7 045
6. 12 7 046
7. 12 7 050

Carry out secondary voltage check using test adapter 12 7 040.

Note. The following checks can be carried out with the adapter kit: Secondary voltage check, refer to 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION DISTRIBUTION . Comparison between ignition coils from different manufacturers, refer to OSCILLOGRAMS OF IGNITION COILS FROM DIFFERENT MANUFACTURERS . Ignition coil faults, refer to IGNITION COIL FAULTS . Spark plug faults, refer to SPARK-PLUG FAULTS . Injection system faults, refer to 12 13 ... FAULT IN FUEL INJECTION SYSTEM .

Scheme 19

Connect special tool 12 7 043 (connecting cable) to special tool 12 7 041 (single adapter).

Scheme 20

Note. Checks on engines with single-spark ignition coils: Special tool 12 7 041 (single adapter) in conjunction with special tool 12 7 045 for fitting onto ignition coil.

Scheme 21

Remove cover for ignition coils.

Version With Single-Spark Ignition Coils

Mount special tool 12 7 041 on ignition coils and connect to special tool 12 7 043.

Scheme 22

Connect DIS Tester with RZV connecting lead to last test adapter (RZV = static ignition distribution).

Connect trigger pliers of DIS tester to feed line on ignition coil of 1st cylinder.

1. Select "Measurement".
2. Select "Preset measurements".

Subsequent procedure in accordance with DIS instructions.

Scheme 23

Version With Rod-Type Ignition Coils

Unlock plug on rod-type ignition coil and disconnect.

Remove rod-type ignition coil, connect special tool 12 7 050 (adapter cable) to spark plug and ignition coil, connect ignition coil to engine wiring harness.

Carry out measurements following DIS instructions.

Scheme 24

Version With Ignition Coil Block

Raise cover on ignition coil block slightly and fit special tool 12 7 046.

Connect special tool 12 7 046 to adapter cable 12 7 042 and then to Tester.

Scheme 25

Note. The adapter cable 12 7 042 is located in the case of the adapter kit 12 7 040. Follow instructions for troubleshooting with aid of adapter kit: Normal oscillogram MG12, refer to NORMAL OSCILLOGRAM (M, S, W ENGINES ONLY) . Ignition coil comparison MG12, refer to OSCILLOGRAMS OF IGNITION COILS FROM DIFFERENT MANUFACTURERS . Ignition coil fault MG12, refer to IGNITION COIL FAULTS . Spark plug G12, refer to SPARK-PLUG FAULTS . Further fault patterns MG12, refer to FURTHER FAULT PATTERNS WITH EVALUATION . Fault at injection system MG12, refer to 12 13 ... FAULT IN FUEL INJECTION SYSTEM .

12 13 511 Replacing Ignition Coil (S54)

Turn off ignition.

Remove heater bulkhead.

Remove engine vent (1).

Release screws.

Unscrew oil filler cap (2).

Remove cover.

Scheme 26

Unlock plug lock (1) for ignition coil.

Scheme 27

Detach plug (1) from ignition coil.

Scheme 28

Withdraw ignition coil.

This removal procedure is applicable to all ignition coils.

Installation

The lug on the cylinder head (2) must be inserted in the opening on the underside (1) of the rubber seal.

Scheme 29

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

12 14 511 Replacing Transmission Speed 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 speed sensor.

Scheme 30

Release screw.

Remove transmission speed sensor (2).

Installation

Replace microencapsulated screw.

Tightening torque, refer to 12 14 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 31

12 14 521 Replacing Pulse Generator On Crankshaft (S54)

Turn off ignition.

Remove reinforcement plate on front axle support.

Note. Installation location of pulse generator for crankshaft is underneath starter motor.

Unlock plug (1) and detach from distributor housing (2).

Note. For a better overview, the intake air manifold is not shown.

Scheme 32

Release screw.

Installation

Tightening torque, refer to 12 14 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Unclip cable of pulse generator (1) from holder (2).

Remove pulse generator (1).

Note. For a better overview, this work step is shown on an engine that has been removed and without the starter motor.

Scheme 33

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

12 14 523 Replacing Pulse Generator On Inlet Camshaft (S54)

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

1. 12 1 120

Turn off ignition.

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

Remove cable strip for fuel injectors with special tool 12 1 120. This operation is described in 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54) .

Release screw on pulse generator (1).

Disconnect pulse generator plug connection on connector strip.

Remove pulse generator (1).

Installation

1. Tightening torque, refer to 12 14 3AZ in «ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES»(ref-201360) .
2. Check sealing ring of pulse generator for possible damage, replace if necessary.

Scheme 34

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

12 14 524 Replacing Pulse Generator On Exhaust Camshaft (S54)

Turn off ignition.

Note. The installation location of the pulse generator for exhaust camshaft is at the rear of the cylinder head on the exhaust side.

Scheme 35

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

Unlock plug (1) and detach from pulse generator.

Release screw on cylinder head.

Remove pulse generator.

Scheme 36

Installation

Tightening torque, refer to 12 14 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Check sealing ring for possible damage, replace if necessary.

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

12 14 550 Replacing Control Module (DME)

Follow instructions for removing and installing electronic control units. Refer to 12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS .

Before replacing the control module, always follow the instructions listed below

1. Code control unit. Refer to «12 14 700 CODING CONTROL MODULE (DME/DDE)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-14-700-coding-control-module) .
2. Program control unit. Refer to «12 14 705 PROGRAMMING CONTROL UNIT (DME/DDE)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-14-705-programming-control-unit) .

Turn off ignition.

Release screws (1).

Remove cover.

Scheme 37

Installation

Correctly install wiring harness with grommet in cover (water tightness).

Hook cover (3) into hinges of underside of electronics box (1). Make sure upper stop (2) is correctly installed above hinges on underside of electronics box.

Scheme 38

Assignment of electronics box (with automatic transmission)

Scheme 39

1. = Control unit, Digital Motor Electronics (DME).
2. = Control unit for automatic transmission.

Disconnect plug connections (1).

Remove control unit (2).

Installation

Replacement

Observe equipment no. and coding.

Scheme 40

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

12 14 600 Replacing Knock Sensor(s) (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) .

Release nuts and place idle-speed control valve (1) to one side.

Scheme 41

Unlock plug and detach from knock sensor.

Release knock sensor screw connection on engine block.

Installation

Tightening torque, refer to 12 14 2AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove knock sensor.

Scheme 42

Installation

1. Clean contact surface of knock sensors on engine block.

Scheme 43

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

12 14 700 Coding Control Module (DME/DDE)

Switch off ignition.

Connect MoDiC or DIS/GT1 Tester.

Switch on ignition.

Select "Coding" program.

For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.

Carry out adjustment of following control units

1. EWS (electronic immobilizer).
2. DME (Digital Motor Electronics) or
3. DDE (Digital Diesel Electronics).

12 14 705 Programming Control Unit (DME/DDE)

Switch off ignition.

Connect MoDiC or DIS/GT1 Tester.

Switch on ignition.

Select "Programming".

For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.

Carry out adjustment of following control units

1. EWS (electronic immobilizer).
2. DME (Digital Motor Electronics) or
3. DDE (Digital Diesel Electronics).

12 63 520 Replacing Main Relay

Switch off ignition.

Connect DIS Tester.

Release screws (1).

Remove electronics box cover.

Scheme 44

Installation

Correctly install wiring harness with grommet in electronics box cover (water tightness).

Hook cover (3) into hinges of underside of electronics box (1). Then correctly install upper stop (2) above hinges on underside of electronics box.

Scheme 45

Arrangement

1. Main relay of Digital Motor Electronics.
2. Engine fuses of Digital Motor Electronics.

Scheme 46

Notes On Troubleshooting

If the starter motor cranks the engine during the starting sequence but the engine fails to fire, then

1. Check engine fuses.
2. If fuses are blown, replace them completely with fuse holder.
3. Find out why fuses have blown.

Continue troubleshooting as per DIS instructions.

12 72 010 Removing And Installing/Replacing Throttle Actuator (S54)

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 47

Unhook pull rod (1) from ball head on servomotor side.

Scheme 48

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

Scheme 49

Release nuts and lay idle-speed control valve (1) to one side to gain access to screw connection of cable duct.

Scheme 50

Release screw and remove manifold support (1).

Installation

In order to avoid torsion stress on manifold, secure manifold support with screw but do not tighten down screw. Only tighten down screw when manifold is mounted on throttle assembly.

Scheme 51

Release screws.

Lay cable duct (1) to one side.

Scheme 52

Release screws (1).

Remove throttle actuator (2).

Installation

Adjust full-load stop after installing throttle actuator. Adjusting the full-load stop is described in 13 54 010 ADJUSTING BASIC THROTTLE SETTING (S54) .

Scheme 53

Installation

Check adapter sleeves (1) for damage and correct installation position.

Scheme 54

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 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 55

Release transmission temperature sensor (2).

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

Remove transmission fluid temperature sensor (2).

Scheme 56

61 35 ... Note On Replacing Codable/Programmable Control Units

Replacement

Carry out coding/programming.

Observe following IDC specifications

1. Programming.
2. Coding.

Scheme 57

12 31 ... Replacing Alternator Belt Pulley

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

1. 12 7 110

Remove and install alternator drive belt.

Depending on alternator type, grip shaft with

1. Hexagon socket.
2. Multi-tooth socket or
3. Torx socket wrench.

Release nut with special tool 12 7 110.

Installation

Tightening torque, refer to 12 31 2AZ/12 31 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 58

12 31 020 Removing And Installing/Replacing Alternator (S54)

Note. Switch off ignition. Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY . Disconnect and cover battery negative lead.

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

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S54) .

Note. Drain the main flow oil filter in order to prevent an excessive discharge of oil when the oil cooler lines are disconnected. This operation is described in 00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54) .

Release screw on holder for oil cooler lines (1).

Scheme 59

Scheme 60

Release screw.

Detach oil lines from main flow oil filter housing.

Lay oil lines to one side to open up access to screw connection of battery positive lead on alternator.

Installation

Replace O-rings.

Release nut (1).

Installation

Tightening torque, refer to 12 31 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove battery positive lead from alternator.

Unlock plug (2) and detach from alternator.

Scheme 61

Release screw (1).

Lift off protective cap of screw (2) of tensioning roller.

Release screw (2) and pull out together with tensioning roller.

Remove alternator.

Scheme 62

Installation

Turning lock of tensioning roller must snap into place in groove.

Scheme 63

12 32 501 Replacing Voltage Regulator (Valeo/Bosch)

Read General Information in MG12, refer to DISCONNECTING AND CONNECTING TEST EQUIPMENT and 12 00 ... INSTRUCTIONS ON COMPONENT INSPECTION .

Read fault memory.

Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY Disconnect battery ground wire

Remove alternator, refer to 12 31 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR (S54) .

Valeo Alternator

Release screws on cover.

Scheme 64

Release screws.

Remove regulator switch.

Scheme 65

Check contact surfaces of collector rings for wear and recondition if necessary.

Scheme 66

Installation

Install regulator switch with assembly cap.

Initially tighten nuts of regulator switch.

Scheme 67

Installation

Remove assembly cap (1).

Scheme 68

Installation

Fit supplied cover cap (2).

Tighten down nuts and ground screw of regulator switch.

Tightening torque, refer to 12 32 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 69

Bosch Alternator

Release screws on cover

Scheme 70

Release screws.

Remove regulator switch.

Check contact surfaces of collector rings for wear and recondition if necessary.

Scheme 71

12 41 020 Removing And Installing/Replacing Starter Motor (S54)

Observe instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect battery negative lead from battery.

Remove rear underbody protection.

Remove reinforcement plate on front axle support.

Note. For a better overview, this work step is shown from above and without the intake air manifold. Do not remove intake air manifold and carry out work from below.

Release nuts.

Installation

1. Tightening torque, refer to 12 41 4AZ in «ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES»(ref-201360) .

Disconnect battery positive leads (1 and 2) from starter motor.

Disconnect lead (3) from starter motor.

Note. For a better overview, the illustrations of other BMW cars are used for the following work steps.

Scheme 72

Releasing both starter motor mounting bolts (1) on transmission

Release starter motor screws from transmission output end with a long extension and universal joints.

Installation

Tightening torque, refer to 12 41 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 73

Withdraw starter motor (1) from transmission flange and remove towards bottom.

Scheme 74

Installation

Check starter motor pinion and ring gear for damage.

Scheme 75

12 41 041 Replacing Solenoid Switch

Turn off ignition.

Remove starter motor.

Release nut (1).

Remove cable lug (2).

Scheme 76

Tightening torque, refer to 12 41 4AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Release screws (1).

Scheme 77

Remove solenoid switch (1) and spring (2). Unhook pin (3).

Installation

Check pin (3) for wear and apply grease.

Scheme 78

12 42 510 Replacing Battery Positive Lead (Between Starter Motor And B+ Support Point) (S54)

Read fault memory. Switch off ignition.

Observe safety instructions for handling vehicle battery. Refer to 61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Remove front underbody protection.

Observe instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect battery negative lead from battery and lay to one side.

Unclip battery positive lead from clips (1).

Feed battery positive lead out of cable duct.

Scheme 79

Fold back protective cap (1).

Release nut (2).

Installation

Tightening torque, refer to 12 51 4AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Disconnect battery positive lead (3) from connection point.

Scheme 80

Detach holder of battery positive lead on intake air manifold

Gently raise lug (1) and slide holder upwards.

Scheme 81

Remove reinforcement plate on front axle support.

Note. For a better overview, this work step is shown without the intake air manifold and from above. Carry out the work from below.

Release nut.

Installation

Tightening torque, refer to 12 41 4AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Disconnect battery positive lead from starter motor.

Remove battery positive lead.

Scheme 82

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

12 42 540 Replacing Safety Battery Terminal (SBK)

Use of safety battery terminal

1. From model year 1998 in Series E38, E39, E46.
2. From 4/99 in E36/Z3.
3. In each of following new Series.

The different models have different installation locations

Battery In Engine Compartment

Safety battery terminal is replaced with cable up to battery positive support point.

Safety Battery Terminal Is Omitted As From 03/2002 From All E46 LHD Models With 4-Cylinder Engines.

Battery In Luggage Compartment Behind Side Trim Panel

Remove side trim panel.

Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect and cover battery negative lead.

Scheme 83

Release front side trim panel partly and fold forward.

Scheme 84

Battery In Luggage Compartment Under Floor Trim Panel

Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Fold back floor trim panel (1).

Lift cover (2) on battery negative lead.

Disconnect and cover battery negative lead (3).

Release nuts (4).

Remove battery cover.

Scheme 85

Battery In Luggage Compartment Under Spare Wheel

Remove spare wheel.

Release screws.

Set air supply system (1) to one side.

Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect battery negative lead.

Scheme 86

Disconnect supply cable (1) for vehicle electrical system.

Installation

1. Remove faulty fuses and carry out troubleshooting.

Scheme 87

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.

Scheme 88

Release cable ties (1).

Disconnect plug connection (2).

Scheme 89

Saw through battery positive cable at marked point with an iron saw.

Scheme 90

Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.

Scheme 91

Push heavy-current connector (1) over stripped cable end and screw into position.

Scheme 92

Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.

Scheme 93

Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).

Scheme 94

Note. Heat up shrink-fit hose until it has settled completely around the connection point.

Scheme 95

When laying the repaired battery positive cable, observe the following

1. The shrink-fit hose must not be scuffed during any movement.
2. The repair cable must not cause any disturbing noises during driving operation.

Note. Offsetting cutting line by approx. 10 cm produces excess length of battery positive lead (1). Lay battery positive lead (1) without kinks or abrasions. (Shown on E46 touring.)

Scheme 96

12 51 001 Replacing Wiring Harness Section For Engine (S54)

Note. Switch off ignition. Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY . Disconnect and cover battery negative lead.

Preparatory tasks

1. Remove intake air manifold. Refer to «11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-61-050-removing-and-installing) .
2. Remove fan cowl. Refer to «17 11 031 REPLACING FAN COWL (S54)»(/bmw/m3/e46-1999-2006/remont/cooling-system-mechanical/#cooling-system-repair__17-11-031-replacing-fan-cowl) .
3. Remove ignition coil cover. Refer to «12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (S54)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-51-100-replacing-wiring-harness) .

NOTES ON CHECKING IGNITION SYSTEM

Release screw and remove manifold support (1).

Installation

To avoid manifold torsion stress, secure manifold support with I screw but do not tighten down screw. Only tighten down screw

Scheme 97

Release screws and remove cable duct (1).

Scheme 98

Detach sealing strip (1).

Turn toggle (2) through 90 degrees.

Remove partition wall for equipment compartment (3).

Release nut.

Remove cable housing (4).

Installation

Ensure profile seals are correctly positioned.

Scheme 99

12 51 100 Replacing Wiring Harness Section For Ignition Coil (S54)

Turn off ignition.

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

Lever out expansion rivets.

Remove air duct (1).

Scheme 100

Remove engine vent (1).

Release screws.

Unscrew oil filler cap (2).

Remove ignition coil cover.

Scheme 101

Release screws (1) on cable strip (2).

Scheme 102

Tilt plug locks (1) of ignition coils upwards.

Scheme 103

Detach plugs (1) from ignition coils.

Scheme 104

Disconnect ground connection (1).

Pull out wiring harness (2) towards top.

Scheme 105

Detach plug connections of wiring harness section for ignition coils in electronics box. This task is described in 12 14 550 REPLACING CONTROL MODULE (DME) .

Detach strip on left equipment partition wall.

Withdraw wiring harness section for ignition coils from left equipment partition wall and remove.

Installation

Pay attention to correct installation position of seal from wiring harness section for ignition coils in left equipment partition wall.

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

12 61 280 Removing And Installing/Replacing Oil Pressure Switch (S54)

Turn off ignition.

Note. Drain the main flow oil filter in order to prevent an excessive discharge of oil when the oil pressure switch is removed. This operation is described in 00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54) .

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

Unlock plug (1) and detach from oil pressure switch (2). Unscrew oil pressure switch (1).

Tightening torque, refer to 12 61 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Scheme 106

Note. Assemble car and set in horizontal position. Start engine and run at idle until oil indicator lamp goes out. Switch off engine and wait approx. 5 minutes. Then check engine oil level. Top up engine oil if necessary.

12 61 285 Replacing Level Switch For Engine Oil (M62, M54, S54, M56)

Necessary Preliminary Tasks

Scheme 107

1. Switch off ignition.
2. Unfasten cover on full-flow oil filter to enable engine oil in filter to flow back into the oil sump.
3. Drain engine oil. These operations are described in «00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__00-00-250-bmw-engine-oil) . Remove reinforcement plate. IMPORTANT: The article «DRIVE AXLE SHAFTS & SEAL (FRONT, ALL WHEEL DRIVE)»(/bmw/m3/e46-1999-2006/remont/axle-shafts/#frontrear-drive-axle-repair-2wd-4wd) contains important installation instructions. Disconnect plug connection (1) Unscrew nuts (2). Remove level switch (3). Installation: Clean sealing surface on oil sump and replace seal of level switch.

Installation

Screw on oil-filter cover tightly.

Tightening torque, refer to 11 42 2AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Top up engine oil. Refer to 00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54) .

Refer to 12 63 520 REPLACING MAIN RELAY .

Refer to 12 72 010 REMOVING AND INSTALLING/REPLACING THROTTLE ACTUATOR (S54) .

Refer to 12 72 010 REMOVING AND INSTALLING/REPLACING THROTTLE ACTUATOR (S54) .

See also:
• 61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
• ENGINE ELECTRICAL SYSTEM TIGHTENING TORQUES
• 54 0. NOTES ON STEEL AND GLASS SLIDE/TILT SUNROOFS (INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE)
• DRIVE AXLE SHAFTS & SEAL (FRONT, ALL WHEEL DRIVE)
• 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54)
• 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54)
• 13 54 010 ADJUSTING BASIC THROTTLE SETTING (S54)
• 17 11 031 REPLACING FAN COWL (S54)
• 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S54)
• 00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54)
• AIR BAG SAFETY PRECAUTIONS
• 13 41 500 REPLACING IDLE-SPEED CONTROL VALVE
• 13 63 555 REPLACING THROTTLE POTENTIOMETER (S54)
• 11 36 010 REMOVING AND INSTALLING, SEALING/REPLACING VANOS ADJUSTMENT UNIT (S54
• 13 62 531 REPLACING COOLANT TEMPERATURE SENSOR (S54)
• 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD
• 12 00 ... INFORMATION ON WORKING ON IGNITION SYSTEM
• 12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS
• 12 00 ... INSTRUCTIONS FOR WELDING WORK (OVERLOAD PROTECTION OF CONTROL UNITS)
• 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• DISCONNECTING AND CONNECTING TEST EQUIPMENT
• 12 00 ... INSTRUCTIONS ON COMPONENT INSPECTION
• 12 00 ... INSTRUCTIONS ON STARTING AID
• 12 13 ... FAULT IN FUEL INJECTION SYSTEM
• SPARK-PLUG FAULTS
• IGNITION COIL FAULTS
• FURTHER FAULT PATTERNS WITH EVALUATION
• ADDITIONAL FAULT NOTES FOR TROUBLESHOOTING
• NORMAL OSCILLOGRAM (M, S, W ENGINES ONLY)
• OSCILLOGRAMS OF IGNITION COILS FROM DIFFERENT MANUFACTURERS
• 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION DISTRIBUTION
• 12 13 511 REPLACING IGNITION COIL (S54)
• 12 13 NOTES ON CHECKING IGNITION SYSTEM
• 12 14 700 CODING CONTROL MODULE (DME/DDE)
• 12 14 705 PROGRAMMING CONTROL UNIT (DME/DDE)
• 12 31 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR (S54)
• 12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (S54)
• 12 72 010 REMOVING AND INSTALLING/REPLACING THROTTLE ACTUATOR (S54)
• 12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (S54)
• 12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SWITCH (S54)
• 12 14 600 REPLACING KNOCK SENSOR(S) (S54)
• 12 14 524 REPLACING PULSE GENERATOR ON EXHAUST CAMSHAFT (S54)
• 12 61 285 REPLACING LEVEL SWITCH FOR ENGINE OIL (M62, M54, S54, M56)
• 12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (S54)
• 12 14 521 REPLACING PULSE GENERATOR ON CRANKSHAFT (S54)
• 12 14 550 REPLACING CONTROL MODULE (DME)
• 12 63 520 REPLACING MAIN RELAY
• 12 72 010 REMOVING AND INSTALLING/REPLACING THROTTLE ACTUATOR (S54)