Engine Electrical System - Repair - e90 BMW M3 E90

61 20... Battery replacement information

A vehicle battery is constructed for the installation location and the individual power requirements of the particular vehicle. These individual power requirements depend on the motorization and different types of optional equipment. The individually assigned vehicle battery is the ideal compromise between the power requirements of the vehicle electrical system and the weight and service life of the vehicle battery.

Vehicles with the automatic engine start-stop function or particular motorization and optional equipment are equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power requirements over the extended service life. Installing a different vehicle battery can cause problems with vehicle electronics, can reduce functions or can cause leakage of battery acid.

In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected through pyrotechnics. This prevents a possible short circuit.

Proper operation of all of these safety and convenience functions requires a battery that conforms with specifications and that is properly registered in vehicles with energy management systems (IBS, power module).

Vehicles with energy management systems (IBS, power module): Register battery replacement

The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age and current power capacity. Therefore, only one work scope will be provided that is permitted by the current status of information.

When installing a new vehicle battery, the battery must be registered and thus must also be registered with the vehicle electrical system.

Diagnosis system

Register battery replacement

1. Service functions
2. Body
3. Voltage supply
4. Register battery replacement
5. Test plan

When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM batteries with the same specifications.

When installing a battery of a different size or a different battery type, this change in vehicle data must be programmed into the vehicle data in accordance with specifications.

Programming system

1. Battery retrofitting

12 00... Instructions for disconnecting and connecting battery

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.

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
3. Detach «TERMINAL OF BATTERY NEGATIVE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) 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 installing battery terminal: Tightening torque «61 21 1AZ»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-tightening-torques-e90) .

After connecting battery

Please refer to the Progman user documentation for further information on vehicle-specific activation.

Vehicles with a two-battery system

Starter and system battery

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

Two AGM batteries, whose design and properties are described in AGM BATTERIES , are used as a storage battery.

Receiving/giving starting aid via jump start terminal point

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 system batteries via jump start terminal point

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 system battery is also included in the charging operation. The auxiliary control unit automatically detects a charging operation at a charging voltage at the starter battery of > or = 13.5 V. The cut-off relay is closed and thus the system 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 cut-off relay is opened immediately and again only the starter battery is charged.

Note. When the engine hood is open, the cut-off 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 cut-off 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

The increased standby current consumption can be compensated for via the jump-start connection point with the aid of the "Acctiva easy" battery trickle charger.

12 00... Instructions for working on the ignition system

High tension! - High tension!

1. Ignition lead
2. spark-plug connectors
3. spark plugs
4. Ignition coil (high voltage at terminal 4 is approx. 40 kV)
5. Lead of terminal 1 from ignition coil to DME control unit (high voltage approx. 350 V)

12 13 Notes on checking ignition system

Troubleshooting

1. Fault in fuel injection system
2. Spark plug faults
3. Ignition coil faults
4. Further fault patterns with evaluation
5. Additional fault notes for troubleshooting

Oscillograms

1. Normal oscillogram
2. Oscillograms of ignition coils from different manufacturers

Check

1. Secondary signal for stationary ignition distribution

61 00... Notes on handling wiring harnesses and cables

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. Make sure cables are laid without kinks or abrasions
3. Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
4. Secure additionally laid cables/lines with cable straps

The following additionally applies

Shielded lines

Contact points in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types

Coaxial line

1. Shielded RTK031 coaxial lines may only be repaired with special Crimping tool for repairing the coaxial line.

CVBS lines

1. CVBS lines may not be repaired.
2. CVBS lines must be replaced in their entirety.

HSD lines

1. HSD lines may not be repaired.
2. HSD lines must be replaced in their entirety.

Optical fibre cable

Note. Optical fibre cables are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) optical fibre Yellow = ISIS ( I ntelligent S afety I ntegration S ystem) optical fibre Orange = repair optical fibre cables

TREATING CABLES AND OPTICAL FIBRE CABLES

FlexRay

It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .

Note. The line is a twisted cable. If possible, maintain twist in line after repair.

Airbag lines

REPAIRING AIRBAG CABLES

Ribbon cables

REPAIRING RIBBON CABLES Z

12 00... Notes/information on removing and installing control units

When replacing the DME/DDE control unit, observe the following

1. In each case read out the hardware/software status of the relevant control unit using the BMW diagnosis system. Comply with the instructions of the DIS diagnosis system on the steps pertaining to coding and programming. On vehicles with electronic vehicle immobilization, comply with the instructions of the BMW diagnosis system.
2. Each control unit is programmed with certain basic values, which serve as mean values. The control unit receives different input values, depending on engine condition, which are compared with the stored values. The adaptive system compares the input values with the stored map values. The control commands are routed to the relevant actuators.
3. If the DME control unit is without current for a long time (more than one hour), its adaptive system loses the stored values. When a cleared control unit is restarted or a new control unit is installed, the adaptive system must read in and store the input values of the associated engine as new basic values itself.
4. This procedure could lead to erratic idling and disturbed overrunning of the engine after starting. Depending on the engine it could require some time before all values are adapted to the engine condition.
5. Therefore observe the following procedure before replacing or reinstalling a DME/DDE control unit: If possible before exchanging control unit, run engine up to operating temperature. Exchange control units and run the vehicle at alternating engine speeds.

12 00... Notes/information on start assistance (jump starting)

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting the engine with a jump starting cable.

1. Ensure that the jump starting cable wires are of appropriate cross-section size.
2. Only use fuse-protected jump starting cables.
3. Check whether the current-supplying battery has 12 V voltage.
4. If the engine is started from the 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.

Operation

It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.

1. Automatic transmission: select drive position "P", apply parking brake.
2. Manual transmission: move gear lever to neutral position, apply parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect both positive poles of the batteries with one jump starting cable (red).
5. Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage compartment.
6. Then use the second jump starting cable (black) to connect the negative post of the current-supplying battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.

Risk of explosion!

After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the negative pole and the earth/ground point. Then remove the starting cable from the positive poles.

00 Safety information for working on vehicles with automatic engine start-stop function (MSA)

Observe safety precautions when working on MSA vehicles

Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as to prevent automatic engine starting while work is being carried out in the engine compartment.

MSA function is deactivated by

Scheme 86

Scheme 87

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode Workshop mode A = 10 mm Basic setting (engine hood/bonnet open) B = 7 mm To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the limit position before starting work and slowly release.

When working with diagnosis tools

1. Observe instructions in diagnosis tool

12 12 011 Replacing all spark plugs (S65)

Necessary preliminary work

1. Switch off ignition.
2. «REMOVE ALL IGNITION COILS.»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-13-512-removing-and-installingreplacing)

Clean spark connector slot with compressed air.

Unscrew spark plugs with special tool 12 1 171 and an extension with a joint.

Installation note

First, hand-tighten the spark plugs with special tool 12 1 171 and with an extension with a joint into the engine.

Then tighten the spark plugs using a torque wrench, special tool 12 1 171 and an extension with a joint.

Observe tightening torque.

Tightening torque 12 12 2AZ .

Scheme 88

Troubleshooting

1. Fault in fuel injection system
2. Spark plug faults
3. Ignition coil faults
4. Further fault patterns with evaluation
5. Additional fault notes for troubleshooting

Oscillograms

1. Normal oscillogram
2. Oscillograms of ignition coils from different manufacturers

Check

1. Secondary signal for stationary ignition distribution

12 13 512 Removing and installing/replacing all ignition coils (S65)

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Switch off ignition
3. «REMOVE AIR FILTER HOUSING»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-71-000-removing-and-installingreplacing)
4. Release and raise coolant expansion tank, do not kink hoses
5. Remove ignition coil cover on left and right

Pull off plug (1).

Pull out ignition coil (2) in upward direction with aid of 11 9 980 EXTRACTOR .

This tool is essential to ensure damage-free removal of the ignition coils.

This procedure is applicable to all ignition coils.

Installation

Insert rubber seal on ignition coils between guides in cylinder head cover.

Scheme 89

Note. Assemble engine. Check stored fault messages. Now clear the 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)

Refer to "Diagnosis and Coding" service information bulletins on subject of coding.

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)

Refer to "Diagnosis and Coding" service information bulletins on subject of programming.

12 90... Removing and installing/replacing electronics box

Note. Follow instructions for REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS

Necessary preliminary tasks

1. Read fault memory.
2. Disconnect «NEGATIVE BATTERY CABLE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
3. Remove microfilter housing
4. Remove tension strut on spring strut dome on right

Release screws (1).

Slacken nut (2).

Lift out right heater end plate (3).

Installation

Ensure gasket (4) is correctly seated.

Scheme 90

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Scheme 91

Lift out plug connection (2), fuse carrier (3) and wiring harness grommet (4) from electronics box (1).

Installation

Make sure wiring harness grommets (4) are correctly seated in electronics box (1).

Scheme 92

Unlock DME control unit at holders (1) and raise slightly.

Pull tab (3) in direction of arrow out of housing and disconnect plug connections (2) on DME control unit.

Scheme 93

If necessary, press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.

Scheme 94

If necessary, press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.

Scheme 95

Unlock device holder (2) at holder (1) and remove.

Remove DME control unit (3).

Scheme 96

Unlock device holder (2) at holder (1) and remove.

Scheme 97

Remove device holder (1) from electronics box.

Scheme 98

Release screws (1).

Replacement

Modify water drain valve (2) and bump stop (3).

Scheme 99

Installation

Make sure gasket (1) is correctly seated on electronics box.

Scheme 100

12 63 520 Replacing DME master relay (S65)

Necessary preliminary tasks

1. Switch off ignition
2. Open electronics box, refer to «REMOVING CONTROL UNIT»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-14-550-replacing-control-unit)

Remove DME master relay (1).

Scheme 101

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 the fuses have blown, replace them completely with the fuse holder
3. Find out why fuses have blown

Continue troubleshooting as per DIS instructions.

12 14 550 Replacing control unit (DME) (S65)

1. Switch off ignition.
2. «DISCONNECT BATTERY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) .
3. Remove lower section of «MICROFILTER HOUSING»(/bmw/m3/e90-2007-2013/remont/automatic-hvac-system/#heating-and-air-conditioning-repair-e90__64-31-063-removing-and-installingreplacing) on right.

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Unlock plug (1) and remove.

Release grommet (2) from electronics box.

Installation

Make sure grommet (2) is correctly seated in housing (watertightness).

Unlock control unit (3) and raise slightly.

Scheme 102

Unlock plugs (1) using slide in direction of arrow and remove.

Remove control unit (2).

Installation

Replacement

Note device identification number and coding.

Scheme 103

Note. Check stored fault message.

Now clear the fault memory.

12 90 100 Replacing fan for electronics box

Necessary preliminary tasks

1. Switch off ignition.
2. Follow «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and) .
3. Disconnect «BATTERY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) ground terminal.
4. Detach fuse box in passenger compartment and pull back; to do so, refer to «REMOVING FUSE BOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-050-removing-and-installing)

Pull back carpet.

Release lower nut on fuse carrier holder.

Pull holder slightly towards front.

Scheme 104

Disconnect plug connections for fan motor (1).

Release screws (2). Remove fan.

Scheme 105

Add final details to vehicle.

Read fault memory.

13 62 610 Replacing pulse generator on crankshaft/transmission (S65)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. «REMOVE UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-490-removing-and-installingreplacing)
4. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)

Release screws (1).

Remove cover.

Scheme 106

Unlock connector and remove.

Release screw (1).

Remove pulse generator.

Scheme 107

Note. Now clear the fault memory.

Add final details to vehicle.

13 62 604 Replacing pulse generator on left exhaust camshaft (S65)

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. Remove «INTAKE FILTER HOUSING»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-72-001-replacing-air-filter)
4. Remove left ignition coil cover

Release plug connector (1) and pull off.

Release screw.

Remove pulse generator (2).

Installation

Aluminium screws must always be replaced.

Replace sealing ring and coat with antiseize agent.

Tightening torque, 13 62 5AZ

Scheme 108

Note. Now clear the fault memory.

13 62 601 Replacing pulse generator on left inlet camshaft (S65)

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. Remove «INTAKE FILTER HOUSING»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-72-001-replacing-air-filter)
4. Remove left ignition coil cover

Release plug connector (1) and pull off.

Release screw.

Remove pulse generator (2).

Installation

Replace sealing ring and coat with antiseize agent.

Tightening torque, 13 62 5AZ

Scheme 109

Note. Now clear the fault memory.

13 62 605 Replacing pulse generator on right exhaust camshaft (S65)

(cylinder bank 1 to 4)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. Release and raise coolant expansion tank. Do not kink hoses.
4. Remove right ignition coil cover

Release plug connector (1) and pull off.

Release screw.

Remove pulse generator (2).

Installation

Aluminium screws must always be replaced.

Replace sealing ring and coat with antiseize agent.

Tightening torque, 13 62 5AZ

Note. Now clear the fault memory.

13 62 602 Replacing pulse generator on right inlet camshaft (S65)

(cylinder bank 1 to 4)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. Release and raise coolant expansion tank. Do not kink hoses.
4. Remove right ignition coil cover

Release plug connector (1) and pull off.

Release screw.

Remove pulse generator (2).

Installation

Replace sealing ring and coat with antiseize agent.

Tightening torque, 13 62 5AZ

Note. Now clear the fault memory.

13 62 607 Replacing pulse generator on transmission (S65)

Necessary preliminary tasks

1. Read out fault memory of DME control unit; if necessary, work through test schedules
2. Switch off ignition
3. Remove underbody protection See «5147490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-490-removing-and-installingreplacing) or «5147491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-491-removing-and-installingreplacing)

Unlock connector and remove.

Release screw (1).

Remove pulse generator.

Scheme 110

Note. TOP UP TRANSMISSION FLUID.

Now clear the fault memory.

Add final details to vehicle.

13 62 029 Replacing suction pressure sensor on air intake manifold (S65)

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Switch off ignition
3. «REMOVE INTAKE AIR MANIFOLD»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing)
4. «REMOVE SECONDARY-AIR PUMP»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-72-000-removing-and-installingreplacing)
5. Release cable duct for engine wiring harness; for information, refer to «REMOVING ENGINE WIRING HARNESS»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-51-001-replacing-wiring-harness)
6. Remove idle actuator suction hose

Note. The installation location for the intake manifold pressure sensor is on the idle air duct at cylinder no. 8.

Unlock plug (1) and remove.

Release screws and pull suction pressure sensor (2) out of intake air housing.

Tightening torque 13 41 1AZ .

Scheme 111

Installation

Check sealing ring for damage, replace if necessary.

When installing, coat sealing ring with suitable antiseize agent.

Scheme 112

Note. Assemble engine.

Check stored fault messages.

Now clear the fault memory.

12 31 009 Checking alternator (BSD)

Necessary preliminary tasks

1. Correct connections on charged battery
2. Correct connections on alternator and starter motor
3. Good ground connection between engine and body
4. Tensioned ribbed V-belt
5. Read out DME/DDE fault memory.

Note. The alternator with BSD interface can communicate with the engine control unit (DME/DDE).

The alternator is not connected to the charge telltale light.

The alternator can identify various faults.

BSD alternator can be recognized by the plug connection on the alternator.

Connect diagnosis tester.

1. Function selection
2. Complete vehicle
3. Drive
4. Voltage and current regulation
5. Voltage and current generation
6. Alternator
7. Follow instruction in diagnostic program

Oscillogram for a fault-free alternator

Scheme 113

Oscillogram for a faulty alternator

One phase interrupted.

Repair/exchange alternator.

Scheme 114

Interturn fault.

Repair/exchange alternator.

Scheme 115

Open circuit in negative diode.

Repair/exchange alternator.

Scheme 116

Short circuit in positive diode.

Repair/exchange alternator.

Scheme 117

Open circuit in positive diode.

Repair/exchange alternator.

Scheme 118

Open circuit in exciter diode.

Repair/exchange alternator.

Scheme 119

Assemble engine.

Check function of DME/DDE.

Necessary preliminary tasks

1. Correct connections on charged battery
2. Correct connections on alternator and starter motor
3. Good ground connection between engine and body
4. Tensioned ribbed V-belt
5. Read out DME/DDE fault memory.

Note. The alternator with BSD interface can communicate with the engine control unit (DME/DDE).

The alternator is not connected to the charge telltale light.

The alternator can identify various faults.

BSD alternator can be recognized by the plug connection on the alternator.

Connect diagnosis tester.

1. Function selection
2. Complete vehicle
3. Drive
4. Voltage and current regulation
5. Voltage and current generation
6. Alternator
7. Follow instruction in diagnostic program

Oscillogram for a fault-free alternator

Oscillogram for a faulty alternator

One phase interrupted.

Repair/exchange alternator.

Interturn fault.

Repair/exchange alternator.

Open circuit in negative diode.

Repair/exchange alternator.

Short circuit in positive diode.

Repair/exchange alternator.

Open circuit in positive diode.

Repair/exchange alternator.

Open circuit in exciter diode.

Repair/exchange alternator.

Assemble engine.

Check function of DME/DDE.

12 31 020 Removing and installing or replacing alternator (S65)

Necessary preliminary tasks

1. Switch off ignition
2. Follow «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and)
3. «DISCONNECT BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) and cover
4. Remove «AIR FILTER HOUSING»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-71-000-removing-and-installingreplacing)
5. «REMOVE UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-490-removing-and-installingreplacing)
6. Remove «ALTERNATOR DRIVE BELT»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-28-010-replacing-alternator-drive)

Release screws.

Unclip hoses from hose holders on radiator.

Carefully press leads (1) to one side.

Scheme 120

Release screws.

Pull alternator (1) forwards until connections are accessible.

Scheme 121

Unlock plug (1) and remove.

Release nut (2), remove battery positive lead from alternator.

Tightening torque 12 31 1AZ .

Pull alternator (3) upwards to remove.

Add final details to vehicle.

Read fault memory.

Scheme 122

12 31... Replacing alternator belt pulley

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 SOCKET WRENCH INSERT .

Installation

TIGHTENING TORQUE, 12 31 2AZ/12 31 3AZ .

Scheme 123

12 31... Replacing alternator belt pulley (with overrunning clutch)

Remove and install alternator drive belt.

Grip alternator shaft with

1. internal serration

Release nut using Special Tool 12 7 120.

Installation

Scheme 124

Special tools required

1. «12 7 110»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-special-tools-e90)

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, 12 31 2AZ / 12 31 3AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS .

Special tools required

1. 12 7 120

Remove and install alternator drive belt.

Grip alternator shaft with

1. internal serration

Release nut with special tools 12 7 120 .

Installation

Tightening torque 12 31 3AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS .

Necessary preliminary tasks

1. Correct connections on charged battery
2. Correct connections on alternator and starter motor
3. Good ground connection between engine and body
4. Tensioned ribbed V-belt
5. Read out DME/DDE fault memory.

Note. The alternator with BSD interface can communicate with the engine control unit (DME/DDE). The alternator is not connected to the charge telltale light. The alternator can identify various faults.

BSD alternator can be recognized by the plug connection on the alternator.

Connect diagnosis tester.

1. Function selection
2. Complete vehicle
3. Drive
4. Voltage and current regulation
5. Voltage and current generation
6. Alternator
7. Follow instruction in diagnostic program

Oscillogram for a fault-free alternator

Oscillogram for a faulty alternator

One phase interrupted.

Repair/exchange alternator.

Interturn fault.

Repair/exchange alternator.

Open circuit in negative diode.

Repair/exchange alternator.

Short circuit in positive diode.

Repair/exchange alternator.

Open circuit in positive diode.

Repair/exchange alternator.

Open circuit in exciter diode.

Repair/exchange alternator.

Assemble engine.

Check function of DME/DDE.

Necessary preliminary tasks

1. Switch off ignition
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and) .
3. Remove air filter housing . See «13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE FILTER HOUSING (S65)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-71-000-removing-and-installingreplacing) .
4. Remove underbody protection . See «5147 FLOOR, LUGGAGE COMPARTMENT, ENGINE COMPARTMENT, TRIM PANELS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90) .
5. Remove alternator drive belt . See «11 28 010 REPLACING ALTERNATOR DRIVE BELT (S65)»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-28-010-replacing-alternator-drive) .

Release screws.

Unclip hoses from hose holders on radiator.

Carefully press leads (1) to one side.

Release screws.

Pull alternator (1) forwards until connections are accessible.

Unlock plug (1) and remove.

Release nut (2), remove battery positive lead from alternator.

Tightening torque 12 31 1AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS .

Pull alternator (3) upwards to remove.

Add final details to vehicle.

Read fault memory.

12 32 501 Replacing voltage regulator

Necessary preliminary tasks

1. Switch off ignition
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and)
3. Remove alternator

Bosch

Release protective caps (1).

Scheme 125

Bosch

Release screw (1) and nuts (2), remove cover.

Scheme 126

Bosch

Release screws and remove regulator switch (1) in direction of arrow.

Scheme 127

Bosch

Installation

Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.

Measurement A = min. 5 mm.

Check collector ring for wear and recondition if necessary.

Scheme 128

Valeo

Slacken nut (1).

Slacken nut (2).

Release screws (3).

Release cover (4).

Scheme 129

Valeo

Release screws.

Remove regulator switch (1) towards top.

Scheme 130

Valeo

Installation

Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.

Measurement A = min. 5 mm.

Check collector ring for wear and recondition if necessary.

Scheme 131

Installation

Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.

Pull off mounting sleeve (2) and replace with cover (3).

Scheme 132

12 41 020 Removing and installing/replacing starter (S65)

Necessary preliminary tasks

1. Switch off ignition
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) and cover
3. Remove «INTAKE AIR MANIFOLD»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing)
4. Remove «IDLE ACTUATOR»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-41-550-replacing-idle-actuator)
5. Remove «THROTTLE VALVE ACTUATING MOTOR»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-system-repair-e90__13-62-540-removing-and-installingreplacing) on left

Remove idle actuator mounting.

Scheme 133

Unlock plug (1) and remove.

Unfasten nut.

Tightening torque 12 41 1AZ .

Remove battery positive lead (2).

Scheme 134

Release screw (1).

Release screws (2).

Tightening torque 12 41 2AZ .

Pull starter motor out of transmission mount and remove.

Scheme 135

Installation

Check starter pinion and ring gear for damage, replace damaged parts if necessary.

Add final details to vehicle.

12 41 041 Replacing solenoid switch

Turn off ignition

12 42 510 Replacing battery positive lead (between starter and B+ terminal) (S65)

Read fault memory. Switch off ignition

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

OBSERVE INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

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

Necessary preliminary tasks

REMOVE INTAKE AIR MANIFOLD .

Release and raise cable duct for engine wiring harness; refer to REMOVING ENGINE WIRING HARNESS

Release nut (2) on B+ lead.

Remove B+ leads.

Installation

Tightening torque, 12 41 1AZ

Release clamp for B+ lead on cylinder no. 4.

Unclip lead from cable holders.

Scheme 136

Remove cover from B+ terminal. Unfasten nut. Remove B+ lead.

Installation

Tightening torque, 12 42 1AZ

Scheme 137

Note. Assemble engine.

Interrogate fault memory of DME control unit.

Check stored fault messages.

Rectify faults and clear fault memory.

12 51... Exchanging plug-in contact of coolant temperature sensor (S65)

Necessary preliminary tasks

1. Read out the fault memory of the DDE control unit.
2. Switch off ignition.
3. Follow instructions for disconnecting and connecting «BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and) .
4. Remove «INTAKE AIR MANIFOLD»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing) .
5. Remove «SECONDARY-AIR PUMP»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-72-000-removing-and-installingreplacing) .
6. Disconnect «BATTERY EARTH LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) and cover.
7. Remove «INTAKE PLENUM»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing) .

Carefully open locks on cable duct.

Scheme 138

Carefully lift the front of the upper part of the cable duct by approx. 10 cm and secure, e.g. with panel wedge set 00 9 310 or a screwdriver.

Scheme 139

Unlock connector (1) from coolant temperature sensor and pull off.

Scheme 140

The cable repair kit consists of

1. Length of corrugated tubing (1) 60 mm.
2. Heat-shrink tubing (2).
3. Chamber 1, brown cable.
4. Chamber 2, yellow/green cable.
5. Crimp connectors (3).

Scheme 141

Cut lines of engine wiring harness for coolant temperature sensor according to the repair kit (1) and strip insulation.

Scheme 142

Connect cable ends of repair kit and engine wiring harness with crimp connectors (1).

Crimp the crimp connectors with suitable pliers.

Scheme 143

Pull heat-shrink tubing (1) over the crimped cable ends.

Bond heat-shrink tubes watertight with hot-air blower.

Scheme 144

Insert wiring harness in cable duct and secure with cable strap. Close cable duct again.

Scheme 145

Delete fault memory of DDE control unit.

Assemble engine.

12 51 001 Replacing wiring harness section for engine (S65)

Necessary preliminary tasks

1. Read out fault memory of control unit of Digital Engine Electronics (DME)
2. Check stored fault messages.
3. Switch off ignition
4. Disconnect «BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and)
5. Remove «INTAKE AIR MANIFOLD»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing)
6. Remove «SECONDARY-AIR PUMP»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-72-000-removing-and-installingreplacing)
7. Remove ignition coil cover on left and right
8. Unlock all plug connections in electronics box and disconnect

Release nuts at cable duct (1).

Scheme 146

WIRE HARNESSING REPLACEMENT PROCEDURE

Lower transmission See 2300018 REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ) (S65) or 2800001 REMOVING AND INSTALLING TWIN CLUTCH TRANSMISSION (GS7D36SG) S65

Release bracket on underside of transmission.

Lay wiring harness, oxygen sensor plug, oil level sensor and crankshaft sensors over bracket or right catalytic converter.

Feed out cable towards top.

Remove wiring harness.

Installation

Pay attention to cable routing/mounting points.

Now clear the fault memory.

12 61 285 Removing and installing/replacing oil level sensor for engine oil (S65)

Necessary preliminary work

1. Switch off ignition
2. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)
3. Drain off «ENGINE OIL»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-00-service-engine-oil)

Release connector (1) and remove.

Unscrew nuts.

Tightening torque 13 62 3AZ .

Remove oil level sensor (2).

Installation note

Clean sealing surface on oil sump.

Replace gasket on oil level sensor.

An excessively low torque value will result in oil leaks.

An excessively high torque value will result in damage to the oil level sensor.

Top up engine oil.

Scheme 147

12 61 280 Replacing oil pressure switch (S65)

Necessary preliminary tasks

1. Switch off ignition
2. «REMOVE INTAKE AIR MANIFOLD»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-repair-e90__11-61-050-removing-and-installing)

Unlock plug and remove

Remove oil pressure switch.

Installation

Tightening torque, 13 62 2AZ

Scheme 148

Note. Check and clear fault memory.

Necessary preliminary tasks

1. Switch off ignition
2. Open electronics box, refer to «REMOVING CONTROL UNIT»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-14-550-replacing-control-unit)

Remove DME master relay (1).

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 the fuses have blown, replace them completely with the fuse holder
3. Find out why fuses have blown

Continue troubleshooting as per DIS instructions.

Note. Follow instructions for REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS

Necessary preliminary tasks

1. Read fault memory.
2. Disconnect «NEGATIVE BATTERY CABLE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
3. Remove microfilter housing
4. Remove tension strut on spring strut dome on right

Release screws (1).

Slacken nut (2).

Lift out right heater end plate (3).

Installation

Ensure gasket (4) is correctly seated.

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Lift out plug connection (2), fuse carrier (3) and wiring harness grommet (4) from electronics box (1).

Installation

Make sure wiring harness grommets (4) are correctly seated in electronics box (1).

Unlock DME control unit at holders (1) and raise slightly.

Pull tab (3) in direction of arrow out of housing and disconnect plug connections (2) on DME control unit.

If necessary, press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.

If necessary, press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.

Unlock device holder (2) at holder (1) and remove.

Remove DME control unit (3).

Unlock device holder (2) at holder (1) and remove.

Remove device holder (1) from electronics box.

Release screws (1).

Replacement

Modify water drain valve (2) and bump stop (3).

Installation

Make sure gasket (1) is correctly seated on electronics box.

Necessary preliminary tasks

1. Switch off ignition.
2. Follow «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and) .
3. Disconnect «BATTERY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) ground terminal.
4. Detach fuse box in passenger compartment and pull back; to do so, refer to «REMOVING FUSE BOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-050-removing-and-installing)

Pull back carpet.

Release lower nut on fuse carrier holder.

Pull holder slightly towards front.

Disconnect plug connections for fan motor (1).

Release screws (2). Remove fan.

Add final details to vehicle.

Read fault memory.

See also:
• SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
• TERMINAL OF BATTERY NEGATIVE
• 61 21 1AZ
• STEERING ANGLE SENSOR ADJUSTMENT
• ADJUSTMENT OF ACTIVE STEERING
• 54 0... NOTES ON GLASS SLIDE/TILT SUNROOF (INITIALIZATION/NORMAL OF CHARACTERISTIC CURVE)
• 6762... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR
• MIRROR WITH COMPASS
• AGM BATTERIES
• TREATING CABLES AND OPTICAL FIBRE CABLES
• BUTT CONNECTORS
• REPAIRING AIRBAG CABLES
• REPAIRING RIBBON CABLES Z
• 12 12 2AZ
• REMOVE AIR FILTER HOUSING
• 11 9 980 EXTRACTOR
• PROTECTION AGAINST ELECTROSTATIC DAMAGE (ESD PROTECTION)
• MICROFILTER HOUSING
• REMOVING FUSE BOX
• REMOVE UNDERBODY PROTECTION
• REINFORCEMENT PLATE
• INTAKE FILTER HOUSING
• 13 62 5AZ
• 5147491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
• TOP UP TRANSMISSION FLUID.
• REMOVE INTAKE AIR MANIFOLD
• REMOVE SECONDARY-AIR PUMP
• ALTERNATOR DRIVE BELT
• 12 7 110 SOCKET WRENCH INSERT
• 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS
• 5147 FLOOR, LUGGAGE COMPARTMENT, ENGINE COMPARTMENT, TRIM PANELS
• IDLE ACTUATOR
• THROTTLE VALVE ACTUATING MOTOR
• 2300018 REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ) (S65)
• 2800001 REMOVING AND INSTALLING TWIN CLUTCH TRANSMISSION (GS7D36SG) S65
• ENGINE OIL
• AUTOMATIC ENGINE START-STOP FUNCTION (MSA)
• REMOVE ALL IGNITION COILS.
• REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS
• REMOVING CONTROL UNIT
• INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• REMOVING ENGINE WIRING HARNESS