Ignition System - Repair Procedures

2005 BMW Z4
2003-05 ENGINE Ignition System - Repair Procedures - Z4/E85
2003-05 ENGINE
Ignition System - Repair Procedures - Z4/E85
TROUBLESHOOTING
12 00 CONTENTS OF ENGINE ELECTRICAL SYSTEM GENERAL
General Information
Working on ignition system

1. Always switch off ignition before working on ignition system.
Never touch components under current with engine running!
Dangerous high tension!
2. Always remove DME master relay for the compression test to avoid activation of ignition coils by
ignition final stages of the DME control unit.
Dangerous high tension!
3. Always switch off ignition before connecting /disconnecting Service Tester, other testers and
adapters or replacing components!
4. The secondary side (high voltage side) of ignition system must be under load of at least 4 kohms.
5. Never start engine after removing distributor cap or disconnecting wire (terminal 4) on ignition coil
(terminal 4).
6. Never connect a shielded capacitor or test light on ignition coil terminal 1.
7. Never connect ignition coil terminal 1 wire earth or battery positive.
For this reason, terminal 1 wire may not be used to interlock starting when service installing a
burglar alarm system.
Removing And Installing Electronic Control Units
CAUTION: Disconnecting the vehicle battery will cancel the fault memories of
control units.
For this reason, before disconnecting the battery, connect up BMW SERVICE TESTER or DIS. DIS:
(select Expert mode) interrogate fault memory and print out fault messages stored in memory. BMW
SERVICE TESTER: Interrogate fault memory and print out fault messages stored in memory. Investigate
stored faults.
Ignition must always be switched off before disconnecting or connecting control-unit connectors.
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2005 BMW Z4
Removal and installation of components, relays, fuse, etc. could cause the storage of faults in fault
memories of control units capable of self-diagnosis. For this reason, fault memories must always be
interrogated after working on the electrical system. Stored faults must be investigated and cancelled.
When Replacing Control Unit Of DME (Digital Motor Electronics), Please Note The Following
Points:
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. Appropriate
correction commands are sent to the concerned drive elements.
If, for example, the DME control unit would be without current for a long time (more than an hour), its
adaptive system would lose the stored values. After re-commissioning a cancelled unit or installing a new
control unit, the input values of the relevant engine must be read in and stored for the adaptive system.
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.
For this reason, follow the procedure described below before replacing or reinstalling a DME control unit:
1. Run engine to operating temperature if possible before replacing the control unit.
2. Remove control unit, install new control unit and drive vehicle.
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:
{ Observe instructions for disconnecting and connecting battery. See INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY.
{ Detach terminal of battery negative lead from car battery and second battery if fitted. Cover
negative terminal posts.
{ If welding is to be performed near the battery/batteries, first remove battery/batteries from vehicle
(flying sparks - combustion of explosive gas).
{ Fit return clamp on welding unit as close as possible to welding point (maximum distance approx. 1
mm).
{ Never connect return clamp to ground pin on body which has ground wires attached!
Disconnecting and connecting battery .
Observe safety instructions for handling vehicle battery. Refer to Safety Instructions For Handling
Vehicle Battery.
Before Disconnecting Battery:
Switch off ignition.

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2005 BMW Z4
NOTE: If the ignition is not turned off when the battery is disconnected, fault
memories may be set in some control units.
Important!
z There is a danger of mixing up battery leads: If the battery positive and negative leads are the same
color and you are in doubt, follow the polarity to the battery, then mark and cover the leads.
z On vehicles with radio code: After disconnecting the battery, the radio code must be re-entered.
Therefore obtain the radio code card from the customer beforehand. Note stored stations and restore
them after connecting the battery.
z Stored settings of the on-board computer and clock will also be lost.
z All available central keys must be receded for cars with first generation infrared transmitter locking
systems.
General Notes On Disconnecting Battery:
z Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
z Cars with IBS on battery negative terminal:
z Do not under any circumstances pull/lever off pole shoes by force.
z Do not under any circumstances release socket-head cap screw of IBS.
z 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.
After Connecting Battery:
Important!
After a power supply interruption some equipment is disabled and must be reactivated.
For further information and instructions on vehicle-specific activation, please refer to PROCEDURE
FOR INITIALIZATION .
Disconnecting and connecting test equipment
When connecting and disconnecting:

{ Service Tester.
{ Testing Devices.
{ Test Leads.
{ When Replacing Control Units.
It is essential to turn off the ignition.
Follow instructions for removing and installing electronic control units. See REMOVING AND
INSTALLING ELECTRONIC CONTROL UNIT.
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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.).
Component inspection
NOTE: On all inspections and operations on the engine electrics and electronics,
comply with prevailing national safety legislation and accident prevention
regulations.
Always disconnect connectors of control units or components before checking electric wires.
Testing Aids:
The relevant wiring diagrams are filed in the Electrical Troubleshooting Manual folder for the 3 Series
E36.
Always use correctly produced inspection lines, adapters, terminals and test tips.
Test values for checking components are contained in the Electrical Troubleshooting Manual.
For further technical information, refer to ENGINE ELECTRICAL SYSTEM - TECHNICAL DATA .
External Jump-Starting Aid
Do not start the engine with help of starting sprays.
Preparation
Conform with the following when starting engine with starting cable.
Ensure that starting cable wires are to appropriate cross-section size.
Only use fuse-protected starting cables.
Check whether the current supplying battery has 12V voltage.
If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of
both vehicles.
CAUTION: Never touch ignition system components under current - dangerous

high tension!
Operation:
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Always conform with the procedures to avoid injury to persons or damage to parts.
Select range P in vehicles with an automatic transmission and apply the parking brake.
Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
Ensure that the starting cables cannot get caught in rotating parts, e.g. fan.
First connect both positive poles of the batteries with one starting cable (red).
Use the positive connection point in the engine compartment for vehicles with the battery in the trunk.
Then connect the second starting cable (black) between the negative pole of the current supplying battery
and engine or body earth of the vehicle to be started.
CAUTION: Never connect the second starting cable (black) on the negative pole
of the battery in the vehicle to be started. Produced gas could be
ignited by sparks.
Danger of explosion!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
After the engine of the vehicle to be started has started up, first disconnect the starting cable on the
negative pole/earth connection. Then remove the starting cable from the positive poles.
Compression Testing See 11 00 039 CHECKING COMPRESSION OF ALL CYLINDERS .
12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe safety instructions for handling vehicle battery .
Before disconnecting battery:
NOTE: If the ignition is not turned off when the battery is disconnected, fault memories
may be set in some control units.
IMPORTANT: z There is a danger of mixing up battery leads: If the battery positive and
negative leads are the same color and you are in doubt, follow the polarity
to the battery, then mark and cover the leads.
z On vehicles with radio code: After disconnecting the battery, the radio
code must be re-entered. Therefore obtain the radio code card from the
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customer beforehand. Note stored stations and restore them after

connecting the battery.
z Stored settings of the on-board computer and clock will also be lost.
z All available central keys must be recoded for cars with first generation
infrared transmitter locking systems.
General notes on disconnecting battery:
z Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
z 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.
z Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery
negative terminal(s) and secure.
z 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.
z When fitting terminal for battery negative lead. Tightening torque, see 61 21 1AZ in GENERAL
ELECTRICAL SYSTEM - TIGHTENING TORQUE .
After connecting battery:
IMPORTANT: After a power supply interruption some equipment is disabled and must be
reactivated.
Likewise, individual settings are lost and must be activated.
Example:
z Vehicles with AFS only: Activate steering angle

z If necessary, activate power windows
z If necessary, activate mirror with compass
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
-> 12 13 ... FAULT IN FUEL INJECTION SYSTEM

-> 12 13 ... SPARK-PLUG FAULTS
-> 12 13 ... IGNITION COIL FAULTS
-> 12 13 ... FURTHER FAULT PATTERNS WITH EVALUATION
-> 12 13 ... ADDITIONAL FAULT NOTES FOR TROUBLESHOOTING
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Oscillograms
-> 12 13 ... NORMAL OSCILLOGRAM

-> 12 13 ... OSCILLOGRAMS OF IGNITION COILS FROM DIFFERENT MANUFACTURERS
Check
-> 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION

DISTRIBUTION
IGNITION WIRES, SPARK PLUGS

12 12 011 REPLACING ALL SPARK PLUGS
Special tools required:
z 12 1 171
z 12 1 200
NOTE: This repair instruction is valid for the following engines:
z M52 / M52TU / M54 / M56

z S52 / S50US
Necessary preliminary tasks:
z Remove ignition coils .
Unscrew and remove spark plugs with special tool 12 1 171 in conjunction with special tool 12 1 200.
Installation:
If special tool 12 1 200 is not used,
Tightening torque, see 12 12 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .
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Fig. 1: Identifying Spark Plug Remover (Special Tool)

Courtesy of BMW OF NORTH AMERICA, INC.
IGNITION COIL
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
-> 12 13 ... FAULT IN FUEL INJECTION SYSTEM

-> 12 13 ... SPARK-PLUG FAULTS
-> 12 13 ... IGNITION COIL FAULTS
-> 12 13 ... FURTHER FAULT PATTERNS WITH EVALUATION
-> 12 13 ... ADDITIONAL FAULT NOTES FOR TROUBLESHOOTING
Oscillograms
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-> 12 13 ... NORMAL OSCILLOGRAM

-> 12 13 ... OSCILLOGRAMS OF IGNITION COILS FROM DIFFERENT MANUFACTURERS
Check
-> 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION

DISTRIBUTION
12 13... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION DISTRIBUTION
z 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.
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Fig. 2: Removing Ignition Coil

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.
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Fig. 3: Connecting Diagnosis Connector

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.
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Fig. 4: Identifying Tester Signal

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
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Fig. 5: Combustion Period Graph

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.
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Fig. 6: Secondary Voltage Patterns (Beside One Another)

Evaluation of ignition voltage peaks at increased speed of approx. 2000 RPM (this example shows an engine
with 4 cylinders).
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Fig. 7: Ignition Voltage Evaluation Graph

Secondary voltage diagrams, superimposed:
Evaluation of combustion characteristics curve and decay characteristics at idle speed (this example shows a 4-
cylinder engine).
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Fig. 8: Secondary Voltage Diagrams (Superimposed)

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.
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Fig. 9: Secondary Voltage Diagrams (Consecutive)

12 13 009 CHECKING ROD-TYPE IGNITION COILS (M54)
z 12 1 301
z 12 7 050
z Remove ignition coil cover.
Unlock plug fastener (1) of ignition coil.
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Fig. 10: Releasing Plug Fastener Ignition Coil

Detach plug (1) in direction of arrow.
Pull out ignition coil (2) towards top.
NOTE: Procedure applies to all rod-type ignition coils.
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Install special tool 12 7 050.
Installation:
Special tool 12 7 050 is attached between spark plug and rod type ignition coil.
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Fig. 12: Attaching Special Tool Between Spark Plug And Rod Type Ignition Coil
Secondary measurement:
Connect KV clip-on probe (1) of DIS Tester to special tool 12 7 050.
Procedure on DIS Tester:
{ Select < Measurement >.

{ Select < Preset measurement >.
{ Select < Secondary ignition signal >.
{ Connect < TD cable to diagnostic head >.
{ Select < static ignition distribution >.
{ Select < Number of cylinders >.
For subsequent procedure, follow DIS instructions.

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Fig. 13: Connecting KV Clip-On Probe Of DIS Tester To Special Tool (illustration Shows: KV Clip-On
Probe (1) US Version)
Primary measurement:
Connect 26-pin pin box with special tool 12 1 301 to connector (1) DME module 5.
Procedure on DIS Tester:
{ Select < Measurement >.

{ Select < Preset measurement >.
{ Select < Ignition signal term.1 >.
For subsequent procedure, follow DIS instructions.
NOTE: Pin assignment acc. to connection scheme.

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Fig. 14: Connecting 26-Pin Pin Box With Special Tool To Connector
IMPORTANT: Ignition signal is a multiple spark ignition.
Illustration of multiple spark ignition
1. Start of ignition peak.

2. Level of ignition voltage.
3. Level of sparking voltage.
4. Spark duration.
5. Sparking voltage curve.
6. Start of decay process.
7. Decay process.
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Fig. 15: Multiple Spark Ignition Graph

M54 / M56 / N40 / N42 / N45 / N46 / N62 / N73:
The following ignition oscillogram applies to engines with multiple spark ignition from a production date of
April 2001:
Depending on engine temperature (approx. -20° to 100°) and engine speed (< 2000 RPM.), some ignition
voltage peaks (approx. 1-5 ignition peaks) can occur before the typical ignition voltage characteristic.
The additional ignition peaks play no role in diagnosis.
The last ignition peak (1) on the oscillogram is decisive.
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Fig. 16: Ignition Oscillogram (Multi Spark Ignition Engine - 4/01 Onwards)
NOTE: The display of the ignition voltage peak is approx. 20-25 % lower than the real
value.
It is not the height of the ignition voltage peaks but rather the uniformity of all the cylinders that is important.
Differences of 3000 to 4000 volts are permitted.
12 13 511 REPLACING IGNITION COILS (M54)
z Check stored fault messages.

z Switch off ignition.
z Remove E65/66 center assembly wall .
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z Remove ignition coil cover .
Unlock plug retainer of ignition coil (1) and disconnect plug.
Pull ignition coil (1) up and out.
This procedure is applicable to all ignition coils.

Installation:
Check that rubber seal of ignition coil (1) is correctly seated.
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Fig. 18: Identifying Ignition Coil Rubber Seal Position

NOTE: Read out fault memory of DME control unit.
Now clear the fault memory.
ELECTRONIC SWITCHING OR CONTROL UNIT

12 14 521 REPLACING PULSE GENERATOR ON CRANKSHAFT (M54/M56)
z Read out fault memory of DME control unit

z Switch off ignition
z E46, E60, E61 only:
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Remove reinforcement plate on front axle support. See 51 71 374 REMOVING AND
INSTALLING/REPLACING REINFORCEMENT PLATE .
IMPORTANT: The section removing and installing reinforcement plate on front axle support
contains important installation instructions.
z If fitted:
Remove vacuum reservoir for exhaust flap.
All models:
NOTE: Installation location of pulse generator for crankshaft is underneath starter

motor.
NOTE: For a better overview, this work step is shown on an engine that has been
removed.
Unlock plug (1) and remove.
Unscrew bolt (2).
Remove pulse generator (3).
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Fig. 19: Removing Pulse Generator

NOTE: Check stored fault messages.
12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (M52TU / M54 / M56)

z Remove suction filter housing .
NOTE: Arrow shows installation position of pulse generator.
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Remove solenoid valve (1) of VANOS adjustment unit for inlet camshaft.
Installation:
Replace sealing ring.
Tightening torque, see 11 36 1AZ in ENGINE - TIGHTENING TORQUES .
Fig. 20: Removing Solenoid Valve

Disconnect plug connection (1) on cable duct (2).
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Fig. 21: Disconnecting Plug Connection

Release screw (1) on pulse generator (2).
Remove pulse generator (2) from cylinder head.
NOTE: To facilitate installation of pulse generator lead:

Secure an approx. 50 cm long auxiliary lead to plug connection of pulse
generator.
Feed out end of pulse generator lead but only to such an extent that the auxiliary lead remains in the original
routing in the intake system.
Remove pulse generator with lead.
Disconnect auxiliary lead from faulty pulse generator. Secure plug connection of new pulse generator to
auxiliary lead.
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Using auxiliary lead, feed new lead of pulse generator through to cable duct at bottom.
Fig. 22: Removing Pulse Generator

Installation:
Check sealing ring for possible damage, replace if necessary.
12 14 524 REPLACING PULSE GENERATOR ON EXHAUST CAMSHAFT (M52TU, M54, M56)

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Location:
On cylinder head at front on exhaust side.
Unlock plug (1) and detach from pulse generator.
Fig. 23: Removing Plug From Pulse Generator

Release screw (1) on cylinder head.
Remove pulse generator.
Installation:
Check sealing ring for possible damage, replace if necessary.

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Fig. 24: Releasing Screw

NOTE: Interrogate fault memory of DME control unit.
Rectify faults.
12 14 600 REPLACING KNOCK SENSOR (M52TU, M54,M56)

z Remove intake air manifold. See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD .
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Unclip plug connection (1) from holder of cable duct (2) and disconnect.
Fig. 25: Disconnecting Cable Duct Holder Plug Connection

Release screw (1) and remove knock sensor for cylinder bank 1-3.
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Fig. 26: Removing Knock Sensor (Cylinder Bank 1-3)

Release screw (2) and remove knock sensor for cylinder bank 4-6.
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Fig. 27: Removing Knock Sensor (Cylinder Bank 4-6)

Installation:
Clean support face of knock sensors on engine block.
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Fig. 28: Cleaning Support Face Of Knock Sensors On Engine Block

Installation:
Read out fault memory of control unit of Digital Motor Electronics (DME).
12 14 700 CODING CONTROL MODULE (DME)
Connect MoDiC or DIS/GT1 Tester.
Switch on ignition.
Select "Coding" program.

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For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.
Carry out adjustment of following control units:
{ EWS (electronic immobilizer)

{ DME (Digital Motor Electronics) or
12 14 705 PROGRAMMING CONTROL UNIT (DME)
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:
{ EWS (electronic immobilizer)

{ DME (Digital Motor Electronics) or
ALTERNATOR WITH DRIVE AND MOUNT

12 31... REPLACING ALTERNATOR BELT PULLEY
z 12 7 110
Remove and install alternator drive belt.
Depending on alternator type, grip shaft with:
{ hexagon socket
{ multi-tooth socket or
{ Torx socket wrench
Release nut with special tool 12 7 110.
Installation:
Tightening torque, see 12 31 2AZ / 12 31 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING

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TORQUES .
Fig. 29: Assembling Special Tool

12 31 009 CHECKING ALTERNATOR (BSD)
z Correct connections on charged battery

z Correct connections on alternator and starter motor
z Good ground connection between engine and body
z Tensioned ribbed V-belt
z Read out DME fault memory.
NOTE: The alternator with BSD interface can communicate with the engine control unit
(DME).
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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.
{ Function selection
{ Complete vehicle
{ Drive
{ Voltage and current regulation
{ Voltage and current generation
{ Alternator
{ Follow instruction in diagnostic program
Oscillogram for a fault-free alternator:
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Fig. 30: Fault-Free Alternator Oscillogram

Oscillogram for a faulty alternator:
One phase interrupted.
Repair/exchange alternator.
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Fig. 31: Faulty Alternator Oscillogram

Interturn fault.
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Fig. 32: Alternator Oscillogram - Interturn Fault

Open circuit in negative diode.
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Fig. 33: Alternator Oscillogram - Open Circuit In Negative Diode

Short circuit in positive diode.
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Fig. 34: Alternator Oscillogram - Short Circuit In Positive Diode

Open circuit in positive diode.
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Fig. 35: Alternator Oscillogram - Open Circuit In Positive Diode

Open circuit in exciter diode.
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Fig. 36: Alternator Oscillogram - Open Circuit In Exciter Diode

Assemble engine.
Check function of DME.
12 31 009 CHECKING ALTERNATOR AND REGULATOR SWITCH
Test requirements:
{ Correct connections on charged battery

{ Correct connections on alternator and starter motor
{ Good ground connection between engine and body
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{ Tightened drive belt
Connect DIS Tester.
{ Measurement
{ Checking alternator
If charge indicator lamp is permanently lit:
Remove voltage regulator and check carbon brushes, replace if necessary.
Replace alternator regulator switch .
NOTE: Minimum length of carbon brushes "A" = 5 mm.
Fig. 37: Identifying Minimum Carbon Brush Length

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If charge indicator lamp goes out while engine is running:
Check control voltage.
Regulator switch must be replaced if control voltage is not achieved.
Replace alternator regulator switch .
From E46/E39 with multifunction regulator.
Recognizable by plug connection on regulator.
Connect DIS Tester.
{ Function selection
{ Complete vehicle
{ Drive
{ Voltage and current regulation
{ Voltage and current generation
{ Work through test modules
Oscillogram for a fault-free alternator:
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Fig. 38: Fault-Free Alternator Oscillogram

Oscillogram for a faulty alternator:
One phase interrupted.
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Fig. 39: Faulty Alternator Oscillogram

Interturn fault.
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Fig. 40: Alternator Oscillogram - Interturn Fault

Open circuit in negative diode.
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Fig. 41: Alternator Oscillogram - Open Circuit In Negative Diode

Short circuit in positive diode.
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Fig. 42: Alternator Oscillogram - Short Circuit In Positive Diode

Open circuit in positive diode.
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Fig. 43: Alternator Oscillogram - Open Circuit In Positive Diode

Open circuit in exciter diode.
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Fig. 44: Alternator Oscillogram - Open Circuit In Exciter Diode

12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (M54)

z Observe Instructions For Disconnecting And Connecting Battery .
z Disconnect battery ground wire and mask it.
z Remove suction filter housing .
z Remove Alternator Drive Belt .
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Unlock and detach plug connection (1).
Release nut (2) and remove battery positive lead.
Fig. 45: Removing Battery Positive Lead

Remove cover from idler pulley (1).
Release screw and remove idler pulley (1).
Release screw and remove alternator (2).
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Fig. 46: Removing Alternator

Installation:
Turning lock of tensioning roller must engage in alternator groove.
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Fig. 47: Identifying Tensioning Roller Lock Position

STARTER WITH MOUNTING

12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (M54)
z Follow Instructions For Disconnecting And Connecting Battery.

z Disconnect battery negative lead from battery
z Remove intake filter housing
NOTE: All the tasks can be performed from above.

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Release nut (1) and remove lead from starter motor.
Installation:
Tightening torque, see 12 41 4AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING

TORQUES .
Release nut (2) and remove battery positive leads from starter motor.
Installation:
Tightening torque, see 12 41 4AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING

TORQUES .
Release screws (3) and remove starter motor (4).
Fig. 48: Removing Starter Motor

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Installation:
Installation:
Check starter motor pinion and ring gear for damage.
Fig. 49: Checking Starter Motor Pinion And Ring Gear

12 41 041 REPLACING SOLENOID SWITCH
Turn off ignition.
Remove starter motor. See 12 41 020 Removing And Installing/Replacing Starter Motor (M54).
Release nut (1).

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Remove cable lug (2).
Fig. 50: Removing Cable Lug

CAUTION: Do not turn cable lug (2) while tightening down - risk of short circuit to
starter motor housing.
Tightening torque, see 12 41 4AZ in ENGINE ELECTRICAL SYSTEM -
TIGHTENING TORQUES .
Release screws (1).
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Fig. 51: Releasing Screws

Remove solenoid switch (1) and spring (2).
Unhook pin (3).
Installation:
Check pin (3) for wear and apply grease.
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Fig. 52: Removing Solenoid Switch And Spring

STARTER LEAD
12 42 540 REPLACING SAFETY BATTERY TERMINAL (SBK)
IMPORTANT: Comply with safety regulations!

Investigate cause of safety battery terminal being triggered.
To do so, read fault memory of airbag control unit. Note down fault messages
stored in memory. Rectify faults.
z Remove luggage compartment floor trim panel. See 51 47 101 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIMS .
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z Follow instructions for Instructions For Disconnecting And Connecting Battery.

z Disconnect battery negative lead and cover.
z Loosen electrical system cable.
z Remove battery.
NOTE: The safety battery terminal is replaced together with a complete cable up to the
battery positive terminal in the engine compartment.
Unlock cover on terminal and remove.
Unlock both plug connections (1) and disconnect.
Release nut on electrical system cable (2).
Fig. 53: Disconnecting Plug Connection (1 Of 2)

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2005 BMW Z4
Unclip plug connection (1), unlock and disconnect.
Release nut on electrical system cable (2).

Remove left rear wheel .
Release screws on cover frame (1).
Unscrew nuts (2).
Feed battery positive lead out of battery well.
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2005 BMW Z4
Fig. 55: Releasing Cover Frame Screws

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2005 BMW Z4
Fig. 56: Cutting Cable Ties

Cut through cable ties (1).
Unlock holder (2) and unclip positive lead.
Release nut (3) and remove holder.
Compress holder (4) and detach.
If necessary, unclip plastic line (1).
If necessary, unclip brake lines (2).
If necessary, release lead (3) from ABS sensor and disconnect.
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2005 BMW Z4
Fig. 57: Releasing Leads From ABS sensor

Feed out battery positive lead in direction of battery well to right and remove.
Installation:
If necessary, replace faulty fuses.
ENGINE WIRING LOOM

12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (M54)

z Follow Instructions For Disconnecting And Connecting Battery.
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2005 BMW Z4
Disconnect battery negative lead and cover
z Remove intake air manifold . See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD .
z Remove ignition coil cover .
z Remove reinforcement plate . See 51 71 374 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE .
WIRING HARNESS SECTION REPLACEMENT WORK STEP

Work step Note:
Unlock plug on oil level sensor and disconnect. See 12 61 285 Replacing Oil Level
Sensor.
Unlock plug on crankshaft sensor and disconnect. See 12 14 521 Replacing Pulse
Generator On Crankshaft (M54/M56)
Unlock plug on coolant temperature sensor and disconnect. See 13 62 531
REPLACING COOLANT TEMPERATURE SENSOR .
Unlock plug on throttle valve assembly . See 13 54 030 REMOVING AND
INSTALLING/SEALING THROTTLE VALVE ASSEMBLY .
Unlock plugs on both solenoid valves for VANOS and disconnect. See 11 36 570
REPLACING SOLENOID VALVE FOR INLET and 11 36 575 REPLACING
SOLENOID VALVE FOR EXHAUST .
Unlock plugs on inlet and exhaust camshaft sensors and disconnect. See 12 14 523
Replacing Pulse Generator On Inlet Camshaft (M52TU / M54 / M56) and 12 14
524 Replacing Pulse Generator On Exhaust Camshaft (M52TU, M54, M56).
Unlock plug on oil pressure switch and disconnect. See 12 61 280 Removing And
Installing/Replacing Oil Pressure Sensor (M54).
Unlock plug on knock sensors and disconnect. See 12 14 600 Replacing Knock
Sensor (M52TU, M54,M56).
Unlock plug on alternator and detach battery positive lead from alternator. See 12 31
020 Removing And Installing Or Replacing Alternator (M54).
Detach battery positive lead and control lead from starter motor. See 12 41 020
Removing And Installing/Replacing Starter Motor (M54).
Unlock plug connections in electronics box and disconnect: z Remove
electronics
z Control unit . See SYSTEM & COMPONENT TESTING article. box cover.
z DME relay See SYSTEM & COMPONENT TESTING article. z Do not
remove
control unit.
12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COILS (M54)
z Read out fault memory of DME control unit

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2005 BMW Z4

z Disconnect battery negative lead from battery.
Follow Instructions For Disconnecting And Connecting Battery.
z Remove cover for ignition coils
Unfasten screws.
Open cover (1) of electronics box and remove.
Fig. 58: Removing Electronics Box Cover

Unlock plug (1) and detach from DME control unit.
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2005 BMW Z4
Lift wiring harness with profile seal (3) out of electronics box.
Installation:
To prevent leaks, you must install profile seal (3) correctly.
Fig. 59: Removing Wiring Harness With Profile Seal From Electronics Box
Unlock plug retainer (1) of ignition coil and disconnect plug.
NOTE: This procedure is applicable to all ignition coils.
Release nuts and remove grounding cable.
Unclip cable duct (2).
Unclip wiring harness (3) and remove.

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2005 BMW Z4
Fig. 60: Removing Wiring Harness

NOTE: Now clear the fault memory.
OIL PRESSURE/OIL TEMPERATURE GAUGE

12 61 250 REMOVING AND INSTALLING/REPLACING OIL TEMPERATURE SENSOR (M54)

z Unfasten oil filter cap to enable engine oil in filter to flow back into the oil sump.
z Remove intake filter housing . See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
FILTER HOUSING .
Installation location: at base of oil filter.

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2005 BMW Z4
Disconnect plug connection (1).
Unscrew oil temperature sensor.
IMPORTANT: Engine oil may emerge when the oil temperature sensor is removed - have a
cleaning cloth to hand.
Catch and dispose of emerging engine oil.
Installation:
Screw on oil-filter cover tightly.
Check engine oil level, top up engine oil if necessary.

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2005 BMW Z4
12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SENSOR (M54)

z Unfasten oil filter cap to enable engine oil in filter to flow back into the oil sump.
z Remove intake filter housing See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
FILTER HOUSING .
Installation location: at base of oil filter.
Unscrew and remove oil-pressure switch.
IMPORTANT: Engine oil may emerge when the oil pressure sensor is removed - have a
cleaning cloth to hand.
Catch and dispose of emerging engine oil.
Installation:
Check engine oil level, top up engine oil if necessary.
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2005 BMW Z4

12 61 285 REPLACING LEVEL SWITCH FOR ENGINE OIL

z Unfasten oil filter cover to enable engine oil in filter to flow back into the oil pan.
z Remove underbody panelling.
z If necessary, remove reinforcing plate . See 51 71 374 REMOVING AND
INSTALLING/REPLACING REINFORCEMENT PLATE .
z Drain engine oil.
Unscrew nuts (2).

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2005 BMW Z4
Remove level switch (3).
Fig. 63: Removing Level Switch

Installation:
Clean sealing face on oil sump.
Replace seal on level switch.
Installation:
Top up engine oil.

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2005 BMW Z4
12 61 285 REPLACING OIL LEVEL SENSOR

z Unfasten oil filter cap to enable engine oil in filter to flow back into the oil sump
z Remove reinforcement plate . See 51 71 374 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE .
z Drain off engine oil
Unscrew nuts.
Remove oil level sensor (2).
Installation:
Clean sealing face on oil sump.
Replace seal on oil level sensor.
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2005 BMW Z4
Fig. 64: Removing Oil Level Sensor

Installation:
Top up engine oil.
Tighten down oil filter cap.
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Ignition System - Repair Procedures

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Ignition System - Repair Procedures

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2005 BMW Z4

2003-05 ENGINE Ignition System - Repair Procedures - Z4/E85

Ignition System - Repair Procedures - Z4/E85

Working on ignition system

Never touch components under current with engine running!

Dangerous high tension!

Dangerous high tension!

Removing And Installing Electronic Control Units

Disconnecting and connecting battery .

Before Disconnecting Battery:

Switch off ignition.

General Notes On Disconnecting Battery:

After Connecting Battery:

Disconnecting and connecting test equipment

When connecting and disconnecting:

{ When Replacing Control Units.

It is essential to turn off the ignition.

Follow operating instructions for testing devices.

External Jump-Starting Aid

Do not start the engine with help of starting sprays.

Ensure that starting cable wires are to appropriate cross-section size.

Only use fuse-protected starting cables.

Check whether the current supplying battery has 12V voltage.

CAUTION: Never touch ignition system components under current - dangerous

Compression Testing See 11 00 039 CHECKING COMPRESSION OF ALL CYLINDERS .

12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY

Observe safety instructions for handling vehicle battery .

Before disconnecting battery:

Switch off ignition.

customer beforehand. Note stored stations and restore them after

General notes on disconnecting battery:

Do not under any circumstances pull/lever off pole shoes by force.

Do not under any circumstances release socket-head cap screw of IBS.

After connecting battery:

z Vehicles with AFS only: Activate steering angle

12 13 NOTES ON CHECKING IGNITION SYSTEM

-> 12 13 ... FAULT IN FUEL INJECTION SYSTEM

-> 12 13 ... NORMAL OSCILLOGRAM

-> 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION

IGNITION WIRES, SPARK PLUGS

Special tools required:

NOTE: This repair instruction is valid for the following engines:

z M52 / M52TU / M54 / M56

Necessary preliminary tasks:

z Remove ignition coils .

If special tool 12 1 200 is not used,

Tightening torque, see 12 12 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Fig. 1: Identifying Spark Plug Remover (Special Tool)

-> 12 13 ... FAULT IN FUEL INJECTION SYSTEM

-> 12 13 ... NORMAL OSCILLOGRAM

-> 12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION

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

Special tools required:

Engine Test Step 10

Fig. 2: Removing Ignition Coil

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

Connect up diagnosis connector.

Fig. 3: Connecting Diagnosis Connector

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