DME-ME 7.

2 ENGINE MANAGEMENT SYSTEM

DME - ME 7.2 is the next generation of engine management systems for current and future
powertrain control. ME 7.2 replaces M5.2.1 for all 8 cylinder engine applications. The ME
designation identifies the system as M = Motronic, E = EML.

Manufactured by Bosch to BMW specifications ME 7.2 LOCATION IN E-BOX

134 pin SKE (standard shell construction) con-
trol module located in E box
New diagnostic communication protocol
(KWP2000)
Uses break-out box set (P/N 90 88 6 121 300)
Integral EML throttle control system
- monitors an interior installed PWG
- actuates an electric throttle valve (EDK)
Integral Cruise control functionality
- monitors cruise control requests
- monitors brake pedal and clutch switches
- carries out throttle control directly via EDK
Carries out DSC III torque reduction requests.
VANOS control
Integrated altitude sensor
Integrated temp sensor for monitoring E box
temperatures
Control of E-box fan
One touch engine start control
Oxygen Sensor heating
Engine overrev & Max speed
limitation
Active Hall sensor for camshaft
position monitoring
Single speed secondary air 1 2 3 4 5
(9 pins) (24 pins) (52 pins) (40 pins) (9 pins)
injection system
Electrically heated coolant system thermostat (same function as previous M62 engine)
Longlife spark plugs
IHKA Auxiliary Fan control

This training manual only covers new or modified input signal components and output con-
trol functions. The balance of the ME 7.2 system functions are as per previous engine man-
agement systems. Refer to Engine Electronics (ST055) and OBD II (ST060) training course
material for detailed functional descriptions.

30
ME 7.2 I.P.O.

31
INTEGRAL ELECTRIC THROTTLE SYSTEM (EML)
FUNCTIONAL DESCRIPTION

When the accelerator pedal is moved, the PWG provides a change in the monitored sig-
nals. The ME 7.2 compares the input signal to a programmed map and appropriately acti-
vates the EDK motor via proportionally high/low switching circuits. The control module self-
checks its activation of the EDK motor via the EDK feedback potentiometers.

Requirements placed on the Electric Throttle System:

Regulate the calculated intake air load based on PWG input signals and programmed
mapping.
Control idle air when LL detected with regard to roadspeed as per previous systems.
Monitor the drivers input request for cruise control operation.
Automatically position the EDK for accurate cruise control (FGR) operation.
Perform all DSC III throttle control interventions.
Monitor and carryout max engine and roadspeed cutout.
32
PWG SIGNAL MONITORING & PWG FAILSAFE OPERATION:

As a redundant safety feature the PWG provides two separate signals from two integral
potentiometers (Pot 1 and Pot 2) representing the drivers request for throttle activation.
If the monitored PWG potentiometer signals are not plausible, ME 7.2 will only use the
lower of the two signals as the drivers pedal request input providing failsafe operation.
Throttle response will be slower and maximum throttle position will be reduced.
When in PWG failsafe operation, ME 7.2 sets the EDK throttle plate and injection time
to idle (LL) whenever the brake pedal is depressed.
When the system is in PWG failsafe operation, the instrument cluster matrix display will
post Engine Emergency Program and PWG specific fault(s) will be stored in memory.
Refer to page 38 for additional PWG component and signal information.

EDK FEEDBACK SIGNAL MONITORING & EDK FAILSAFE OPERATION:

The EDK provides two separate signals from two integral potentiometers (Pot 1 and Pot
2) representing the exact position of the throttle plate.
EDK Pot 1 provides the primary throttle plate position feedback. As a redundant safe-
ty feature, Pot 2 is continuously cross checked with Pot 1 for signal plausibility.
If plausibility errors are detected between Pot 1 and Pot 2, ME 7.2 will calculate the
inducted engine air mass (from HFM signal) and only utilize the potentiometer signal that
closely matches the detected intake air mass.
- The ME 7.2 uses the air mass signalling as a virtual potentiometer (pot 3) for a
comparative source to provide failsafe operation.
- If ME 7.2 cannot calculate a plausible conclusion from the monitored pots (1 or 2
and virtual 3) the EDK motor is switched off and fuel injection cut out is activated
(no failsafe operation possible).
The EDK is continuously monitored during all phases of engine operation. It is also
briefly activated when KL 15 is initially switched on as a pre-flight check to verify its
mechanical integrity (no binding, appropriate return spring tension, etc). This is accom-
plished by monitoring both the motor control amperage and the reaction speed of the
EDK feedback potentiometers. If faults are detected the EDK motor is switched off and
fuel injection cut off is activated (no failsafe operation possible). The engine does how-
ever continue to run extremely rough at idle speed.
When a replacement EDK is installed, the ME 7.2 adapts to the new component
(required amperage draw for motor control, feedback pot tolerance differences, etc).
This occurs immediately after the next cycle of KL 15 for approximately 30 seconds.
During this period of adaptation, the maximum opening of the throttle plate is 25%.
Refer to page 39 for additional EDK feedback signal information.
33
NEW OR MODIFIED INPUT SIGNALS/COMPONENTS
CAMSHAFT POSITION SENSORS

Located on the upper timing case covers, the camshaft position sensors monitor the posi-
tion of the camshafts to establish start of ignition firing order, set up sequential fuel injection
triggering and for accurate camshaft advance-retard (VANOS) timing feedback.

Each intake camshafts advance-retard angles are adjusted simultaneously yet indepen-
dently. For this reason ME 7.2 requires a camshaft position sensor on each cylinder bank
for accurate feedback to monitor the VANOS controlled camshaft positioning.

The sensors are provided with operating power from the ECM main relay. The sensors pro-
duce a unique asymmetrical square-wave signal representative of the impulse wheel shape.
The sensors are new in the fact that they are active hall effect sensors. Active hall sen-
sors provide:
low signal when a tooth of the camshaft impulse wheel is located in front of the sensor
high signal when an air gap is present.
The active hall sensors supply a signal representative of camshaft position even before the
engine is running. The ME 7.2 determines an approximate location of the camshafts posi-
tions prior to engine start up optimizing cold start injection (reduced emissions.)

34
HOT FILM AIR MASS SENSOR (HFM 5)

The M62 TU is equipped with a new Hot Film

Air Mass Sensor identified as HFM 5. It is a
combined air mass/intake air temperature
sensor. The separate intake air temperature
sensor is no longer used on the M62 TU.

The HFM 5 is provided with operating power

from the ECM main relay. Based on calcu-
lated intake air mass, the HFM 5 generates a
varying voltage between 0.5 and 4.5 volts as HFM 5 WITH
an input signal to the ME 7.2 NEW CONNECTOR

HOT
An additional improvement of the HFM 5 is that the hot
SENSING film element is not openly suspended in the center bore
FILM of the sensor as with previous HFMs. It is shrouded by
a round fronted plastic labyrinth which isolates it from
intake air charge pulsations.

This feature allows the HFM to monitor and calculate the

intake air volume with more accuracy. This feature adds
further correction for calculating fuel injection on time
(ti) which reduces emissions further.
ROUNDED
LABYRINTH

35
INTEGRATED AMBIENT BAROMETRIC PRESSURE SENSOR

The ME 7.2 Control Module contains an integral ambient barometric pressure sensor. The
sensor is part of the SKE and is not serviceable. The internal sensor is supplied with 5 volts.
In return it provides a linear voltage of approx. 2.4 to 4.5 volts representative of barometric
pressure (altitude).

The ME 7.2 monitors barometric pressure for the following reasons:

The barometric pressure signal along with calculated air mass provides an additional
correction factor to further refine injection on time.

Provides a base value to calculate the air mass being injected into the exhaust system
by the secondary air injection system. This correction factor alters the secondary air
injection on time, optimizing the necessary air flow into the exhaust system.

To recognize downhill
driving to postpone
start of evaporative
emission leakage diag-
nosis.

36
RADIATOR OUTLET TEMP SENSOR

First seen on the MS 42.0 control system, the ME

7.2 uses an additional water temperature sensor
located on the radiator outlet.

ME 7.2 requires this signal to monitor the water

temperature leaving the radiator for precise acti-
vation of the IHKA auxiliary fan.

DSC III - ROAD SPEED SIGNAL

ME 7.2 receives the road speed signal directly

from the DSC III control module for maximum
vehicle speed management. The DSC control
module provides a processed output of the right
rear wheel speed sensor as a digital square wave
signal. The frequency of the signal is proportion-
al to the speed of the vehicle (48 pulses per one
revolution of the wheel).

The cruise control function (FGR) of the ME 7.2 also monitors vehicle speed from the redun-
dant vehicle speed CAN bus signal. The CAN bus speed signal is provided by the DSC III
control module and based on the combined average of both front wheel speed signals.

Additionally, ME 7.2 monitors all four wheel speed signals via CAN bus signalling to detect
abrupt fluctuations in vehicle speed signals for the purpose of detecting rough road sur-
faces. This is continuously monitored as part of the OBD II emission requirements provid-
ing a correction factor for misfire detection plausibility. Earlier systems only monitored the
right rear speed signal input from DSC.

37
ACCELERATOR PEDAL SENSOR (PWG)

The driver's application of the accelerator pedal is monitored by a PWG sensor in the dri-
ver's footwell as with previous non-bowden cable EML systems.

The PWG provides two separate variable

voltage signals to the ME 7.2 control
module for determining the request for
operating the Electric Throttle Valve (EDK)
as well as providing a kickdown request
with automatic transmission vehicles.

The ME 7.2 monitors the changing signal

ranges of both circuits as the pedal is
pressed from LL to VL.

PWG Pot 1 = 0.5V to 4.5 V

PWG Pot 2 = 0.5V to 2.0 V

Standard transmission
vehicles (E39 540i)
have slightly lower
voltage signals at max
throttle position due to
the throttle pedal stop
(ie Pot 1 = 3.8volts).
However, ME 7.2 programming recog-
nizes the lower values of a standard trans-
mission vehicle as the max throttle posi-
tion.
In vehicles equipped with an automatic
transmission (A5S 440Z), the ME 7.2 rec-
ognizes the max pedal value (4.5V) as a
kickdown request and signals the AGS via
CAN bus.
The signals are continually monitored for
plausibility. If the signal ranges are detect-
ed as incorrect, ME 7.2 will only utilize the
signal of lesser voltage value as a failsafe
measure. With this condition, the EDK will
also be set to idle (LL) whenever the brake
pedal is pressed. Refer to PWG monitor-
38 ing and failsafe operation on page 33.
EDK THROTTLE POSITION FEEDBACK SIGNALS

The EDK throttle plate position is monitored by two integrated potentiometers. The poten-
tiometers provide DC voltage feedback signals as input to the ME 7.2 for throttle and idle
control functions.
Feedback potentiometer 1 provides a sig-
nal ranging from 0.5V (LL) to 4.5V (VL),

Feedback potentiometer 2 simultaneously

provides a signal ranging from
4.5V (LL) to 0.5V (VL).

Pot signal 1 is the primary signal, signal 2 is

used as a plausibility cross-check through
the total range of throttle plate movement.
If there is an open or short in signal 1, signal
2 is used as a temporary substitute providing
failsafe operation (faults stored).
If the signals are not plausible, ME 7.2 deter-
mines intake air mass from the HFM signal
(virtual Pot 3) and compares it with Pot 1 and
Pot 2. The signal that is closest to virtual Pot
3 is then used and the other disregarded.
If ME 7.2 cannot calculate a plausible con-
clusion from the monitored pots (1 or 2 and
virtual 3) the EDK motor is switched off and
fuel injection cut out is activated (no failsafe
operation possible).
Refer to EDK monitoring and failsafe opera-
tion on page 33.
39
MFL CRUISE CONTROL DATA SIGNAL

The ME 7.2 control module provides the FGR cruise control function. Throttle activation is
provided by ME 7.2 automatic control of the EDK and monitoring of the throttle plate posi-
tion feedback potentiometer signals.

All of the familiar driver requested cruise control function requests are provided to the ME
7.2 control module via the MFL control module on a single FGR data signal wire.

BRAKE LIGHT SWITCH

The Electronic Brake Switch (Hall effect) provides brake pedal position status to the ME 7.2.
The control module monitors both the brake light and a separate brake light test switch cir-
cuits for plausibility.

When the brake pedal is pressed the brake light segment of the switch provides a ground
signal. Simultaneously, the brake light test switch (located in the same housing) provides a
high signal.

CLUTCH SWITCH

The clutch switch is equipped on manual transmission vehicles for deactivating the FGR. It
is housed in the footwell by the clutch pedal. The hall effect clutch switch interrupts the sin-
gle wire circuit to the ME 7.2 control module when the clutch pedal is pressed.

40
ME 7.2 & M5.2.1 CAN BUS TOPOLOGY
The CAN bus consists entirely of
a twisted pair wire set. This con- 750iL, M73 TU - M5.2.1
CAN BUS
figuration eliminates the need for
a ground shield.

The Engine Control Modules

(ME7.2 & M5.2.1) have two CAN
bus communication ports, one
dedicated to AGS (and DME I of
the 750iL to EML) and the other
for the balance of the vehicles
CAN bus control modules.

This configuration improves the

reliability of CAN bus signalling. If
an open occurs in one area, the
other control systems can still
communicate on either side of
the open.

However, signals not reaching

their intended recipients will
cause CAN bus faults to be
stored in the affected systems.

ME 7.2 CAN BUS

41
NEW OR MODIFIED OUTPUT CONTROL FUNCTIONS
FUEL PUMP RELAY CONTROL

ME 7.2 controls the fuel pump relay as with previous systems with regard to engine speed
input for continual activation of the relay.

When MRS III is incorporated into production vehicles (SOP 3-99) the ME 7.2 will also
switch off the fuel pump relay when an airbag is activated as an additional safety function.

E BOX FAN CONTROL

The E Box fan is controlled by ME 7.2. The control module

contains an integral NTC temperature sensor for the pur-
pose of monitoring the E box temperature and activating the
fan.

When the temperature in the E-Box exceeds predetermined

values, ME 7.2 provides a switched ground for the E Box fan
to cool the E box located control modules.

With every engine start-up, ME 7.2 briefly activates the fan

ensuring continued fan motor operation for the service life of
the vehicle. This feature is intended to prevent fan motor
lock up from lack of use due to pitting or corrosion over
time.

42
SECONDARY AIR INJECTION

The secondary air injection system is new to the 4.4 liter V8 engine. The system consists
of the same components as previous systems with V8 specific locations.
VACUUM NON RETURN VALVE PUMP/MOTOR
RESERVOIR
AIR PUMP SUPPLY HOSE
VACUUM
CONTROL TO
NON RETURN
VALVE

AIR DELIVERY TUBE WITH O RING

CONNECTIONS TO CYLINDER HEADS

VACUUM
VENT VALVE

The DME ME7.2 control unit controls the vacuum vent valve and the secondary air injec-
tion pump relay separately but simultaneously.

The secondary air pump operates at a start temperature of between 10C and 40C. It con-
tinues to operate for a max. of 2 minutes at idle speed.

ME 7.2 contributes an additional correction factor for secondary air on time with the addi-
tional input from the integral ambient barometric pressure sensor.

This sensor provides a base value to calculate the air mass being
injected into the exhaust system. This helps to fine tune the sec-
ondary air injection on time, optimizing the necessary air flow
into the exhaust system which reduces the time to catalytic con-
verter light-off.

43
AUXILIARY FAN CONTROL

The Auxiliary Fan motor incorporates an out- FAN MOTOR MODULE

put final stage that activates the fan motor at
variable speeds.

The auxiliary fan is controlled by ME 7.2. The

motor output stage receives power and
ground and activates the motor based on a
PWM signal (10 - 100 Hz) received from the
ME 7.2.

Similar to the aux fan in the E46 with MS 42.0

control, the fan is activated based on the fol- POWER, GROUND & SIGNAL WIRES
lowing factors:

Radiator outlet temperature sensor input exceeds a preset temperature.

IHKA signalling via the K and CAN bus based on calculated refrigerant pressures.
Vehicle speed
Battery voltage level

When the over temperature light in the instrument cluster is on (120OC) the fan is run in the
overrun function. This signal is provided to the DME via the CAN bus. When this occurs
the fan is run at a frequency of 10 Hz.

44
ELECTRIC THROTTLE VALVE (EDK) CONTROL

The throttle valve assembly of the M62 TU is an elec-

tric throttle valve (EDK) controlled by an integral EML
function of the ME 7.2. The throttle plate is posi-
tioned by a gear reduction DC motor drive.

Similar to the original Bosch EML 1.2 and 1.7 sys-

tems, the motor is controlled by proportionately
switched high/low PWM signals providing precise
plate positioning. The PWM signal is at a basic fre-
quency of 2000 Hz.

45