M60 Engine Test - Access in DIS
Group 11Engine
Bulletin Number
11 12 95
Woodcliff Lake, NJ
May 1999
Product Engineering
This Service Information bulletin supersedes S.I. 11 12 95 (4307) and S.I. 11 13 95 (4319) dated November 1995 which should be removed and discarded from your S.I. binder.
Changes to this revision are identified by asterisks.
SUBJECT:
M60 Engine Test - Access in DIS
MODELS:
All with M60 Engines
**Situation:
The procedure outlined in this manual may be used as a step-by-step guide when performing a complete M60 Engine Test which is included as of DIS software version 17.1. For additional information on M60 Engine Diagnosis refer to Service Information 11 11 95 (43O5).**
Procedure:
Prior to selecting the "Engine Test" check the DME for faults. If faults are found they must be corrected and cleared before continuing the test.
At the main menu screen of DIS:
E38 M60 E32, E34 M60
1. Press diagnosis button 1. Press diagnosis button
2. Select series being tested 2. Select series being tested and right
arrow button (right arrow button
always pages to next screen when
selected)
3. Select right arrow button (right arrow 3. Select "Engine Test" and right arrow
button always pages to next screen
when selected)
4. Select "Digital Motor Electronics" 4. Select model information (model,
country-specific vehicles, model year)
and right arrow. Do not enter VIN
at this time.
5. Select right arrow 5. Select right arrow at "Vehicle
Identification" screen, provided all
information displayed is correct
6. Select Function Selection button
7. Select "Drive"
8. Select "M60 Test"
9. Select "Test Schedule" button (lower center of screen)
10. Select NO for answer to question
11. Select right arrow at the "Test Schedule" screen
12. Read all instructions in the green window (lower right of screen)
13. Select right arrow
14. Read the instructions in the green window
15. Select right arrow
TEST CONDITIONS M60
16. Put automatic transmission in P. Put manual transmission in N
17. Set parking brake on
18. Connect diagnostic cable to the vehicle
19. Select right arrow
20. If ignition is on switch it off
21. Select right arrow
22. Battery voltage must be greater than 12.3 volts to continue the M60 Engine Test (If battery voltage is less than 12.3 volts, the battery must be charged.)
23. Select right arrow
24. Switch ignition on
NOTE:
The engine can be started at this time in order to assist in bringing the engine up to operating temperature.
25. Select right arrow button
26. The DME fault memory will be checked automatically.
26a. If there are no faults in the DME, the test will continue automatically.
26b. If there are faults present in the DME, the test will be aborted.
You must select END and cancel to exit the M60 engine test.
Enter the DME diagnosis program and correct any existing problems. Also check if the DME identification displays a valid control module (i.e. displays Bosch HW #, software #, BMW HW #, Part #, etc.).
If the control module or EPROM are not valid the M60 update must be performed.
THE M60 ENGINE TEST MUST BE RESTARTED AFTER CORRECTING ANY EXISTING PROBLEMS.
27. Is the engine mileage greater than 3000 miles?
28. Select YES or NO
29. Select right arrow
30. Enter the last seven digits of the VIN
31. Select right arrow
32. Enter the vehicle mileage
33. Select right arrow
34. Enter the date
35. Select right arrow
36. Enter your retailer number
37. Select right arrow
38. Enter your name - (First and Last)
39. Select right arrow
40. Start engine if not already running
41. Select start
42. Once coolant temperature is greater than 850 C (185°F) select right arrow
43. The coolant temperature is displayed in the green window
44. Select right arrow
TEST CONDITIONS IDLE QUALITY WITHOUT LOAD - MEASURE TIME SHORT
45. Turn the ignition oft
46. Remove center plastic engine cover
47. Remove covers over ignition coils
48. Connect trigger clamp to primary wire harness of ignition coil #1
49. Switch oft all electrical consumers (radio, lights, rear window defogger, AC, etc.)
50. Turn front wheels in straight ahead position
51. Perform test at idle without raising the engine speed
52. Select right arrow
53. Start the engine
54. Select right arrow
55. Select "Measuring System"
56. Select "Preset Measurement"
57. Select "Smooth Running"
58. Select "OK"
59. Idle quality "Measure time short" screen is now displayed
The first idle quality test (measure time short - with no engine load) will begin automatically after selecting the idle quality test in the preset measurements.
The test is completed when the "Hold Screen" button is automatically activated.
NOTE: There are four different idle quality tests:
- Measure time short - with no engine load
- Measure time short - with engine load
- Measure time long - with no engine load
- Measure time long - with engine load
60. Print the screen
61. Hand write the VIN and "without engine load" on the printout
62. Select left arrow
63. Select right arrow
64. If the maximum value is greater than or equal to 1.3, select YES If less than 1.3, select NO
NOTE:
The values are located below the cylinder identification numbers on the idle quality printout.
65. Select right arrow
TEST CONDITIONS IDLE QUALITY WITH LOAD - MEASURE TIME SHORT
66. Switch on all electrical consumers (radio, lights, rear window defogger, AC, blower max etc.)
NOTE:
To prevent the air conditioner compressor from cycling, the doors of the vehicle should be left open
67. Select right arrow
68. Start engine if it is not already running
69. Select right arrow
70. Select "Measuring System"
71. Deactivate "Hold screen" button to start the Idle Quality test (measure time short- with engine load)
The test is completed when the "Hold screen" button is automatically activated.
72. Print the screen
73. Handwrite the VIN and "with engine load" on the printout
74. Select left arrow
75. Select right arrow
76. If the maximum value is greater than or equal to 1.3, select YES
If less than 1.3, select NO
NOTE:
The values are located below the cylinder identification numbers on the idle quality printout.
77. Select right arrow
NOTE:
If the Idle Quality Test results of the "Measure time short" test, with and without engine load are above the stored nominal values in the tester, the test program automatically bypasses the Idle Quality Tests "Measure time long".
In this case the M60 Engine Test will continue with the Pressure Distribution Test. (Go to step 106)
TEST CONDITIONS IDLE QUALITY WITHOUT LOAD - MEASURE TIME LONG
78. Switch oft all electrical consumers (radio, lights, rear window defogger, AC, etc.)
79. Select right arrow
80. Start engine if it is not already running
81. Select right arrow
82. Select "Measuring System"
83. Select "Measure time long" button
84. Select "Hold screen" button to start Idle Quality Test (measure time long -without engine load).
The test is completed when the "Hold screen" button is automatically activated.
85. Print the screen
86. Handwrite the VIN and "without engine load" on the printout
87. Select left arrow
88. Select right arrow
89. If the maximum value is greater than or equal to 1.3, select YES
If less than 1.3, select NO
NOTE:
The values are located below the cylinder identification numbers on the idle quality printout.
90. Select right arrow
TEST CONDITIONS IDLE QUALITY WITH LOAD - MEASURE TIME LONG
91. Switch on all electrical consumers (radio, lights, rear window defogger, AC, blower max etc.)
NOTE:
To prevent the air conditioner compressor from cycling, the doors of the vehicle should be left open
92. Select right arrow
93. Start engine if it is not already running
94. Select right arrow
95. Select "Measuring System"
96. Deactivate "Hold screen" button to start the Idle Quality Test (measure time long- with engine load)
The test is completed when the "Hold screen" button is automatically activated.
97. Print the screen
98. Handwrite the VIN and "with engine load" on the printout
99. Select left arrow
100. Select right arrow
101. If the measured maximum value is greater than or equal to 1.3, select YES
If less than 1.3, select NO
NOTE:
The values are located below the cylinder identification numbers on the idle quality printout.
102. Select right arrow
103. Switch off all electrical consumers (radio, lights, rear window defogger, AC, etc.)
104. Switch ignition off
105. Select right arrow
PRESSURE DISTRIBUTION TEST
106. If battery charger is connected, disconnect at this time
107. Select right arrow
108. If battery voltage is greater than 12.3 volts, continue with the test; if not, charge the battery.
109. Select right arrow
110. Switch ignition on
111. Select right arrow
112. Select the "start" button to read out the coolant temperature
113. Select right arrow
114. Select right arrow again
115. Select "start" to read out intake air temperature
116. Select right arrow
TEST CONDITIONS PRESSURE DISTRIBUTION TEST
117. Switch ignition off if it is not already off
118. Remove electric fuel pump relay or fuel pump fuse.
119. Start and run engine until it stalls.
120. Restart engine to eliminate residual fuel mixture in cylinders.
121. Remove ignition coil of cylinder #1 (primary wire harness connected). Lay coil on top of cylinder head cover (disconnected from spark plug).
122. Connect trigger clamp to primary wire harness of ignition coil #1.
123. Disconnect the harness from all ignition coils (primary side), except cylinder 1.
124. Select right arrow
125. Select "Measuring System"
126. Select "Preset Measurements"
127. Select "Pressure Distribution" and "OK"
NOTE:
The current clamp must be mounted on its calibration holder for proper calibration. This takes place when the "pressure distribution" screen is selected. If the current clamp was previously calibrated, this step will be bypassed.
128. Place the current clamp over the starter cable
129. Deactivate the "Hold Screen" button if it is not already deactivated, then, crank the engine until the "Hold Screen" button is automatically activated.
130. Print the screen
131. Handwrite the VIN on the printout
132. Select left arrow
133. Select right arrow
134. Review Pressure Distribution test printout
If all values are greater than or equal to 1.94, enter YES
If values are less than 1.94, enter NO
NOTE:
The values are located below the cylinder identification numbers on the idle quality printout.
135. Select right arrow
136. NOTE:
If either the Engine Idle Quality or Pressure Distribution tests are not within specifications, the cylinder Leakdown Test must be performed. The program will prompt you accordingly and will not display any test results at this time. (Go to step 145)
Otherwise select right arrow
137. If the engine Idle Quality and Pressure Distribution tests are within specifications, a satisfactory test report will be displayed.
NOTE:
If the Engine Test report indicates "the need for engine disassembly and further inspection", SI 11 11 95 (4305) should be referred to for additional information. Likewise, if the engine test report indicates: "Potential complaints of poor idle when the engine is not subject to load are not due to excessive wear.." refer to SI 11 11 95 (4305) for troubleshooting hints.
138. Print the Engine test result/test report display and keep it with the vehicle file. This printout may also be given to the customer upon request.
139. Print Diagnosis Report - This report must be kept with the vehicle history file along with the other four or six printouts.
140. Select right arrow
141. The M60 Engine test is complete (NOTE: cancel all DME faults)
142. Select right arrow.
143. Select "End"
144. Select "Cancel"
LEAKDOWN TEST
If either one of the Engine Idle Quality or Pressure Distribution tests are not within specifications, the cylinder leakdown test must be performed.
145. Start engine
146. Bring engine up to 4,500 RPM, 10 times with short sharp applications of the gas pedal
147. Keep the engine speed at 3,000 RPM for about 15 seconds
148. Select right arrow
149. Select the start button to display the coolant temperature, select right arrow
150. Select right arrow again
151. Turn off ignition
152. Select right arrow
TEST CONDITIONS FOR LEAKDOWN TEST
153. Remove fan.
154. Remove all ignition coils.
155. Remove all spark plugs.
156. Install whistle tool on cylinder #1.
157. Rotate engine by hand (clockwise direction when standing in front of vehicle) until whistle sounds. This will establish that the piston is moving toward TDC on the compression stroke.
158. Remove whistle tool.
159. Insert the tip of a long screwdriver carefully into cylinder # 1 through the spark plug hole, letting it rest on top of the piston.
160. Rotate the crankshaft until the piston is at Top Dead Center (TDC)
161. Calibration of Snap-On� Leakdown tester (steps 160-165)
NOTE:
The tester will need to be calibrated prior to making the first measurement. The tester must also be rechecked for zero calibration before each new measurement. If it is not at zero. the calibration procedure indicated below must be repeated.
162. Connect shop air supply hose to leakage tester input hose.
163. Set gauge to 0% using leakdown tester adjusting knob.
164. To verify leakdown tester 0% setting, connect tester output hose to engine adapter hose (not connected to engine).
165. Disconnect tester output hose again.
166. Verify tester reads 0%. If not, repeat calibration procedure until it does.
167. Remove the screwdriver from the cylinder
168. Install the Snap On� Leakdown Tester adapter hose into the spark plug hole of cylinder number 1
169. Connect the output air hose of the Leakdown tester to the adapter hose
170. Record the reading on the idle quality printout
171. Repeat steps 155 through 169 on the remaining 7 cylinders in firing order (5-4-8-6-3-7-2). Once all of the test results have been obtained they must be entered into the program.
172. Select right arrow
173. Select right arrow again
174. Is the leakdown value greater than 15%? Select YES or NO
175. Select right arrow again
176. Repeat step 172 through 174 for the remaining 7 cylinders in firing order (5-4-8-6-3-7-2)
177. Remove leakdown test equipment (all 8 cylinders completed)
178. After completion of Leakdown Test, reinstall all spark plugs and ignition coils
179. Reinstall fan and covers
180. The M60/Leakdown evaluation screen summarizes the leakdown results
181. Select right arrow
182. Select right arrow again
183. If at least two of the three tests (Engine Idle Quality, Pressure Distribution or Leakdown) are within specifications, a satisfactory test report will be displayed.
184. Print the Engine test result/test report display and keep it with the vehicle file. This printout may also be given to the customer upon request.
NOTE:
If the Engine Test report indicates "the need for engine disassembly and further inspection", SI 11 11 95 (4305) should be referred to for additional information. Likewise, if the engine test report indicates: "Potential complaints of poor idle when the engine is not subject to load are due to excessive wear.." refer to SI 11 11 95 (4305) for troubleshooting hints.
185. Print Diagnosis Report - This report must be kept with the vehicle history file along with the other four or six printouts.
186. Select right arrow
187. The M60 Engine test is complete (NOTE: cancel all DME faults)
188. Select right arrow
189. Select "End"
190. Select "Cancel"