528i M73 manual

[Jhelgesen]

I’m neck deep into a m73 (1995) install into a e39 528 chassis. Engine was running and driving in the donor 750il. The auto trans has been swapped for a manual using a Adamat adapter kit. Amazingly most of the harness was plug and play, had to add the wires for the pedal assm. Using the 750 dme’s, trans ecu, eml3, used a ews bypass box installed in the chassis.

Engine ran fine in the donor.

Installed in the 528, starts but won’t rev. Above 1.5k and starts to pop and backfire.

Needless to say the factory DME’s don’t talk to anything. Did the ads box, serial connection laptop, tried DIS, wont talk. Can get to the dme’s through tool32.



May have an issue since the original traction control ecu isn’t installed yet. Got to figure out if that’s the issue or if its time to go Rusefi.

Interesting the light module was needed on our host’s project. Wasn’t needed here.

Working on the next steps.

[Jhelgesen]

Hi Andrey, can you help direct me on the parts needed to use a proteus for my swap? I can document the process here for sure. Thanks JH

[AndreyB]

Have you seen https://github.com/rusefi/rusefi/wiki/HOWTO-M73-v12-on-Proteus?

Will add some info a bit later today

[Jhelgesen]

Yes, I've reviewed the github docs. Its a great start Thanks for the info!

[AndreyB]

You have a ton of options really, the quality/cost/time triangle

Fully custom harness is possible and I can help with it but that's $$$
134+134 harness is the quickest way you would be able to use the orange box adapter from my store
AEM 30-0300 X-Series Wideband for AFR ratio data
Some MAP sensor to read manifold.
Any 6 pin pedal from the last 20 years whatever is simplest to mount.

[Jhelgesen]

Super!

I have the later harness I can use and use the adapter from the store. I will have to look at how the later one plugs into the earlier car, suspect the chassis plugs will need to be adapted. (the earlier m73 harness was plug and play except for the pedal in the 528i)
Wideband, no prob
Map sensors, no prob
6 pin pedal, no prob, I have plenty on the shelf.

Need to review all the posts on v12 installs, started down that path and I see the Nissan throttle bodies, no prob, and using a balance tube between the manifolds.

[Jhelgesen]

Pulled the trigger, can't wait....

Thanks!

[AndreyB]

Pulled the trigger, can't wait....

Thanks!

Please get/install Aem 30-0300 in the meantime?

[Jhelgesen]

parts rolling in....

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[AndreyB]

Finally shipping.

Larger cables can go either way, smaller patch cord has orange tape to mark orange box side.

Orange box side does not have a hole for on-board MAP sensor - if you want to use that MAP sensor please drill/dremel a hole, else snip MAP sensor nipple.

Loose green/blue wires are secondary CAN bus for AEM WBO input.

Harness is set for Toyota/Nissan pedal, feel free to cut grey connector off for any other pedal.

Green loose wire on the large PCB is supposed to be +12v pin D6 start request but I could not get it to work on my partial harness. Long orange wire is alternative start request button that one connects to GND to request cranking.

Hopefully it's not too much of a mess, I am available on the phone to help make sense of all it.

[Jhelgesen]

ooohhhh exciting....

I have bmw pedals on the shelf, shouldn't be an issue to plug in.

I can start swapping over the wire harness this weekend.

JH

[Jhelgesen]

Ready to swap over to the later engine harness.

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[Jhelgesen]

That was easy

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[Jhelgesen]

Bugger. The knock sensor plugs are different.

[Jhelgesen]

Making adapters for the throttle bodies.

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[AndreyB]

How is it going? I assume that one wideband would be enough for first month but eventually would be nice to monitor second side just as a safety precaution?

At the moment fuel correction only games one sensor in the account.

[Jhelgesen]

Going okay.

Old 1995 harness is off, started installing 1999 harness. Most of the plugs are the same, except for knock sensors. Putting together some plug adapters from older parts.

Did a few revisions on the throttle body adapters.

Starting with one af meter looks like.

[Jhelgesen]

Big piece of the wiring done. Harness has some swaps to do going from 95 to 99 harness. Alternator and knock sensor plugs are different.

Need to modify the 1-6 side throttle body mount to get it lower as it hits the hood right now. Don’t know if there is a opposite handed model available.

Need a connector for the af meter to the adapter board, and figure out the adapter to the chassis connections. Fuel pump, power, etc.

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[Jhelgesen]

I'm into some fiddly parts of the wiring. Since I'm adapting the engine harness into a e39 528, need to create the harness from the 528 engine plug 2 into the v12 engine harness plug 4.

Looking for some diagrams/details on the adapter board connections too. Having fun

[AndreyB]

All adapter files are actually public https://github.com/rusefi/proteus-M73tu-adapter/ including schematics PDF at https://github.com/rusefi/proteus-M73tu-adapter/tree/main/proteusM73tu/gerber

[Jhelgesen]

Perfect! Thanks! Jh

[Jhelgesen]

Looks preloaded for v12. Nice.

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[Jhelgesen]

Connected. Didn’t let any smoke out. Yipee.

Tps won’t calibrate though. Gives same value 146 at close and open. Pedal okay goes on and off.

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[AndreyB]

https://github.com/rusefi/rusefi/wiki/HOWTO-upload-log

Do you have any ETBs connected? Do you have any pedal connected? When you move pedal do you have raw values change? When you move throttle manually do you have raw values change? Did you hear any ETB noise? Why is battery voltage showing 0.1v?

[Jhelgesen]

Picture is after I disconnected the battery. It was 12v.

Throttle bodies connected, no noise, no movement. Values don’t change with the pedal movement.

I’ll get a log in the morning

[Jhelgesen]

Log is uploading. Compared to one of the other m73 tunes, analog channel for the tps is different. I tried several times to calibrate the tps with no luck.
Thanks for your patience .

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[AndreyB]

When you move pedal do you have raw values change?

https://rusefi.com/online/view.php?msq=1546&dialog=pedalSensor does not look like a valid pedal calibration. Let's get pedal to work?

[Jhelgesen]

Tps readings were very erratic on the gauge in the calibration screen. Maybe a bad tps or wrong input?

[Jhelgesen]

Reset the pedal numbers and turned on the etbs while motor is off. Pedal sensor maxes out at halfway.

[AndreyB]

You are not holding the complete pedal in your hands only the sensor right?

I believe that while mounted on the pedal you only get certain potion of the movement available to you.

Overall it looks like you are in a great place: pedal calibration is the easiest part of the whole mess, the main thing is you have ETBs moving!