Basic problem - dirty pins
Stabilant 22A Electrical Contact Enhancer Model: All BMW Complaint: Connectors
which carry low current are more likely to form deposits which affect
the resistance of the circuit through the plug connector. Depending
upon the particular circuit these deposits can cause malfunctions and
consequently activate warning lamps and check control indicators. Remedy: Part replacement can temporarily stop the problem. If
the connector is the problem then without disconnecting the connector
measure the resistance of the circuit running through the connector to
make sure the connector has a high resistance. A good resistor will
have close to 0 ohms resistance. Visually
examine the male and female terminals in the connector housing by
removing them. Look at the integrity of the wire crimps, and in some
male terminals the integrity of the weld of the male pin to the
terminal. Then reinstall. With a zero residue electrical contact cleaner liberally spray the male and female connectors, and allow the air to dry.
Apply
Stabilant 22A to both male and female terminals so they are saturated,
and reconnect the connectors while they are still wet. When the
Stabilant 22A dries it will leave a thin coating of polymer film which
is conductive between mating surfaces, and is non-conductive between
adjacent pins. It can also prevent the formation of more harmful
deposits.
Hazard lights come on intermittently 2 years ago I had the
problem that the hazards came on while driving. That bothered me a long
time. I cleaned the hazard light switch, checked the crash module etc.
Finally it turned out to be the crash control relay/module in the fuse
box, that small brown relay right of the CCM (check the wiring diagram for your year and model!!). You can try to resolder
it, but I just replaced it. You can also try to drive without that
relay, but note that in case of a crash the doorlocks will not open
automatically, the courtesy lights will not go on automatically, and
the fuel pump(s) will not be automatically stopped.
BMW service bulletins - electrical problems
Others:
Voluntary Emissions Recall Campaign No. 99E-A01 Model: E36 - BMW 323i and BMW 328i with M52 engine
produced June 1995 - December 1998 E36-BMW M3 with S52 engine produced January 1996 - December 1998
E39-BMW 528i with M52 engine produced March 1996 -August 1998 BMW Z3-with M52 engine produced July
1996 - September 1998 BMW Z3-with S52 engine produced January 1998 - January 1999 Complaint: Vehicles
that have a faulty crankshaft position sensor have had a Voluntary
Emission-Recall Campaign. This is to check the illumination of the
check engine lamp as well as fault code 83 - Crankshaft position
sensor, and fault code 244 - Crankshaft segment timing. Remedy: The
crankshaft position sensor should be replaced with the same sensor used
on a M52TU engine. An adaptor harness must also be installed so that it
has a 12V operating voltage instead of the 5 volts currently supplied
by the DME.
Quality Monitoring M44/M62 Camshaft Sensor Model:
E36 - BMW 318i/A/ti with M44 engine produced February 1996 to February 1997
E39 - BMW 540i/iA with M62 engine produced February 1996 to February 1997
E38 - BMW 740i/iA/iL with M62 engine produced February 1996 to February 1997
BMW Z3 - with M44 engine produced February 1996 to February 1997 Complaint: The
above listed models need to replaced with a new sensor and the old
sensor must be sent back to the Warranty Parts Return Centre with a
copy of any of the DME fault codes if they are present. Based on the results
of the Dealer Communications System the following procedure must be followed:
Remedy: The customer's permission and signature must be obtained before the procedure
begins. Read and print out DME fault codes if present. Ignore the camshaft sensor
fault codes if they are present. Clear all fault codes stored in the DME
Replace the camshaft sensor as outlined in the repair manual group.
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No Start Caused by Faulty Oil Level Switch Model: BMW E39 (5series) with
M52 engine, BMW E46 (3 series) Vehicles up to November 1998 Complaint: The
vehicle will not start, there is no crank. It may also be noticed that
there is no transmission range display in the Instrument Cluster. The
charge indicator lamp flickers or is permanently on. The oil level
switch is stored in the Instrument Cluster (E46). Fuse 15 or Fuse 30 is
blown. This is due to a faulty oil level switch which causes the
fuse to blow so there is a loss of input to EWS from the Transmission
Range Switch. Remedy: -If Fuse 15 or Fuse 30 is blown then install a new fuse
(7.5A), turn the ignition to attempt to start the engine. -If the fuse blows again,
disconnect the Oil Level Switch at the plug connector. Install a new fuse and
start the engine. -If the engine starts, and the range display is shown in the Instrument Cluster then replace the Oil Level Switch.
In
order to confirm a defective switch then use a DVM to check the
resistance between the pins of the 3 pin connector. If the switch is
good it should measure infinite resistance between any 2 pins in the
connector.
Fault Code 227/228 Model: E36 - BMW 328i with M52 engine
E39 - BMW 528i with M52 engine Complaint: The 'Check Engine' lamp is
illuminated. FC 227 - Mixture deviation, cylinder 1-3 and/or FC 228 - Mixture deviation cylinder 4-6 Remedy: Check
the correct Air Mass Meter is installed. If the wrong one is installed
then it needs to be replaced as well as the Suction Silencer. The
rubber boot may not need replacing as it has a rubber 'downsizing' ring
which is used for installing the smaller Air Mass Meter on other
models. Remove the inner rubber ring from the rubber boot in order to
install the larger Air Mass Meter. If the correct air mass meter is
installed then check the adaptation values located in the DME
diagnostic status section. These values can provide a further insight
into what has made the fault set. After repairs are made relating to
an adaptation related fault, the adaptation values should be cleared.
This will allow the vehicle to driven under various load conditions and
readapted. If the adaptation values are rechecked an indication of the
success of the repair can be obtained.
Multiplicative mixture adaptation (Part Load) Vehicle under load
If
the value is greater than 6% there may be an air leak and not
enough fuel is reaching the system, or an erroneous signal from the air
mass meter. Then the oxygen sensor will measure a lean signal, which
will cause the DME to compensate for the problem by trying to make the
mixture rich. If the value is less than 7% there could be an air
restriction, erroneous signal from the air mass meter, or too much fuel
in the system. The oxygen sensor signal will then measure a rich signal
which causes the DME to compensate for the problem by making the
mixture lean.
Additive mixture adaptation (Idle) Vehicle idle
If
the value is greater than 0.2 ms then there is an unmetered air leak
where not enough fuel is being supplied to the system or an erroneous
signal from the air mass meter. The oxygen sensor signal measures a
lean signal which causes the DME to compensate and make the mixture too
rich. If the value is less than -0.2ms then there is an air
restriction, and too much fuel is being supplied to the system or an
erroneous signal from the air mass meter. The oxygen sensor signal
measures a rich signal which causes the DME to compensate for the
problem by making the mixture too lean.
Once a certain threshold (ms) value
is exceeded the system can no longer offset the problem and a fault is logged.
Seal on 2 and 3 Pin Plug Connectors
Model:
All BMW
Complaint: When
connecting or disconnecting 2 or 3 pin plug connectors it is possible
for the rectangular seal to fall out of the plug housing unnoticed. The
seal prevents moisture from seeping into the plug as well as ensuring
that the two halves of the plug are properly tensioned so that the
contacts do not move within the plug. If this movement occurs the
contacts can develop corrosion. Corroded or loose contacts could cause
problems with the proper functioning of the vehicle, as well as causing
difficulty in diagnosis due to the possibly intermittent nature of such
problems.
Remedy: Ensure
that when working with 2 or 3 pin plug connectors the seal is in place
before the plug connector is connected. If it is missing then it must
be replaced.
Oil Pressure Warning Light Comes On
Model: BMW E38 with M60, M62 and M73 Engines Complaint: During
production an oil pressure switch wiring harness was installed which
could let water into the electrical connector, which in turn will cause
corrosion at the oil pressure switch pin connections. As a consequence
of this corrosion the engine oil pressure warning light will come on,
even if the oil pressure is fine. Remedy: The oil pressure switch
and the oil pressure switch wiring harness needs to be replaced. This
procedure will apply to vehicles produced before January 1996.
M52 Engine Control Module Fault Code 12 Model: E36-BMW 328i and E39-BMW 528i with M52 Engine Complaint: Due
to a software error in the DME results an erroneous setting of fault
code 12 in the DME will occur. The customer can experience the ASC lamp
being illuminated, the 'check engine' lamp is illuminated. The vehicle
may also show Fault Code 12 (Throttle valve potentiometer in the DME),
Fault Code 154 (CAN accelerator pedal setting in the EGS/AGS), and
Fault Code 57 (Throttle valve signal from DME in ASC/ABS). Remedy: The
Engine Control Module (DME) needs to be reprogrammed using the MODIC
programming software version P9.0 or higher. Once the DME has been
reprogrammed perform "Quick Clear" which will clear any faults that
have been set as a result of the reprogramming. Next clear the
"Throttle Position adaptation values" under service functions.
Oil Level Sensor Model: BMW E31 and E34 with M60 and M62 engines produced from
January 1995 - January 1996. Complaint: As a result of a porous float in the
level sensor assembly the engine oil level sensor may indicate an incorrect oil level. Remedy: Utilize
the 'Service Menu' of the Dealer Communication System, and based upon
the response of the system either proceed with corrective action, or
take no action at all. If action is necessary then replace the oil
level sensor on the affected vehicles.
Engine Control Module Fault Code for
Throttle Position Sensor Model: BMW E34 and E36 with M50 engines Complaint: The
'check engine' light is on, and in automatic transmission vehicles the
failure indicator for transmission control module is on, and the
transmission operates in the failsafe mode. Remedy: The idle speed control valve is to be replaced if:
-The
engine control module has a fault code 12 (M50), or fault code 73
(M50TU), and transmission control module fault code 105 (only automatic
transmission vehicles) is experienced. -The throttle position sensor and its circuit have tested good, and -No
other outside influence can be found. (These include the floor mat
pushed up against the pedal, a misadjusted throttle cable, or a
misadjusted cruise control actuator assembly).
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Coolant Temperature Sensor (NTC) Model: BMW E34 (M5) produced from October 1992 to December 1992 Complaint: During
production of the S38 engines the incorrect NTC coolant temperature
sensors with a blue connector housing and tin plated electrical
contacts may have been installed. Due to the vehicles' wiring harness
which connects to the NTC have gold plated connectors the two metals
can corrode which will cause implausible signals to be transmitted to
the DME control module, and adversely affect the driving
characteristics. Remedy: Utilize the 'Service Menu' of the Dealer
Communication System, enter the chassis number of the vehicle involved
and based upon the response of the system either proceed with
corrective action, or take no action at all. If action is necessary
then:
-Remove the NTC coolant temperature sensor plug which is
mounted in the coolant pipe above the exhaust manifold-blue connector. -If
the contacts on the NTC coolant temperature sensor are tin-plated then
replace with a new NTC sensor with gold-plated contacts. -Top off coolant
level if necessary. -If the sensors on the NTC are gold-plated the sensor
does not need to be replaced.
Incorrect Fuel Gauge Reading Model:
BMW E36 (3 series) including BMW 318ti produced from January 1995 Complaint: Due
to the formation of a non-conducting deposit on the conductor surface
of the fuel level sensor, the fuel gauge does not read full after
re-fuelling, or the fuel gauge is erratic. Remedy: Remove and replace both
fuel level sensors with "Gold system" sensors.
Fuel Gauge Stays Empty
after Refuelling/Fuel Gauge Erratic Model: BMW Z3 Roadster/coupe, BMW
M roadster/coupe (E36/7). Vehicles produced before December 15 2000 Complaint: After
refuelling the fuel gauge will stay on empty or the fuel gauge is
erratic. This is caused by a non-conducting deposit being formed on the
conductor surface of the fuel level sensor. For the Z3 from September
1998 and the M roadster/coupe FC 2 (Fuel sensor voltage plausibility)
will be set in the Instrument Cluster. Remedy: Remove and replace the
fuel level sensor with a 'Gold system' sensor referring to repair instructions
16 12 000.
Incorrect Fuel Gauge Reading Model: BMW E53 (X5) vehicles produced before August 17 th 2000. Complaint: After
the tank has been filled the fuel gauge will either not read "full", or
the correct reading will only be shown once the ignition has been
switched OFF and ON again. These faults will be stored in the
Instrument Cluster:
- Fault Code 8 - Fuel tank sensor 1 (fuel-pump side)
and/or -Fault Code 9 - Fuel tank sensor 2 (without fuel pump) These errors
are caused by a non-conducting deposit being formed on the conductor surface of
the fuel level sensor. Remedy: Using the DIS or MoDiC: -Select diagnosis
-Select Function Selection/Complete Vehicle/Body/Displays and Information/Instrument Cluster.
-Select Test Plan -Select 4 - Expert Mode/ Read Fault Memory to confirm fault codes 8 and/or 9 are set. -Select 3 Service Functions/ 1 - Test Code -Press 'Test Code' button to save test code. -Print Diagnosis Report -Remove
and replace the right hand delivery unit and the left hand fuel level
sensor. Refer to repair instructions 16 12 000 and 16 12 001. -Also to ensure a correct
installation of the left side sensor use the following procedure: -Lubricate
the small o-ring for the fuel transfer pipe to ensure the o-ring does
not push out of position when the fuel transfer pipe is being installed. -Lubricate the inside
edge of the large o-ring seal, so that the fuel level sensor will slide easily into position. -The
fuel level sensor must be installed keeping the top flange square to
the tank at all times. Rotate the sensor so that the lug is located
above it's recess, then push the sensor vertically down into position.
It must NOT be installed at an angle. -Using the DIS or MoDiC select 4 - Expert Mode/ Clear
Fault Memory to clear the fault code memory.
Fuel Gauge Reads three quarters full when Tank Is Full Model:
BMW Z3 (E36/7) produced from September 1998 to April 1999 Complaint: After
refuelling the fuel gauge reads one quarter full, and will then move extremely
slowly to read full. This is due to a software error in the Instrument
Cluster. Remedy: Re-code the instrument cluster using DIS CD Version 18.0 or later:
-Select
Coding/Programming/ZCS Coding/E36/Recoding/Kombi and then follow the
on-screen instructions to complete the coding process. -Recoding the
instrument cluster will start an internal day counter. If the test3.1
contains a value greater than 0 indicates the instrument cluster will
already contain the fix.
Jump to top Evaporative Emission Control - On Board Diagnostic System
Model: E36 - BMW 318i and BMW Z3 with M44 produced from January 1997 E36 - BMW 328i produced from
October 1995 E36 - BMW M3 produced from March 1996 E38 - BMW 740i/iL and BMW 750iL produced from
May 1997 Complaint: The 'check engine lamp is illuminated, and one or more of the following faults
are set in the Engine Control Module (DME):
-In
the M52 Engine the complaints include the tank venting system, minor
leak (Code 251), Tank ventilation (Code 252), Shut-off valve, activated
charcoal filter, jammed shut (Code 253) or Tank venting system, major
leak (Code 254). -In the M44, M62 or M73 Engine the complaints
include the tank venting system, major leak (Code 94), Shut -off valve,
activated charcoal filter, jammed shut (Code 96) or Tank venting
system, minor leak (Code 97).
Remedy: The check engine lamp
will only be illuminated if the fault is present during two consecutive
drive cycles. To complete a check of these systems the vehicle needs to
run in a way that allows these functions to work fully. Any attempt to
duplicate the specific driving condition will be unsuccessful, thus it
is recommended that the test modules through BMW specific test tools
are utilized. One driving cycle includes engine start up - drive -
engine shutoff and will test the:
-Evaporative system - component functional check
-Evaporative system leak detection -Tank venting/shutoff valve operation
-Monitoring catalytic converter efficiency -Secondary air induction operation
If
a fault occurs due to a major leak or a minor leak being present then
check if the fuel filler cap has been installed correctly. This can be
easily detected if the cap can be easily pulled off. To clear the fault
properly install the cap, printout the fault information, clear the
fault, select service functions, select DME system test, select 3-
Leakage diagnosis, tank venting system. If the fault returns the
system needs to be checked for further leaks using the Evaporative
System Leak Test Pool with an A/C leak detector. If NO leak is detected the
following component checks need to be carried out:
-Check the fuel filler
gasket has not been damaged. -Check operation of purge valve. -Check purge
valve using a hand held vacuum pump to check the valve can hold a vacuum.
-Check the o-ring is properly installed. -Check for any broken hose fittings in the expansion tank.
-Check the operation of the shut-off valve. -Check the shut-off valve has been correctly
installed into the charcoal canister. -Check routing of hose going to the fuel tank pressure sensor.
If the hose is pinched it should be rerouted or shortened.
If the fault occurs
through the shut-off valve the following must be checked:
-The routing of the
hose going to the fuel tank pressure sensor. If the hose is pinched it should be rerouted or
shortened. -The operation of the Shut-off Valve, Purge Valve and Fuel Tank Pressure Sensor
should be tested. -Remove the shut-off valve from the charcoal canister and look for
obstructions which do not allow the valve to shut correctly
Service Action to
Recode Instrument Cluster Model: BMW Z3 (E36/7) produced between August 1998 to May
1999 Complaint: After filling with fuel the fuel gauge can show a low reading, then
while driving can move to correct position. Remedy: Utilize
the 'Service Menu' of the Dealer Communication System, enter the
chassis number of the vehicle involved and based upon the response of
the system either proceed with corrective action, or take no action at
all. If action is necessary then: Recode the instrument cluster using DIS CD Version 18.0 by Connect
the DIS or MoDiC III to the diagnostic connector, switch on the engine,
select 'Encoding ZCS ('3')', select Series E36 ('4'), Select recoding
('1'), select Kombi ('10'), follow the on screen instructions to
complete.
Coolant Temperature Gauge Reads High Under Normal Operating Conditions
Model: BMW M roadster (E36/7) All vehicles produced until June 1998 Complaint: Under
normal operating conditions the pointer on the coolant temperature
gauge reads between the mid-way point and the mark above the mid-way
point. This is due to a coding error during the vehicle assembly. Remedy: Do not
replace any components instead: Recode the instrument cluster using DIS CD Version 18.0 by Connect
the DIS or MoDiC III to the diagnostic connector, switch on the engine,
select 'Encoding ZCS ('3')', select Series E36 ('4'), Select recoding
('1'), select Kombi ('10'), follow the on screen instructions to
complete.
Oxygen Sensor
Oxygen Sensor Update and DME Reprogramming Model: BMW E36 with M44 engine Complaint: Over
time the oxygen sensors on these vehicles can develop poor internal
electrical connections which will illuminate the check engine light.
When this occurs possible fault codes set in the DME are: Fault Code 10,
Oxygen Sensor Pre Catalyst and/or Fault Code 12, Oxygen Sensor Post Catalyst. Remedy: Utilize
the 'Service Menu' of the Dealer Communication System, enter the
chassis number of the vehicle involved and based upon the response of
the system either proceed with corrective action, or take no action at
all. If action is necessary then: Replace both oxygen sensors (pre
cat regulating sensor and post cat monitoring sensor) and using the DIS
or MODIC P14.0 programming software and reprogram the Engine Control
Module.
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Quality Monitoring M60 Oxygen Sensors Model: BMW E34
and BMW E38 with M60 B40 engines produced from September 1994 to August 1995 Complaint: The
oxygen sensors of the listed vehicles need to be replaced with new
sensors as a quality monitoring gauge. The old sensors should be
returned to the Warranty Parts return Centre with a copy of any DME
fault codes if present. Remedy: Utilize the 'Service Menu' of the
Dealer Communication System, enter the chassis number of the vehicle
involved and based upon the response of the system either proceed with
corrective action, or take no action at all. If action is necessary
then:
-Obtain customer permission and signature to authorize the
extraction of both left and right oxygen sensors. -Read and print out
DME faults.
Test/hex code printout procedure: Select '3 service
functions' and right arrow button. Select '1 test code' and right arrow button.
Select 'test code R' Select print 'diagnosis report'
-Ignore any oxygen sensor fault
codes if present. -Clear all fault codes stored in the DME -Replace both oxygen
sensors referring to the repair manual group 11 section.
Oxygen Sensor Wiring
Harness Voluntary Recall Campaign No. 98E A02 Model: BMW E36 with M42 engine (manual transmission only) Complaint: A
voluntary campaign from BMW in North America is recalling the oxygen
sensor wiring harness of the above vehicles. The oxygen sensor harness
may have been routed incorrectly during production. One possible
solution could be the oxygen sensor harness has been accidentally
secured with clips to the exhaust heat shield and/or to a bracket on
the transmission housing. The oxygen sensor harness could stretch and
eventually break with the movement between the vehicle body,
transmission and exhaust system causing the check engine light to
illuminate and the fault code 70 - oxygen sensor disconnected to set in
the DME. Remedy: Utilize the 'Service Menu' of the Dealer
Communication System, enter the chassis number of the vehicle involved
and based upon the response of the system either proceed with
corrective action, or take no action at all. If action is necessary
then:
-Read and print out the DME faults. -Troubleshoot and
repair DME fault codes other than fault code 70 using the DIS tester instructions as necessary. -Check
the oxygen sensor harness for hold down clips or any signs (crimped or
pinched areas in the sheathing) where a clip or other hold down device
may have been installed in the past. -Remove all clips and other
oxygen sensor wiring harness hold down devices from the exhaust heat shield,
transmission bracket. -If installed, bend the transmission bracket using a pair of up over the bolt head. -
The oxygen sensor must only be replaced if the oxygen sensor harness
had any fastener holding it in place, or the oxygen sensor shows any
signs of it being fastened previously, or Fault Code 70 is stored in
the DME.
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