Engine - MIL ON/Rough Running/Poor Driveability
GROUP 12Engine - Electrical
Bulletin Number
12 01 88 (1574)
Montvale, NJ
February 1988
Technical Dept.
SUBJECT:
Moisture in Oxygen Sensor Multiplug
MODELS:
E30 (Equipped with M20 Engines - Produced September 1987 through November 1987)
Complaint:
Poor driveability, rough running, "Check Engine" light illuminated. These complaints may result from engine operation during (or after) heavy rains or following engine compartment washing.
Cause:
Insufficient weather sealing capability of G103 harness.
Correction:
Beginning with December 1987 production, a 100% inspection program has been implemented to check the G103 ground cable for sufficient quantity of moisture sealant. This is readily apparent by the presence of heat shrink insulation covering the G103 harness exit point.
All vehicles in the above production range should be inspected and the following procedures should be performed whether or not a customer complaint has been received.
Basic
Procedure:
Inspect the G103 ground cable for the moisture seal which can be confirmed by the presence of a heat shrink weather seal where the ground cables exit from the harness sheath. Should no heat shrink weather seal be present where the G103 ground cables exit the harness sheath, perform the following repair procedure(s) as applicable.
Repair
Procedure:
Disconnect Oxygen Sensor Multiplug and inspect electrical pins and general condition. If the multiplug is dry and free of traces of moisture corrosion, perform Repair Procedure "A" only. If the multiplug is wet or has evidence of electrical corrosion, perform both Repair Procedures "A" and "B".
A. 1) Disconnect G103 and allow harness to hang down vertically and drain any trapped moisture.
2) When the harness sheath is free of all moisture, fill the last 30 mm of the G103 harness sheath with silicon sealant.
3) Additionally, seal the G103 ground cable exit point with standard heat shrink covering.
B. 1) Access the DME fault memory and print the contents.
2) Erase DME fault memory.
3) Renew the Oxygen Sensor harness multiplug as follows:
^ Disconnect the Oxygen Sensor Multiplug.
^ Pull back the rubber boots on both sides of the O2 Sensor Multiplug.
^ Release both multiplug latching collars.
^ Remove electrical connectors with BMW Tool 88 88 6 611 110. Refer to SI 04 06 87 (1357).
^ Cut off all electrical connectors and remove both rubber boots.
^ Trim back the harness sheath approx. 25 mm.
^ Install new rubber boots P/N 12 52 1 719 569 over wire ends.
^ Apply a small amount of silicone sealant where the wires enter the rubber boots.
^ Attach new male and female electrical connectors P/N 61 13 1 376 191 and 61 13 1 376 202 using the Crimpac II hand pliers from the BMW Electrical Repair Kit.
^ If the multiplug connectors are not in perfect condition (traces of corrosion) renew with P/N 12 52 1 718 056 and 12 52 1 718 057.
^ Insert wires with new electrical connectors into multiplug connectors.
^ Note the correct wire arrangement as shown.
MULTIPLUG CONNECTORS - REAR VIEW
^ Relock both multiplug latching collars.
^ Slide rubber boots over multiplug housings.
^ Connect multiplug to underside of the battery tray.
Note:
All dealership Service personnel should be instructed that steam cleaning or high pressure water sprays must not be pointed directly at harness junctions or multiplug connections. Considering the numerous underhood components and multiplugs that could be affected by such cleaning, engine compartment high pressure washing is not recommended.
Parts Information
Warranty
Status:
Parts and labor reimbursed under the provisions of the 5 Year/50,000 Mile Emissions-Related Defect Warranty.
Defect code: 00 00 12 46 00
Labor operation:
A repair 00 50 685
B repair 00 50 686
Labor allowance:
A repair 3 FRU
B repair 11 FRU