Recall - Heater Core Cracking Additional Notice: Overview
17 03 93Coolant System
March 2000
SUBJECT
Coolant System Recall Campaign - No. 93V-015
MODEL
E30 with M42 Engine (318i, 318is, 318iC)
This Service Information bulletin supersedes S.I. 17 03 93 (3774) dated October 1993. Customer notification letters were originally sent during the period of June 1993 - April 1994 to the registered owners (as ascertained from States Motor Vehicle Registration data) of affected vehicles. The current owners of "not yet repaired" vehicles will be mailed notification letters during the period of March 2000 - April 2000. A copy of the customer letter is included, for your information.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
SITUATION
BMW of North America, Inc. has voluntarily initiated a safety-related defect recall campaign that involves the coolant system of the affected vehicles. This bulletin outlines specific procedures for implementing the modification portion of the campaign.
The malfunction or failure of a coolant system component, such as a thermostat, water pump, or fan belt, can result in significantly increased coolant temperature and system pressure.
If the indications (e.g. movement of the coolant temperature gauge needle into the red zone) of such a critical overheating condition are not heeded by the driver, and if, in addition, the vehicle is operated under high-load conditions such that the elevated pressure cannot be adequately relieved, it is possible that damage to, or failure of, a coolant system component could occur.
If a crack were to form in the end piece of the heater core, coolant could be expelled, perhaps suddenly. In some cases, the coolant could contact the lower right leg of the driver, possibly resulting in injury. It is also possible that, in some cases, coolant expelled from the heater core as vapor could cause fogging of the interior surfaces of the windows, reducing the drivers field of view.
AFFECTED VEHICLES
This Recall Campaign involves E30 (318i, 318iC) vehicles with M42 engines which were produced 11/89-5/92.
In order to determine if a specific vehicle is affected by this Recall Campaign, it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.
The Chassis Number Ranges listed below are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
As this modification will not prevent engine overheating, any problems (e.g. mechanical defects, improper coolant level/antifreeze protection, etc.) with the coolant system should be corrected before performing the recall modification.
Such repairs are not reimbursable under this recall campaign.The customer must be made aware of the required repairs, and their liability for payment, before such repairs are made.
Replace the radiator cap with a new version to control system pressure and provide greater coolant overflow in the event of overheating. Install thermostatic bypass valve and associated installation hardware to control coolant temperature in the heater core.
PROCEDURE
Remove the radiator cap. Remove the drain plug located in the bottom left comer of the radiator, and drain the coolant into a large clean catch pan. A funnel may be helpful in directing the flow of coolant. Save the coolant, since it will be poured back into the system later.
Remove the plastic cover over the wiring tray that runs along the top of the firewall. The cover is secured with clips underneath. Loosen the wiring tray by removing three phillips screws (one on each side of the diagnostic plug, and one at the passenger end). This assembly (wiring tray and wiring) may now be moved forward to gain better access for the modification. Refer to the illustration.
1. Tray Cover, secured w/clips
2. Wiring Tray, move forward for access Black arrows indicate screw locations
Note:
Original coolant hoses must be left in the vehicle when performing this procedure. Do not loosen the hose clamps at either end of the hose. Tests have shown that reinstalled hoses may develop a leak at their ends due to settlement of the hose material during the first installation, and likely over-torquing during reinstallation. If during this modification the coolant supply and/or return hoses are found to be damaged (ripped/torn), so that they are no longer watertight, the hose(s) must be replaced. Remove the damaged hose(s) carefully - do NOT cut the hose(s) to remove. Note that all replaced hoses must be returned for evaluation by the Warranty Parts Center.
Reinstall the radiator drain plug, and move the catch pan directly where the heater hoses pass through the firewall. The next two steps in the procedure will illustrate where the hoses need to be cut for installation of the bypass assembly. coolant will spill from the hoses as they are cut. Bend the hoses down to drain as much coolant as possible into the catch pan.
1. Supply Hose for Heater
2. Return Hose for Heater
Carefully remove a 30 mm section of the supply hose measuring from the lower bend at the firewall end, using tin snips, hose cutters, or a sharp knife. This must be done with the hose installed in the vehicle. Refer to the illustration for location of cuts.
1. Cut out this section carefully. The section to be removed is measured from the lower bend near the firewall.
Make a single cut in the return hose, still installed on the vehicle. Refer to illustration below. Cut carefully, since assembly will be easier if the cut is clean and square.
1. Make single cut along dotted line. The drawing shows the hose with the heater core side on the right.
The required parts to assemble the bypass are shown below. Assemble the bypass valve (item # 3) into the cut supply hose. The illustration # 5 17 93 U 11 shows the proper orientation of the components when installed in the vehicle. Note that an arrow on the body of the bypass valve shows the direction of coolant flow, from the cylinder head to the heater core. Do not install the valve backwards. Secure the supply hose to the bypass valve with two of the larger hose clamps (item # 2). Attach the curved end of the bypass hose (item # 4) to the small nipple on the bypass valve and secure with a small hose clamp (item # 1). Large hose clamps are to be torqued to 2.5 Nm, small hose clamps to 1.5 Nm, using a torque wrench.
1. Clamp - bypass hose (10-16 mm)
2. Clamp - supply/return hose (23-29 mm)
3. Bypass valve
4. Bypass hose
5. "T" piece
Trim the bypass hose to the proper length as shown in the illustration:
Bypass hose length: Trim off 60 mm
Install the "To" piece into the cut return hose, using new large hose clamps to secure. Connect the free end of the bypass hose to the small fitting on the "To", and secure with a new small hose clamp. Verify that all hose clamps are tight, and that none of the hose or valve components rub on the engine, intake manifold, etc.
FINAL ASSEMBLY: Note orientation of components. Hoses should not rub against engine block, intake manifold, etc.
1. Completed valve/supply hose assembly
2. Connect bypass hose to nipple on "T"
3. "To" piece installed into return hose
Pour the coolant from the catch pan back into the system. Strain coolant through a screen funnel to filter out any dirt or grit. Install the new redesigned radiator cap. Add enough new, properly mixed coolant to compensate for any spillage during the modification (typically less than 32 oz. of 50/50 mix antifreeze/water). Bleed the coolant system according to the E30 repair manual (operation 17 00 039), and leak check per E30 repair manual (operation 17 00 009). Verify that there are no leaks once the car is warmed up, and that the heater works. Reinstall the wiring tray with the phillips screws, and snap the cover back into place.
PARTS INFORMATION
LABEL INSTRUCTIONS
This Recall Campaign has been assigned code number 92 After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-008) and:
a. emboss your BMW dealer warranty number in the middle of the label (1);
b. punch out code number 92 printed on the label and,
c. affix the label to the B pillar as shown.
If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on top of another one because a number from an underlying label could appear in the punched-out hole of the new label.
WARRANTY INFORMATION
Reimbursement for this recall will be provided through DCS Campaign Entry.
Special Defect Code: 00 17 01 04 00
Work Package # 1
The following work packages are only to be used if hoses are found damaged during the modification procedure. Note that all replaced hoses are to be returned to the Warranty Parts Return Center for evaluation.
Work Package # 2
Work Package # 3
Work Package # 4
DISCLAIMER