Xenon Headlamp - Reduced Service Life
Group 63Lights
Bulletin Number
63 O8 98
Woodcliff Lake, NJ
December 1998
Product Engineering
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
SUBJECT:
Xenon Headlamp Reduced Service Life - 1999 740iL
MODEL:
1999 740iL equipped with Xenon headlights (SA 522)
Situation:
Xenon headlamps may experience a reduced service life on E38 vehicles produced between 8/26/98 - 9/28/98.
Cause:
The Xenon headlamp control unit.
Affected Vehicles:
In order to determine if a specific vehicle is affected by this Service Action, it will be necessary to utilize the "Service Menu" of the DOS (Dealer Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.
The Chassis Number flanges listed below are only for informational purposes and are not to be considered as the only deciding factor
Chassis Number Range
DN73064 - DN73441
DP00120 - DP01094
Correction:
Check the production date of the headlamp assembly, if necessary check the Xenon headlight control unit using the Xenon wiring adapter tool (p/n 90 88 6 631 000) and replace the control unit(s) as required.
Procedure:
To check the headlamp production date:
1. Check the date on the yellow manufacturer's label attached to the top of the headlamp assembly.
2. If the production date is "17.09.98" (September 17, 1998) or later, the Xenon control unit is 0k and no further action is required.
3. If the production date is "16.09.98" (September 16, 1998) or earlier, check the Xenon control unit with the DIS or MoDiC III.
To check the Xenon control unit:
4. Connect the multifunction cable 2 (MFK2) to the DIS/MoDiC III.
5. Connect the test adapter (p/n 90 88 6 631 000) for Xenon headlamp between the headlamp and vehicle wiring harness.
6. Connect the MFK2 to the test adapter.
7. Select "Measurement" on the DIS/MoDiC III and select "Oscilloscope settings".
8. Set the scope parameters for the DIS/MoDiC III as follows:
OSCILLOSCOPE SCREEN SETTINGS FOR DIS
OSCILLOSCOPE SCREEN SETTING FOR MoDiC III
To record the pattern:
9. Switch on the low beam (Xenon lights) and immediately (within 1 second) press the "freeze frame" button to capture the pattern of the headlamp. It may be necessary to scroll the screen display until the curve appears or repeat this step until the pattern is captured.
10. Compare the voltage pattern read out from the scope display as shown.
Control Unit "OK": There is a distinct voltage drop of 300 - 400 mV between points A and B. Voltage curve will level to 100 mV after 5O ms (milliseconds).
Control unit "NOT OK": The voltage drop between A and B is between 100 - 150 mV. The voltage curve will level to 300mV or higher.
11. If the control unit is "OK", no further action is necessary.
12. If the control unit is "not OK", replace the Xenon control unit as per the BMW repair manual (63 12 860). Note: The headlamp must be removed from the vehicle (63 12 001).
Parts Information:
Part Number Qty Description
63 12 8 386 960 1 or 2 Xenon headlight control unit
Service Action Label Instructions:
This Service Action has been assigned code number 235. After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-095) and:
a) emboss your BMW dealer warranty number in the middle of the label (1);
b) punch out code number 235 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:
Parts and Labor are reimbursable under the terms of the BMW New Car Limited Warranty. Reimbursement will be provided through campaign entry.
Defect Code: 00 63 O6 01 00
Work Package # 1
Labor Operation: OO 52 528 Check the production date of both
headlights
Labor Allowance: 3 FRU
Work Package # 2
Labor Operation: OO 52 540 Check the production date of both
head lamps. Check the voltage pattern of
both headlamps. Control units "OK"
Labor Allowance: 4 FRU
Work Package # 3
Parts Allowance: 63 12 8386 960 (1) Xenon Control Unit
Labor Operation: 00 52 541 Check the production date of both
head lamps. Check the voltage pattern of
both headlamps. Replace the control unit
on 1 headlamp.
Labor Allowance: 14 FRU
Work Package # 4
Parts Allowance: 63 12 8 386 960 (2) Xenon Control Units
Labor Operation: OO 52 542 Check the production date of both
headlamps. Check the voltage pattern of
both headlamps. Replace the control unit
on both headlamps
Labor Allowance: 21 FRU