Electrical - Engine Hesitation/No Start Condition
SI B 12 03 06Engine Electrical Systems
February 2006
Technical Service
This Service Information bulletin supersedes S.I. B12 10 04 dated December 2004
[NEW]designates changes to this revision
SUBJECT
Loss of Power or Intermittent Crank, No Start Situation
MODEL
E60 525i, 530i (5 Series) equipped with M54 engine
SITUATION
Customer complains the vehicle will intermittently hesitate or intermittently exhibits a crank, no start situation.
CAUSE
A voltage drop occurs between the Car Access System connector X10318, pin 7 and the Fuel Injector Relay connector X6327, pin 8 caused by an internally shorted Oil Condition Sensor (OEZS) located in the lower section of the oil sump. This condition is accompanied by the following fault codes being stored:
CAS FC A0C0 Terminal 15 output 3, signal fault or value above threshold
DME FC 27C3 Thermal oil level sensor signal dropped
PROCEDURE
1. Select "Control Unit Functions"
2. Select "Diagnosis Requests"
3. Select "Terminals"
4. Select "Voltage terminal 15-1", "Voltage terminal 15-2" and "Voltage terminal 15-3" in the far right column
5. Select "Display"
If the display does not indicate battery voltage for "Voltage terminal 15-3" then disconnect the Oil Condition Sensor connector X6254 and measure the voltage with the ignition switch turned to the Terminal 15 position. The voltage drop should be no longer present. Attempt to start the vehicle. If the vehicle starts replace the Oil Condition Sensor
and install the Power Supply Retrofit Harness (PN 12 51 4 512 589) according to the installation instructions attached to this Service Information Bulletin.
PARTS INFORMATION
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
E60 M54 Oil Condition Sensor Power Supply Retrofit Kit
PN 12 51 4 512 589 Installation Procedure
1. Disconnect the battery and remove the E-Box cover to access connector X60531 and Fuel Injector Relay K6327.
2. Remove connector X60531 (maroon) from it's mounting in the front top of the E-Box and unplug.
3. Open connector lock and remove pin 1 (male) green and white wire from connector housing.
4. Remove the contact area of the male pin using a suitable metal cutting device.
5. Pin with contact area removed.
6. Install the yellow insulating cap and tape it back to the harness.
7. Insert the retrofit harness male pin into pin 1 of connector X60531.
8. Relock connector.
Reassemble and reinstall in the E-Box.
9. Remove connectors from the DME Control Module to more easily access the K6327 Fuel Injector Relay. Route retrofit harness toward the right side of the E-Box and secure it to the engine electrical harness.
10. Access and remove the K6327 Relay (light green).
11. Remove Relay and lift the connector lock releasing the electrical contacts for service.
12. Insert the female pin for the retrofit harness into pin 5 of the relay connector.
13. Remove the adjacent 10 Amp fuse holder and attach retrofit harness fuse holder to one another.
14. Relock the connector and reinstall the relay. Mount the retrofit harness fuse holder and 10 Amp fuse holder in the original factory location.
15. Reinstall all components in E-Box to their proper locations. Replace the Oil Condition Sensor, reconnect the vehicle battery and clear fault code memory using the DIS Plus or GT1 Diagnostic device.