Recall - DME Module Replacement: Overview
SI B 12 04 04Engine Electrical
July 2004
Technical Service
This Service Information bulletin supersedes S.I. B12 04 04 dated July 2004.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the consumer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery.
[NEW] designates changes to this revision
SUBJECT
Safety Recall Campaign 04V-344: DME Replacement on N62/N73 Engines
MODEL
2004 MY 545i and 545iA produced from May 2004 through July 2004.
2004 MY 645Ci, 645CiA, 645Cic, 645CicA produced from May 2004 through July 2004
2004 MY 745i and 745Li produced from May 2004 through July 2004
2004 MY 760i and 760Li produced from May 2004 through July 2004
2004 MY X5 4.4i and X5 4.8i produced from May 2004 through July 2004
SITUATION
Due to an internal manufacturing error, some DME's installed in the listed vehicles may fail. This could cause the vehicle to stall unexpectedly or fail to start at all. Should the vehicle stall, it may or may not be capable of being restarted. Should the vehicle stall, the driver will lose power steering assistance and power braking assistance as well. The vehicle may still be steered and braked but it will require much more effort.
Copies of the customer notification letters and Q & A are shown.
To minimize customer's inconvenience caused by this Recall Campaign, you are being asked to pick-up (and deliver after repair) the affected vehicle from customer's home, and provide appropriate alternative transportation.
Customers will be impressed when you return their cars cleaned inside and out and with a full tank of gas. Reimbursement information for the vehicle fueling and valet costs can be found in the Warranty portion of this bulletin.
AFFECTED VEHICLES
This Recall Campaign involves 545i, 545iA, 645Ci, 645CiA, 645Cic, 645CicA, 745i, 745Li, X5 4.4i and X5 4.8i vehicles with N62 engines, as well as 760i and 760Li with N73 engines, which were produced from May 12th through July 6th, 2004. Determination of the DME production is no longer required as all DMEs within this production range are defective.
IMPORTANT NOTE:
On vehicles which recently arrived from Vehicle Distribution Centers through normal delivery process, please check B-pillar for campaign sticker 416. If such a sticker is found, no further actions are required.
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. If the report does not have Defect Code 0012930100 listed in the "Open Campaign Information" section, the vehicles is not affected. No further action has to be taken and that vehicle can be released.
NOTE:
A description for this defect code may not appear in the Open Campaign Information section of the Vehicle History Report.
The Chassis Number Ranges shown are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
On the affected vehicles, the DME control modules have to be REPLACED and reprogrammed with the latest dataset.
On E53, X5 4.4i and 4.8is vehicles, replace DME and reprogram/recode using DIS CD 38, or higher.
IMPORTANT NOTE:
Due to a software error in the DME control unit (PN 12 14 7 544 610) used in Recall Campaign 04V-344, when the new (unprogrammed), basic DME control module is installed in E53 X5 4.4i or X5 4.8is prior to programming and the ignition is turned on, the starter is activated. The following procedure should be used when programming basic DME control module on X5 4.4i or X5 4.8is vehicles:
1. Connect the battery charger and DIS/GT1 loaded with CD38 (or higher) to the affected vehicle with the defective DME still installed.
2. Select Coding/Programming and then "1. DME Programming". Next, perform automatic DME determination:
3. Select "2. Exchange Control Unit".
4. Select "1. Determine basic control unit" Follow through the next screen's instructions until the initial "Determine DME/Program DME" screen appears.
5. At this point, turn the ignition OFF, disconnect DIS/GT1 tester and replace DME module with the new part.
6. Turn ignition ON (KL15). When the starter starts to crank, apply the brakes and select Drive gear. The starter operation is then canceled
7. Next, turn ignition OFF again and reconnect DIS/GT1 tester.
8. Turn ignition ON and continue with the programming process:
9. From the DIS/GT1 select "2. Program basic control unit". Follow through the next screen's instructions.
This software programming error of starter self-activation with ignition ON is rectified after programming is successfully performed. Only E53 X5 4.4i and X5 4.8is vehicles are affected.
On E60, E63, E64, E65 and E66 vehicles, replace DME and update & code the complete vehicle using CIP 12.0, or higher.
To update the complete vehicle with CIP 12.0, or higher follow instructions from SI B09 05 01. After software updating is completed, recode complete vehicle according to procedure "E" from SI B09 05 01.
IMPORTANT NOTE:
During the measure plan determination, "Enter DME Assembly Part Number" dialog box appears on the screen. At this point, manually enter the DME programmed control module number from the defective (replaced) DME.
Programmed part number (7 digit) is printed at the bottom of the square identification label (label with with VIN).
LABEL INSTRUCTIONS
This Recall Campaign has been assigned code number 416. After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-253) and:
a. emboss your BMW dealer warranty number in the middle of the label (1);
b. punch out code number 416 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.
PARTS INFORMATION
All orders must be placed through DCSnet as a CODED PARTS ORDER. This will require the entering of a valid VIN. Initially, only vehicles in customer possession will be eligible for parts location. A new enhancement to the BMW mainframe system will only allow parts locations to VINs for these vehicles. Orders for VINs that are not in the system will automatically be canceled.
After customer's vehicles have been addressed VINs for vehicles in center inventory will be added to the system.
There will be NO Direct Shipment orders accepted or processed.
If a vehicle that is not part of this action is in need of a DME please contact the Parts Consultant Group @ 1-800-272-0202. A VIN will be required for verification.
Arrangements will be made to provide a DME. Do not attempt to order the part in any other manner.
WARRANTY INFORMATION
Reimbursement for this Recall will be via Campaign Entry.