Recall - Fuel Pump Resistor Retrofit: Overview
SI B 16 02 04Fuel Supply Systems
May 2004
Technical Service
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.
SUBJECT
Recall Campaign 04V-182: Fuel Pump Resistor Retrofit
MODEL
All B85 Z4 vehicles produced from February 2003 through October 2003.
SITUATION
When driving at higher altitudes (5,000+ feet) and in temperatures exceeding 80 degrees F, certain Z4 vehicles may experience loss of performance or stalling. Should stalling occur, it could take between 15 to 20 minutes before the vehicle would be capable of a restart.
Cars affected by this recall campaign should be returned to the customer, cleaned inside and out and with a full tank of gas. Reimbursement information for the vehicle fueling costs can be found in the Warranty Information section of this bulletin.
CAUSE
Pockets of fuel vapor may be created within the fuel pump causing a vapor lock condition. The cause is the higher rotational speed of the fuel pumps within the listed production dates.
AFFECTED VEHICLES
This Recall involves all Z4 vehicles with the 2.5 and 3.0 liter engines which were produced from February through October 2003.
In order to determine if a specific vehicle is affected by this Recall, 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 are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
Install a resistor in the ground side of the fuel pump circuit to limit pump speed.
PROCEDURE
Remove luggage compartment floor to expose the battery. If there is a white sticker on the battery holder (see illustration), no further action is necessary. If there is no sticker, proceed with resistor installation.
Remove the right side luggage compartment trim. Removal information can be found in Repair Instruction 51 47 161. Locate the comb connector fastened on a stud at the front right side of the luggage compartment.
Using the 50A current probe attached to the DISplus tester, clip the probe to one of the brown ground wires located near the center of the connector. Turn on the ignition. A 5-8 amp current flow should be observed for a few seconds. If so, the ground side of the fuel pump circuit has been located. If not, switch the probe to another nearby brown wire and retry.
Switch off the ignition and wait approximately 10 seconds between attempts.
Disconnect the battery and unbolt the comb connector from the body.
Cut the fuel pump ground wire about 5 cm from the comb connector. Strip both ends 5 mm.
Crimp the pin contact to the vehicle side of the wire and the socket contact on the wire to the comb connector. Lock these connectors within their respective insulator.
Place the resistor (3) on the comb connector mounting stud first, followed by the comb connector (1). Reinstall the nut and tighten (2). Connect the resistor leads to the lead from the comb connector and the one to the vehicle harness. Secure the cables with a tie wrap. Reconnect the battery and start the engine. If everything checks out, reassemble the luggage compartment.
PARTS INFORMATION
LABEL INSTRUCTIONS
This Recall Campaign has been assigned code number 396. Afier the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-245) and:
a. emboss your BMW dealer warranty number in the middle of the label (1);
b. punch out code number 396 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 Campaign will be via Campaign Entry
REFUELING COST
BMW of North America, LLC will provide reimbursement to have the gas tank topped off once as required, for each vehicle affected by this recall campaign. Attach the appropriate receipt to the work order.