Procedure A

Applies to Chassis Number Ranges "TB30290 - TB30304", "TC30020 - TC3004511, "TD50028 - TD50064" and "TE10017 - TE10035" only.

Replace the BC1 and install additional sealing and BC1 protection as follows:

1. "A" pillar roof finisher clip sealing

^ Remove the right hand side roof finisher in accordance with TIS Repair Instruction 51 13 301.





^ Remove finisher clip (1) from the roof panel and discard the clip.

^ Take the new expanding nut (see Parts Information) and carefully remove the black foam washer from the nut. Discard the nut.

^ Take the new finisher clip (see Parts Information). Remove and discard the rubber washer.

^ Install the foam washer onto the finisher clip and push the clip firmly into the hole in the roof panel. Make sure that both legs of the clip have expanded correctly and that the clip is sitting flat against the roof panel.

^ Reinstall the roof finisher.

2. Removing the BC1

^ Before removing the BC1, using DISPlus/GT1 in "Coding", select "Vehicle Memory", then select "Print List" to record the customer's current Vehicle Memory settings

^ [NEW]Select "Vehicle Memory", then select "Print List" to record the customer's current Vehicle Memory settings

^ [NEW] Select "ZCS/FA Coding"/"R50/R53 Series"/"Recoding"/"ZKE"/"Replace Control Unit"/"Read data out of faulty unit"

[NEW] Note:
In order to avoid unnecessary delays in the return of the car to the customer, it is MOST IMPORTANT that this step to "Read data out of faulty unit" is carried out.

If it is omitted, then when the replacement part is installed, the key barcode data will have to be entered manually. If the barcodes tags cannot be located, then the barcodes must be requested overnight from the Technical Hotline with the resulting delay in the return of the vehicle to the customer.

^ Disconnect the battery and remove the BC1 in accordance with TIS repair instruction 61 35 510.

^ Inspect the harness connector for any deposits which may have resulted from the presence of water and clean as necessary using compressed air (please observe necessary safety precautions).

3. Disconnecting the redundant door lock wires at the BC1 connector

^ Locate the black connector from the top of the BC1.





^ Release the latches and slide out the inner connector (1).





^ Slide apart the two inner connectors.





^ Remove the connector pins from connector cavity numbers 10 and 28 (white/gray and blue/red wires). See illustration (1). Cut off the connector pins from the wires.

^ Inspect the remaining connector pins for any deposits which may have resulted from the presence of water and clean as necessary using compressed air (please observe necessary safety precautions).

^ Reassemble the inner and outer connectors.

^ Fold back the two disconnected wires and tape each of them to a single adjacent wire as close to the connector as possible.

4. Harness sealing

This modification introduces a barrier of sealing material into the harness to prevent water running down the harness into the BC1 connectors.

^ Locate the two connectors from the top of the BC1, and apply sealing to each of the harnesses as follows:

Starting with one harness, remove the protective tape for a length of 4 out 3/4 inch (120 mm) away from the BC1 connector.





^ Group the wires into three equal bunches and spread the wires from the first bunch so that the wires lie along side each other.

Take a strip of sealing material (see Parts Information), remove the protective paper from one side of the strip and apply the strip lengthwise onto the wires with the center of the strip positioned 2-3/8 inch (60 mm) away from the BC1 connector (A).





^ Remove the protective paper from one side of a second strip of sealing material and lay it on top of the first strip of protective paper so that the wires are sandwiched in between.

^ Before removing the remaining pieces of protective paper from the sealing strips, squeeze the sealing material into the harness.





^ Repeat the operation on the other two groups of wires, remove any remaining protective paper and then bring all three bunches together. Mould the sealing material into a single cylinder around the harness.

^ Repeat the sealing operation on the second BC1 harness.

5. Installing the new BC1 and soft cover





^ Pass the BC1 harness connectors through the two "legs" of the BC1 cover. Align the connectors in the correct orientation for connection to the BC1 and install a cable strap (1) to each "leg" of the cover.

NOTE:
The position of the cover leg relative to the harness sealing material is important. The top of the cover "leg" must be positioned half way along the length of the sealing material. Dimension "B" is 1 inch (25 mm).

^ Apply PVC insulation tape (see Parts)

NOTE:





1. The tape must start from the cover "leg" and work upwards towards the sealing material.

2. The application of tape MUST finish before the end of the sealing material. i.e. a small section of sealing material must remain visible when the tape application is complete.

^ Connect all four connectors onto the new BC1.

^ Locate the eyelet in the BC1 cover and thread it onto the BC1 front mounting stud. Install the new BC1 onto its mounting studs. Install and tighten the retaining nuts.





^ Pull the cover down over the body of the BC1.

^ Do not reconnect the battery at this stage.

6. Cleaning and applying grease to the door connectors and sealing the connectors to the "A" pillars

This modification prevents water entering the door connector and running down the harness into the BC1.

^ Remove the single screw securing the door harness connector to the right hand "A" pillar.





^ Pull the connector partly out of the "A" pillar, slide the locking device rearwards and disconnect the door harness.





^ Inspect the "A" pillar surface finish in the area where it abuts the door harness seal (1). The surface must be flat and free from paint runs, wax runs or any other irregularity. Flatten and/or clean the area accordingly.





^ Pull the connector carefully out of the "A" pillar as far as possible. Release the catches and remove the blue locking slide from the connector.

^ Inspect the connector pins for any deposits which may have resulted from the presence of water and clean as necessary using compressed air (please observe necessary safety precautions).





^ Apply connector grease (see Parts Information) liberally around and amongst the wires at the back of the connector (1). Also apply grease to the terminals, which are exposed by removal of the locking slide (2), on both sides of the connector. Reinstall the blue locking slide.





^ Apply connector grease liberally to all the connector pins inside the "mouth" of the connector.





^ Reconnect the door harness to the "A" pillar connector and, before sliding the assembly into the "A" pillar, apply grease liberally to the lip of the door harness connector seal (for clarity, the door harness connector is shown disconnected).





^ Apply grease to the retaining screw aperture (1) (shown disconnected for clarity)

^ Slide the connector into the "A" pillar and install the retaining screw.

^ Wipe away any excess grease from the "A" pillar and around the connector seal.

^ Repeat the operation on the left hand "A" pillar connector.

^ Reconnect the battery.

^ Using DISPlus/GT1, code the BC1 (ZKE), then set any Vehicle Memory features that are not at Factory Setting (refer to the "Print List" in step # 2 or additional customer selection).

^ [NEW] Select "ZCS/FA Coding"/"R50/R53 Series"/"Recoding"/"ZKE"/"Replace Control Unit"/"Transfer data to new Control Unit and code the Control Unit"

^ [NEW] Set any Vehicle Memory features that are not at Factory Setting (refer to the "Print List" in step # 2 or additional customer selection).

^ Reset the clock (if necessary) and reinitialize the windows (refer to TIS Repair Instruction 61 35)

7. Electrical functional check

Start the check by sitting in the vehicle with the doors closed and unlocked. Switch on the ignition.

Activate and check for correct operation of the following:

^ Lighting system

Side lamps.

Dipped headlamps.

Headlamp flash.

Indicators left and right.

Fog lamps.

Brake lamps.

Interior light (open and close door) and map lights.

Headlamp leveling.

Switch OFF all lights.

^ Wiper system

Front flick wipe.

Rear wiper.

Rear washer.

^ Center switch pack

Lock master switch (lock and unlock).

Door windows - one touch down (left and right).

Door windows - hold switch up to fully close (left and right).

Door windows - drop slightly when doors opened (left and right).

^ Air conditioning and heated rear window (with engine running)

All functions of air conditioning and switch LEDs.

Heated rear window (check switch LED only).

^ Locking

Close the doors, hood and tailgate, fully open the RH door window, open the sunroof (if installed), turn off the ignition and lock the vehicle with the key.

With the vehicle unlocked, open the tailgate and check the trunk lamp.

Lock the vehicle with the key and hold the key in the locked position to close the RH window and sunroof (if installed).