Service Action 166 - Fault Code 245 & 246 In Engine Control Module (12 04 96)

Publication date: 1996-07-01
Reference number: 12 04 96

VOLUNTARY EXHAUST EMISSION RECALL CAMPAIGN 96E-A01

TECHNICAL SERVICE BULLETIN

Reference Number(s): 12 04 96, 96E-A01

VOLUNTARY EXHAUST EMISSION RECALL CAMPAIGN NO. 96E-A01

Model(s): 1996 BMW (E36) 328i, 328is, 328iC With M52 Engine,

Produced 10/95-2/96

Group: 12 - Engine electrical system

Bulletin No.: 12 04 96

Date: November 1996

NOTE: This Service Information bulletin supersedes S.I. 12 04 96 dated June 1996 and replaces S.I. 11 06 96 dated July 1996.

Perform the procedure outlined in this service information on all affected vehicles the next time they are in the shop for maintenance or repairs.

SITUATION

BMW of North America, Inc. has initiated a voluntary emission-related recall campaign to correct vehicles that may be in non-compliance with Federal and California Emissions Standards. Customer notification letter will be sent out by November 1996. One or both of the following may apply:

The two wires in connector X6133 located under the secondary air pump may have been reversed during production, causing the pump to run backwards on E36 models with M52 engines produced from 10/95-2/96. The "Check Engine" light is illuminated as a result.
An error in the data structure of the DME may result in the erroneous setting of fault code 245 and/or 246. The "Check Engine" light may be illuminated as a result.

AFFECTED VEHICLES

This recall involves E36 with M52 B28 engines which were produced from 10/95-2/96.

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 below are only for informational purposes and are not to be considered as the only deciding factor.

AFFECTED VEHICLES

Model	Chassis Number Ranges
328i/4	AV15000 - AV16671
328iA/4	AV35000 - AV39901
328i/2	ET00009 - ET01819
328iA/2	ET30015 - ET31979
328iC	ET60003 - ET61107
328iCA	ET90006 - ET92497
328i/4	LB10026 - LB10430
328iA/4	LB30025 - LB31139

CORRECTION

In order to complete this recall one or both of the following must be performed:

The secondary air pump wiring must be checked and correctly positioned.
Reprogram the engine control module in order to revise the software/data structure of the currently installed DME using P7.2 programming software or higher.

RECALL CAMPAIGN LABEL INSTRUCTIONS

After the vehicle has been checked and corrected, obtain a label (SD 92-079) and with a ball point pen print your dealer code (5 digits) on the Recall Completion Label (See Fig 1 ). An initial quantity of 6 labels will be sent to all BMW automotive dealers Peel the label from its backing and affix it to the left front strut tower (in the engine compartment) next to the Vehicle Emission Control Label.

For California dealers only it is required by the California Code of Regulations that a completed orange "Vehicle Emission Recall - Proof of Correction" certificate (SD92-084 - See Fig 2 ) be provided to each customer (for vehicles registered in the state of California) once the recall campaign on their vehicle has been completed. All California BMW automotive dealers will receive an initial quantity of certificates.

NOTE: Additional labels can be ordered from Product Engineering.

PROCEDURE

A. CHECK/MODIFY SECONDARY AIR PUMP WIRING

(IF SPECIAL DEFECT CODE 00 12 03 01 00 IS INDICATED ON DCS)

Read out DME fault codes If fault codes other than 245 and 246 are present, proceed with DME system troubleshooting to eliminate the faults.
If fault codes 245 and 246 are present they should be cleared without further DME system troubleshooting.
Remove 3 (M6) air pump mounting bolts See Fig 3 .
Tilt the air pump up and remove the connector. See Fig 4 .
NOTE: The hoses can remain connected to the air pump.
Check the air pump wires for correct location. See Fig 5 .
NOTE: CORRECT WIRE LOCATIONS:
- Pin number 1 = 4.0 mm Brown
- Pin number 2 = 4.0 mm Red wire with yellow tracer
Slide the yellow locking tab over to unlock the connectors. See Fig 6 .
Remove the connectors using pin removal tool (BMW tool number 88 88 6 611 132). See Fig 7 . Reinstall the connectors with the brown wire in position number 1 and the red wire with the yellow tracer in position number 2.
Slide yellow locking tab back to the locked position. See Fig 8 .
Reinstall the air pump connector and resecure the pump with the 3 (M6) bolts.

B. REPROGRAM (DME) ENGINE CONTROL MODULE USING P7.2 PROGRAMMING SOFTWARE OR HIGHER (IF SPECIAL DEFECT CODE 00 12 02 01 00 IS INDICATED ON DCS)

NOTE: Prior to reprogramming the DME any pre-existing faults set in the control module will need to be repaired.

If Fault code 245 and/or 246 are set they can be ignored/cleared, repair any other faults that are set.
Check that the wiring of the secondary air pump is correct, refer to step "A" above.
Reprogram the engine control module by following the attached reprogramming procedure. Neither the EPROM nor the engine control module need to be replaced in order to complete this recall.
In order to reprogram the control module, MODIC programming software P7.2 or higher must be used.
Refer to the attached procedure and S.I. 12 05 96 for more information on how to reprogram a "flash" engine control module.
The original DME part number, 12 14 1 429 547, although it is invalid in our system, it will display before the reprogramming is performed.
The new DME part number is 12 14 1 429 579 when the reprogramming is completed.
Print out new DME control module labels and attach one label to the top of the engine control module next to the old label which must be crossed out. Attach the other label to the repair order.
Once the update is complete perform a "quick clear" of all control modules. The "quick clear" will clear any erroneous faults that may have set in other modules during the reprogramming of the engine control module.
Start the engine and assure a smooth idle. During the DME control module adaptation period following the reprogramming, a rough idle or rough running conditions may be experienced. These conditions are temporary and will be rectified at the completion of adaptation.