2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 640599 Date: 990901

A/C System - Diagnostic Hints

GROUP 64

Heating and Air Conditioning

Bulletin Number

64 05 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

DIAGNOSIS HINT: E38, E39 A/C Inoperative

MODEL:

E38, E39 produced 9/98 and later

Situation:

Complaint of A/C not functioning. The following malfunctions may be encountered:

-- A/C compressor always "on".

-- Auxiliary fan does not switch on.

-- High side pressure reading above 300 lbs. and compressor pressure relief valve may have been activated.

Cause:

IHKA possibly not coded correctly.

Correction:

Recode the IHKA with CD 18.0 or higher.

Procedure:

To verify the A/C operation:

1. Start the engine and turn the A/C "off".

2. Visually inspect the A/C compressor to determine if the clutch is engaged.

3. If the compressor is always engaged, recode the IHKA module. After coding, check for proper A/C operation.

If the compressor is not engaged after coding, shut the engine off and connect the A/C manifold gauges. Start the engine and activate the A/C.

Set the temperature to 60 F.

4. Check the system pressure. If the pressure is low, the refrigerant may have been lost through the compressor relief valve.

5. Recover the remaining refrigerant and recharge to the specified quantity. Check the system for proper operation and refrigerant leaks. If the

system is not functioning properly, further diagnosis is required.

Warranty Information: For information only.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 640699 Date: 990901

Windshield - Fogging/Condensation Avoidance Tips

GROUP 64

Heating and Air Conditioning

Bulletin Number

64 06 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

131

Windshield Fogging

MODEL:

All E46, E38 and E39

Situation:

The front windshield may fog after heavy rain and high humidity.

Correction:

Advise the customer to keep the inside surface of the windshield clean to avoid excessive condensation. In addition, some E46 customers may find it

desirable to reprogram the Key Memory settings to activate the A/C compressor on engine start-up and "open the defrost vent when cooling".

This setting will automatically activate the A/C compressor each time the ignition key is turned on and will still allow for the A/C compressor to be

turned off or on "manually" from the IHKA control panel.

Procedure:

To set the Key Memory in the E46 only:

1. Choose the key(s) to be programmed.

2. Connect the DIS/MODIC to the vehicle and select Coding/Programming.

3. Select "KEY MEMORY".

4. After a short period of time the system will display a key number selection list (only two remote keys are supplied with new vehicle). The

display also shows the identification number of the last used key (helpful to identify the key if later on the labels are misplaced or are missing).

5. Select the key for Key Memory assignment, and press arrow to continue.

6. Select "Heating/Air Conditioning/Ventilation".

7. Select "Flaps".

8. Select "Close Defroster when cooling".

9. Select "No".

10. After pressing the "continue" arrow, the system will accept the change in selection and the KEY MEMORY main menu will be displayed.

11. Select "Heating/Air Conditioning/Ventilation".

12. Select "Air Conditioning on at:".

13. Select "Ignition on".

14. When all of the required KEY MEMORY configuration changes are entered, scroll down to the bottom of the main menu and select: "99" set

changes.

15. After selecting "99 SET VEHICLE", all configuration changes are being displayed.

16. To continue, press the arrow button. The display will request to cycle the ignition. Turn the ignition switch off, then switch back on. Press

"Yes" to continue.

17. When the display changes to "Vehicle setting completed", turn the ignition off for 10 seconds and turn it back on again. Verify the

configuration changes by activating the new functions.

Warranty Information: Information only.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 640499 Date: 990901

A/C - Inoperative, Compressor Not Engaged

GROUP 64

Heating and Air Conditioning

Bulletin Number

64 04 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

DIAGNOSIS HINT: Intermittent - No A/C on E38, E39, and E46

MODEL:

E38, E39 produced 9/98 and later; All E46

Situation:

Customer complaint of no A/C, compressor not engaged.

Cause:

424

Possible A/C pressure sensor malfunction.

Procedure:

Using the DIS/MODIC, compare the pressure sensor output to the A/C manifold gauge reading on the high pressure line.

Note:

All E46, E38 (9198 and later) and E39 (9198 and later), use a pressure sensor on the high side A/C line(at the drier). The pressure sensor has a

variable output signal as compared to the pressure switch, which is "on - off". The switch is not interchangeable with the sensor. To check the

A/C pressure sensor:

1. Connect the DIS/MODIC to the vehicle.

2. Select: "Control Unit Functions"

Select: " C Control System"

Select: "Pressure sensor" and "Display"

The pressure sensor value will be displayed under "Messages and Results".

3. Connect the A/C manifold gauges to the high and low pressure valves.

4. The high and low side gauges should read approximately 90 - 120 psi (depending on the vehicle and temperature). Before proceeding, make

sure the high and low side pressures are equal. if the gauges are not equal, wait until the system pressures equalize.

5. Select: "Control Unit Functions"

Select: "A/C Control System"

Select: "Pressure sensor" and "Display"

6. The pressure sensor value will be displayed under "Messages and Results". Compare the DIS/MODIC pressure sensor value to the high side

manifold gauge.

7. if the high side manifold gauge is in "psi" only, then the DIS/MODIC reading must be multiplied by 14.5.

(pressure sensor value) bar X 14.5 = (pressure sensor value) psi

8. The values should be within 锟斤拷 10% (due to gauge calibration).

9. If the pressure sensor value is "negative" or not within 锟斤拷 10% of the manifold gauge value then the sensor must be replaced.

Note:

The A/C system must be evacuated before replacing the sensor.

Parts Information:

Refer to the EPC.

Warranty Information:

Diagnostic hint for information only.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 180199 Date: 990901

Catalytic Converter - Unnecessary Replacements

GROUP 18

Exhaust Systems

Bulletin Number

18 01 99

Woodcliff Lake, NJ

September 1999

Product Engineering

205

This Service Information bulletin supersedes S.I. 18 01 99 dated August 1999 which should be removed and discarded from your S.I. binder.

SUBJECT:

Unnecessary Catalytic Converter Replacements

MODEL:

E36 with M44 engine from 1/96 prod.

Z3 with M44 engine from 10/96 prod.

E36 with M52, 852 engines from 10/95 prod.

E46 with M52 engine from 6/98 prod.

E39 with M52 engine from 3/96 prod.

Z3 with M52, 852 engines from 1/96 prod.

E38, E39, E31 with M62 engine from 1/96 prod.

E38, E31 with M73 engine from 1/95 prod.

Situation:

Analysis of returned catalytic converters has proven that some converters are not defective and are replaced unnecessarily.

The reason for unnecessary converter replacements may be due to the misfire fault code(s) in conjunction with the statement "catalyst damaging"

being stored in the Engine Control Module (ECM/DME).

Example:

Fault Codes 63 - 70: "Cylinder misfire detected - catalyst damaging"

If a vehicle is found with the "Check Engine" lamp on and one or more misfire faults are stored in the engine control module, the fault code

description "cylinder X misfire detected - catalyst damaging" will be displayed on the diagnosis fault survey of the DIS or MoDIC.

The qualifier "catalyst damaging" is a reminder that this type of fault (cylinder misfire) may over time cause damage to the catalytic converter if it is

not repaired.

Troubleshooting cylinder faults should be carried out using the DIS or MoDIC i.e. check secondary ignition system, etc.

A catalytic converter should not be replaced automatically when a - catalyst damaging" fault code is stored in the Engine Control Module.

A catalytic converter replacement is only necessary if fault codes 40, 45 or 233 (E9 hex), 234 (EA hex) are stored in the Engine Control Module

which are catalytic converter efficiency or conversion faults and/or if a customer complaint of an audible rattle noise coming from the converter is

verified.

Warranty Information: Information only.

2000 BMW 328i (E46) Technical Service Bulletin # 640699 Date: 990901

2000 BMW 328i (E46) Technical Service Bulletin # 640699 Date: 990901

Windshield - Fogging/Condensation Avoidance Tips

GROUP 64

Heating and Air Conditioning

Bulletin Number

64 06 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

Windshield Fogging

MODEL:

All E46, E38 and E39

Situation:

The front windshield may fog after heavy rain and high humidity.

Correction:

Advise the customer to keep the inside surface of the windshield clean to avoid excessive condensation. In addition, some E46 customers may find it

desirable to reprogram the Key Memory settings to activate the A/C compressor on engine start-up and "open the defrost vent when cooling".

This setting will automatically activate the A/C compressor each time the ignition key is turned on and will still allow for the A/C compressor to be

turned off or on "manually" from the IHKA control panel.

Procedure:

To set the Key Memory in the E46 only:

1. Choose the key(s) to be programmed.

2. Connect the DIS/MODIC to the vehicle and select Coding/Programming.

3. Select "KEY MEMORY".

4. After a short period of time the system will display a key number selection list (only two remote keys are supplied with new vehicle). The

display also shows the identification number of the last used key (helpful to identify the key if later on the labels are misplaced or are missing).

5. Select the key for Key Memory assignment, and press arrow to continue.

6. Select "Heating/Air Conditioning/Ventilation".

7. Select "Flaps".

8. Select "Close Defroster when cooling".

9. Select "No".

10. After pressing the "continue" arrow, the system will accept the change in selection and the KEY MEMORY main menu will be displayed.

11. Select "Heating/Air Conditioning/Ventilation".

12. Select "Air Conditioning on at:".

13. Select "Ignition on".

14. When all of the required KEY MEMORY configuration changes are entered, scroll down to the bottom of the main menu and select: "99" set

changes.

15. After selecting "99 SET VEHICLE", all configuration changes are being displayed.

16. To continue, press the arrow button. The display will request to cycle the ignition. Turn the ignition switch off, then switch back on. Press

"Yes" to continue.

132

17. When the display changes to "Vehicle setting completed", turn the ignition off for 10 seconds and turn it back on again. Verify the

configuration changes by activating the new functions.

Warranty Information: Information only.

2000 BMW 328i (E46) Technical Service Bulletin # 651099 Date: 990901

2000 BMW 328i (E46) Technical Service Bulletin # 651099 Date: 990901

Radio - CD43 CD will Not Eject

GROUP 65

Sound System Cruise, Alarm, Monitors

Bulletin Number

65 10 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

In-Dash CD43 Radio-CD Will Not Eject

MODEL:

E46, 3 Series (323i, 328i)

Situation:

CD will not eject from radio. However, the unit will operate correctly after the center wood trim panel (above the CD drive slot) is removed.

Cause:

Excessive pressure on CD drive slot caused by molding residue (flashing) in the center of wood trim panel.

Vehicles Affected:

Vehicles manufactured up to March of 1999, equipped with in-dash CD radio (CD43) and wood trim finish option (SA 438).

Correction:

In case of a verified complaint, remove radio and center wood trim panel (follow Repair Instruction 65 11 030).

Using a sharp scraper (or similar tool) remove any excessive flashing from the center locating slot on the back of the wood finisher panel.

218

If still necessary, using a fine file, trim the center locking tab (dimension A = ~ 1 mm) located on top of the radio face plate.

Important:

Make sure that no foreign material/dust enters the CD drive. (by protecting the slot with a piece of tape)

Important:

Due to dimensional sensitivity of the loading mechanism of the CD43 unit, only standard sized CD's (without additional labels attached) should

2000 BMW 328i (E46) Technical Service Bulletin # 640499 Date: 990901

2000 BMW 328i (E46) Technical Service Bulletin # 640499 Date: 990901

A/C - Inoperative, Compressor Not Engaged

GROUP 64

Heating and Air Conditioning

Bulletin Number

64 04 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

DIAGNOSIS HINT: Intermittent - No A/C on E38, E39, and E46

MODEL:

E38, E39 produced 9/98 and later; All E46

Situation:

Customer complaint of no A/C, compressor not engaged.

Cause:

412

Possible A/C pressure sensor malfunction.

Procedure:

Using the DIS/MODIC, compare the pressure sensor output to the A/C manifold gauge reading on the high pressure line.

Note:

All E46, E38 (9198 and later) and E39 (9198 and later), use a pressure sensor on the high side A/C line(at the drier). The pressure sensor has a

variable output signal as compared to the pressure switch, which is "on - off". The switch is not interchangeable with the sensor. To check the

A/C pressure sensor:

1. Connect the DIS/MODIC to the vehicle.

2. Select: "Control Unit Functions"

Select: " C Control System"

Select: "Pressure sensor" and "Display"

The pressure sensor value will be displayed under "Messages and Results".

3. Connect the A/C manifold gauges to the high and low pressure valves.

4. The high and low side gauges should read approximately 90 - 120 psi (depending on the vehicle and temperature). Before proceeding, make

sure the high and low side pressures are equal. if the gauges are not equal, wait until the system pressures equalize.

5. Select: "Control Unit Functions"

Select: "A/C Control System"

Select: "Pressure sensor" and "Display"

6. The pressure sensor value will be displayed under "Messages and Results". Compare the DIS/MODIC pressure sensor value to the high side

manifold gauge.

7. if the high side manifold gauge is in "psi" only, then the DIS/MODIC reading must be multiplied by 14.5.

(pressure sensor value) bar X 14.5 = (pressure sensor value) psi

8. The values should be within 锟斤拷 10% (due to gauge calibration).

9. If the pressure sensor value is "negative" or not within 锟斤拷 10% of the manifold gauge value then the sensor must be replaced.

Note:

The A/C system must be evacuated before replacing the sensor.

Parts Information:

Refer to the EPC.

Warranty Information:

Diagnostic hint for information only.

2000 BMW 328i (E46) Technical Service Bulletin # 410299 Date: 990901

2000 BMW 328i (E46) Technical Service Bulletin # 410299 Date: 990901

363

Rear Control Arm - Bolt Holes Stripped

GROUP 41

Body

Bulletin Number

41 02 99

Woodcliff Lake, NJ

September 1999

Product Engineering

SUBJECT:

Threads Strip When Adjusting Toe on Rear Axle

MODEL:

E46

Situation:

When performing a wheel alignment on an early production (prior to 7/98) E46, it is possible to strip the threads for the toe adjustment, if the bolts

are tightened with an impact wrench or are over torqued. The mounts in the body of later production cars were strengthened to be able to take an

overtightening without failure.

Correction:

If the threads are stripped in an early production car there is insufficient wall thickness to permit a repair with a helicoil type insert. The mounts in

the body must be replaced with late style (7/98 and later production) mounts which have more material.

Procedure:

Remove complete rear axle assembly per Repair Instructions 33 31 000. Remove fuel tank per Repair Instructions 16 11 030.

Scribe a line around both control arm mounts on the body to assist in properly locating the new mounts.

Use a spot weld drill to remove all accessible spot welds, taking care not to drill through the body. Two or three welds that are inaccessible can be

ground out with a die grinder.

Remove both mounts and clean up area for welding.

Drill out the ten pre-marked welding points on the new mounts to 8 mm, and drill two additional holes as indicated (1).

Plug weld the mounts in position taking care that the welds are continuous and without voids that can cause corrosion.

364

Apply four bead welds (2) as per illustration.

Prime, paint and apply corrosion protection to the area. Inject cavity sealer through the bolt holes and through the access hole in the wheel well.

Parts Information:

This repair requires two mounts, part numbers 41 11 7 012 047/048.

Warranty Information:

Covered under the terms of the BMW new car limited warranty.

2000 BMW 328i (E46) Technical Service Bulletin # 180199 Date: 990901

2000 BMW 328i (E46) Technical Service Bulletin # 180199 Date: 990901

Catalytic Converter - Unnecessary Replacements

GROUP 18

Exhaust Systems

Bulletin Number

18 01 99

Woodcliff Lake, NJ

September 1999

Product Engineering

202

This Service Information bulletin supersedes S.I. 18 01 99 dated August 1999 which should be removed and discarded from your S.I. binder.

SUBJECT:

Unnecessary Catalytic Converter Replacements

MODEL:

E36 with M44 engine from 1/96 prod.

Z3 with M44 engine from 10/96 prod.

E36 with M52, 852 engines from 10/95 prod.

E46 with M52 engine from 6/98 prod.

E39 with M52 engine from 3/96 prod.

Z3 with M52, 852 engines from 1/96 prod.

E38, E39, E31 with M62 engine from 1/96 prod.

E38, E31 with M73 engine from 1/95 prod.

Situation:

Analysis of returned catalytic converters has proven that some converters are not defective and are replaced unnecessarily.

The reason for unnecessary converter replacements may be due to the misfire fault code(s) in conjunction with the statement "catalyst damaging"

being stored in the Engine Control Module (ECM/DME).

Example:

Fault Codes 63 - 70: "Cylinder misfire detected - catalyst damaging"

If a vehicle is found with the "Check Engine" lamp on and one or more misfire faults are stored in the engine control module, the fault code

description "cylinder X misfire detected - catalyst damaging" will be displayed on the diagnosis fault survey of the DIS or MoDIC.

The qualifier "catalyst damaging" is a reminder that this type of fault (cylinder misfire) may over time cause damage to the catalytic converter if it is

not repaired.

Troubleshooting cylinder faults should be carried out using the DIS or MoDIC i.e. check secondary ignition system, etc.

A catalytic converter should not be replaced automatically when a - catalyst damaging" fault code is stored in the Engine Control Module.

A catalytic converter replacement is only necessary if fault codes 40, 45 or 233 (E9 hex), 234 (EA hex) are stored in the Engine Control Module

which are catalytic converter efficiency or conversion faults and/or if a customer complaint of an audible rattle noise coming from the converter is

verified.

Warranty Information: Information only.