Recall - Renotification Heater Core Cracking: Overview
Bulletin170293
Group
Coolant System
March 2000
SUBJECT
Coolant System Recall Campaign - No. 93V-015
MODEL
E30 with M20 Engine (325, 325e, 325es, 325i, 325is, 325ix, 325iC)
This Service Information bulletin supersedes S.1. 17 02 93 (3773) dated May 1993. Customer notification letters were originally sent during the period of June 1993 - April 1994 to the registered owners (as ascertained from States Motor Vehicle Registration data) of affected vehicles. The current owners of "not yet repaired" vehicles will be mailed notification letters during the period of March 2000 - April 2000. A copy of the customer letter is attached, for your information.
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 voluntarily initiated a safety-related defect recall campaign that involves the coolant system of the affected vehicles. This bulletin outlines specific procedures for implementing the modification portion of the campaign.
The malfunction or failure of a coolant system component, such as a thermostat, water pump, or fan belt, can result in significantly increased coolant temperature and system pressure.
If the indications (e.g. movement of the coolant temperature gauge needle into the red zone) of such a critical overheating condition are not heeded by the driver, and if, in addition, the vehicle is operated under high-load conditions such that the elevated pressure cannot be adequately relieved, it is possible that damage to, or failure of, a coolant system component could occur.
If a crack were to form in the end piece of the heater core, coolant could be expelled, perhaps suddenly. In some cases, the coolant could contact the lower right leg of the driver, possibly resulting in injury. It is also possible that, in some cases, coolant expelled from the heater core as vapor could cause fogging of the interior surfaces of the windows, reducing the drivers field of view.
AFFECTED VEHICLES
This Recall Campaign involves E30 (325, 325e, 325es, 325i, 325is, 325ix, 325iC) vehicles with M20 engines which were produced from 9/83 - 12/92.
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
The Chassis Number Ranges listed are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
As this modification will not prevent engine overheating, any problems (e.g. mechanical defects, improper coolant level/antifreeze protection, etc.) with the coolant system should be corrected before performing the recall modification.
Such repairs are not reimbursable under this recall campaign. The customer must be made aware of the required repairs, and their liability for payment, before such repairs are made.
Replace the radiator cap with a new version to control system pressure and provide greater coolant overflow in the event of overheating. Install thermostatic bypass valve and associated hardware to control coolant temperature in the heater core.
PROCEDURE
Remove the radiator cap. Remove the drain plug located in the bottom left corner of the radiator, and drain the coolant into a large clean catch pan. A funnel may be helpful in directing the flow of coolant.
Save the coolant, since it will be poured back into the system later.
It may be helpful to loosen the wiring that runs along the top of the firewall to gain better access for the modification. Reinstall the radiator drain plug, and move the catch pan directly under where the heater hoses pass through the firewall. Loosen the hose clamp on the supply hose (# 1 in the illustration) at the firewall. A 6 mm swivel socket/6 mm socket with a universal joint together with a long extension work well on the these clamps. A long screwdriver may also be used. Slide the clamp away from the firewall and pull off the hose carefully. Coolant will spill from the hose as it is removed. Bend the hose down to drain as much coolant as possible into the catch pan. Loosen the hose clamp behind the cylinder head, and remove the supply hose completely from the vehicle.
1. Supply Hose for Heater
2. Return Hose for Heater
Note: The original return hose must be left in the vehicle when performing this procedure. Do not loosen the hose clamps at either end of the hose. Tests have shown that reinstalled hoses may develop a leak at their ends due to settlement of the hose material during the first installation, and likely over4orquing during reinstallation. If during this modification the coolant return hose is found to be damaged (ripped/torn), so that it is no longer watertight, the hose must be replaced. Remove the damaged hose carefully - do NOT cut the hose to remove. Note that all replaced hoses must be returned for evaluation by the Warranty Parts Center.
Make a single cut in the return hose, still installed on the vehicle. Refer to illustration. Cut carefully, since assembly will be easier if the cut is clean and square.
1. Make single cut along dotted line. The drawing shows the hose with the heater core side on the right
The required parts to assemble the bypass are shown. Assemble the bypass valve (item # 3) into the new supply hose halves. The illustration # S 17 93 U 21 shows the proper orientation of the components when installed in the vehicle. Note that an arrow on the body of the bypass valve shows the direction of coolant flow, from the cylinder head to the heater core. Do not install the valve backwards. The proper orientation of the new supply hose pieces can be achieved by aligning the arrow on the valve body with the arrow markings on the hose pieces. Secure the supply hose to the bypass valve with two of the larger hose clamps (item # 2). Attach the curved end of the bypass hose (item # 4) to the small nipple on the bypass valve and secure with a small hose clamp (item # 1). Large hose clamps are to be torqued to 2.5 Nm, small hose clamps to 1.5 Nm, using a torque wrench.
1. Clamp - bypass hose (10-16 mm)
2. Clamp - supply/return hose (23-29 mm)
3. Bypass valve
4. Bypass hose
5. "T" piece
Trim the bypass hose to the proper length as shown in the illustration:
Bypass hose length: Trim off 60 mm
Reinstall the supply hose (with the completed bypass valve assembly) into the vehicle, referring to the illustration for hints on orientaion. Secure using new hose clamps on both ends. Install the "T" piece into the cut return hose, using new hose clamps to secure. Connect the free end of the bypass hose to the small fitting on the "T", and secure with a new small hose clamp. Verify that all hose clamps are tight, and that none of the hose or valve components rub on the engine, intake manifold, etc.
FINAL ASSEMBLY: Note orientation of components. Hoses should not rub against engine block, intake manifold, etc.
Pour the coolant from the catch pan back into the system. Strain coolant through a screen funnel to filter out any dirt or grit. Install the correct, redesigned radiator cap, depending on production date of vehicle (see Parts Information). Add enough new, properly mixed coolant to compensate for any spillage during the modification (typically less than 32 oz. of 50/50 mix antifreeze/water). Bleed the coolant system according to the E30 repair manual (operation 17 00 039), and leak check per E30 repair manual (operation 17 O0 009). Verify that there are no leaks once the car is warmed up, and that the heater works. Reattach the wiring to the firewall (if removed).
PARTS INFORMATION
LABEL INSTRUCTIONS
This Recall Campaign has been assigned code number 92 After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-008) and:
a. emboss your BMW dealer warranty number in the middle of the label (1);
b. punch out code number 92 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 will be provided through DCS Campaign Entry.
Special Defect Code: 00 17 01 03 00
Work Package # 1: Install components with new supply hose, bleed coolant system, pressure test (VEHICLES PRODUCED UNTIL 9/87)
Part Allowance:
Work Package # 2: Install components with new supply hose, bleed coolant system, pressure test (VEHICLES PRODUCED 9/87 and LATER)
Part Allowance:
The following work packages are only to be used if the return hose is found damaged during the modification procedure. Note that all replaced hoses are to be returned to the Warranty Parts Center for evaluation.
Work Package # 3: Install components with new supply hose and NEW RETURN HOSE, bleed coolant system, pressure test (VEHICLES PRODUCED UNTIL 9/87)
Part Allowance:
Work Package # 4: Install components with new supply and NEW RETURN HOSE, bleed coolant system, pressure test (VEHICLES PRODUCED 9/87 AND LATER)
Part Allowance:
DISCLAIMER
**FIX IT RIGHT THE FIRST TIME, ON TIME, EVERY TIME**
For administrative convenience and to reduce costs, this bulletin may contain repair procedures for authorized BMW car centers and/or authorized BMW SAV centers. All references to SAVs and/or the X5 are ONLY intended for authorized BMW SAV centers. Furthermore, ONLY BMW SAV centers are authorized to perform repair and service work on SAVs.