Service Action - Clutch Switch for Starter Interlock
Group 61General Electrical Systems
Bulletin Number
61 04 99
Woodcliff Lake, NJ
June 1999
Product Engineering
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
SUBJECT:
Service Action - Clutch Switch for Starter Motor Interlock
MODEL:
Z3 roadster, Z3 coupe (E36/7). Vehicles with manual transmission.
Situation:
BMW of North America, Inc. has initiated a Service Action that involves the starter motor/clutch interlock switch.
On some vehicles, the wiring harness to the clutch switch may be routed in such a way as to be permanently under tension. This may cause internal damage to the clutch switch, which could result in a no crank/no start condition.
Affected vehicles must be reworked, or checked and reworked as necessary.
Affected Vehicles:
In order to determine if a specific vehicle is affected by this Service Action, 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.
Model Chassis Number Range
Z3 coupe LE95001 - LE95479
Z3 roadster 2.8 LF40006 - LF40714
Z3 roadster 2.3 LF79005 - LF81 991
Procedure:
Procedure A - Defect Code 00 61 36 01 00 (Vehicles produced 8/98 - 9/98)
Important: To avoid damaging the replacement clutch switch, follow the procedure in the order described.
A1. Disconnect the battery negative cable.
A2. Remove lower instrument panel trim. Refer to Repair Instructions 51 45 180.
A3. Remove nut (2) holding the power distribution box (1). Turn the power distribution box to the side, to give access to the mounting bracket.
A4. Remove and replace the mounting bracket (1) which is retained by two bolts (3). Remove the protective strip (2) from the old mounting bracket, and fit on the new bracket.
A5. Remove the clutch switch.
A6. Connect the adapter harness (1) to the vehicle harness (3). The harness must be routed behind the power distribution box mounting bracket. Connect the adapter harness to the new clutch switch (2), and install the clutch switch. Slide the red retaining ring in the direction of the arrow to lock the clutch switch into place.
A7. Reinstall the power distribution box.
A8. Reinstall the lower instrument panel trim.
A9. Reconnect the battery.
Procedure B - Defect Code 00 61 37 01 00 (Vehicles produced 9/98 - 12/98)
B1. Locate the wiring harness label located at the left hand side of the engine compartment immediately adjacent to the power distribution fuse box, and check the "Engineering Change Level" (ECL) (1) on the wiring harness label (see illustration).
If the ECL is letter T, U, V, etc., (alphabetically ascending), no further actions are necessary.
If the ECL is letter S, R, Q, etc., (alphabetically descending), continue with the procedure which follows.
Important: To avoid damaging the replacement clutch switch, follow the procedure in the order described.
B2. Disconnect the battery negative cable.
B3. Remove lower instrument panel trim. Refer to Repair Instructions 51 45 180.
B4. Remove the clutch switch.
B5. Connect the adapter harness (1) to the vehicle harness (3). The harness must be routed behind the power distribution box mounting bracket. Connect the adapter harness to the new clutch switch (2), and install the clutch switch. Slide the red retaining ring in the direction of the arrow to lock the clutch switch into place.
B6. Reinstall the lower instrument panel trim.
B7. Reconnect the battery.
Parts Information:
Part Number Description
61 31 8 363 710 Clutch switch
61 12 4 101 940 Adapter harness
61 13 8 367 764 Bracket(Procedure A only)
Label Instructions:
This Service Action has been assigned code number 247. After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-120) and:
a) emboss your BMW dealer warranty number in the middle of the label (1);
b) punch out code number 247 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:
Covered under the terms of the BMW New Car Limited Warranty. Reimbursement for this Service Action will be provided through campaign entry.
Procedure A
Defect Code: 00 61 36 01 00
Work Package 1
Labor Operation: 00 51 472 Replace clutch switch and bracket for power distribution box, and install adapter harness.
Labor Allowance: 7 FRU
Parts Allowance: 61 31 8 363 710 Clutch Switch (1)
61 12 4 101 940 Adapter Harness (1)
61 13 8 367 764 Bracket (1)
Procedure B
Defect Code: 00 61 37 01 00
Work Package 1
Labor Operation: 61 00 009 Check wiring harness label.
Labor Allowance: 3 FRU
Work Package 2
Labor Operation: 00 51 474 Check wiring harness label, and replace clutch switch and install adapter harness.
Labor Allowance: 5 FRU
Parts Allowance: 61 31 8 363 710 Clutch Switch (1)
61 12 4 101 940 Adapter Harness (1)