Table of Contents Service and Maintenance Subject Page Quality Certification I (QCI) .4 Display Vehicle Check- BMW Technician .4 Delivery Check-BMW Technician .5 Sample Quality Certification I.6 Transportation Mode.7 Deactivating Transport Mode.7 Vehicle and Key Memory.8 Vehicle Memory.8 Key Memory.8 Service.9 Required Preconditions.9 Vehicle Memory Configuration Procedure.9 Vehicle/Key Memory Service Considerations .9 FZV Key Initialization Procedure.9 Technician Awareness.9 Service Maintenance Programs.10 Scheduled Maintenance .10 Engine Oil Service .10 BMW Inspection I.11 BMW Inspection 2 .11 Condition Based Service.11 Sample 2005 BMW Service Maintenance Checklist .12 Service Interval Indicator System .14 SIAII.14 SIA II Components.14 Instrument Cluster with LED Display.15 DME.15 Vehicle Speed Input .15 Engine Temperature Sensor.15 Principle of Operation .15 Service .16 Reset Procedure using Special Tool .16 Instrument Cluster Replacement .17 Diagnosis.17 SIA III .18 SIA III Components:.18 Instrument Cluster (IKE, KOMBI) with LED Display.18 DME.18 Principle of Operation .18 Initial Print Date: 02/06 Revision Date: Subject Page Service .19 Reset of the SIA III: .19 Instrument Cluster Replacement .20 Diagnosis .21 Read SIA Data .22 SIA IV.23 SIA IV Components:.23 Instrument Cluster (IKE, KOMBI) with LED Display.23 DME.23 ASC/DSC Control Module.23 Principle of Operation .24 Service .24 Reset Procedure using the Reset Mode.25 Reset Procedure using Diagnosis Program .26 Instrument Cluster Replacement .26 Diagnosis.26 Connected Service.27 Condition Based Service (CBS).28 Coded Keys.28 Key Reader .28 Service Acceptance Module Software (SAM) .28 TeleService .28 Transfer and Analysis of Vehicle Operation and Service Data (FASTA).29 Condition Based Service (CBS).30 Principle of Operation .30 Sensor Based (CBS) Schedules.30 Engine Oil Condition.31 Microfilter State of Wear.31 Front and Rear Brake Linings State of Wear .32 Internal Calculation of CBS Service Items .33 Service Indications.34 Service Need Display (SBA) .34 Check Control Message .34 CBS Indicator in the Control Display.35 CBS Reset.36 DISPIus/GTI.36 Instrument Cluster.37 CBS Data Correction.39 CBS Handover Inspection .42 Key Reader.43 Key - Vehicle Data Holder and Business Card .43 Service Acceptance Module Software (SAM).44 BMW Group Technical Hotline .45 Service and Maintenance Model: All Production: All After completion of this module you will be able to: • Know the requirements of the Quality Certification. • Perform Oil Service and Inspection I and II as specified. • Understand the Battery Maintenance Requirements. • Locate BMW Service Bulletins 3 Service and Maintenance Quality Certification I (QCI) Every new vehicle which arrives at the BMW center requires that a Quality Certification (QCI) be performed. The QC I is performed in two parts. • Display Vehicle Check • Delivery Check When performing a QCI, a checklist has to be competed. Refer to Centernet for latest forms (based on Model and Model Year). The requirements for a vehicle’s Quality Certification vary slightly by model. The check¬ list must be adhered to strictly. Every item checked off signifies that it has been verified and in proper working condition. If an item is found defective an extra line has to be added on the repair order. The QCI checklist has two sections that should be checked off by a technician. Page Size Page Color Operation Half blue Display Vehicle Check performed by Technician. Perform when vehicle is being used for showroom display or demonstrator. Full White Display Vehicle Check performed by technician. Delivery Check performed by Technician. Delivery Check performed by BMW Client Advisor. Perform when vehicle is being prepared for customer sale. Display Vehicle Check- BMW Technician The Display Vehicle Check is performed if the vehicle is to be stored on the centers lot or in the showroom. The vehicle is inspected for shipping damage and any defects that may not have been caught at the VPC (Vehicle Preparation Center). • Complete the upper portion of the checklist and the box labeled 00 00 008 Display Vehicle Check-Technician. • Remove the top copy of the checklist and attach it to the repair order. The remaining portion of the checklist should be left in the vehicle or put into the vehicle sales file. Note: The automobile inventory should be verified frequently, so there are no open recalls/campaigns. Recalls/campaigns should be performed prior to the TECHNICIAN DELIVERY CHECKLIST to avoid any delays during delivery, including spot deliveries. 4 Service and Maintenance Delivery Check- BMW Technician The Delivery Check is performed no more than 24 hours prior to the customer taking delivery of the vehicle. The purpose of the Delivery check is to ensure that no damage or system problems have appeared since the vehicle was first checked at arrival to the center. The BMW center must deliver a vehicle to the customer free of any defects at time of delivery, this is difficult to ensure if the vehicle has not been inspected for several days or weeks. Vehicles that are sold before arrival to the center or to be put into service as Loaner Cars may have both parts of the QC I performed together, this is referred to as a Spot Delivery. In this case the vehicle will not be sitting on the lot more than 24 hours before delivery. Always refer to the latest Service Information for special instructions and warranty information that is necessary to properly perform a QC I. Notes: 5 Service and Maintenance Sample Quality Certification I “ p “ w QUALITY CERTIFICATION I 2006 325i/330i (E90), 525i/530i, 7 Series DOT TIRE DATA 1) 2) 3) 4) Spare 00 00 008 DISPLAY VEHICLE CHECK - TECHNICIAN Check for Transportation Damage _ Remove 6 Series Convertible Top Shipping Cover Check Car Cleaned - Interior & Exterior _ Check Cleanliness of Engine Compartment Remove Transportation Battery Disconnect Switch Initialize Windows and Sunroof (incl. toll function & child safety button) Connect Approved BMW Charger if displayed in Showroom Remove Shipping Spacers if equipped 00 00 010 DELIVERY CHECK - TECHNICIAN (Prior to Customer Delivery) Note: Items in the DISPLAY VEHICLE CHECK should also be included. Customer Name: _ Stock No.:_ Chassis #:_ Model:_ . Year:_ BMW Center Name: _ BMW Center No.:_ DELIVERY CHECK-SALESPERSON |||| (Prior to and at Customer Delivery): [LTj M -i Car Cleaned - Interior & Exterior 1 Check Tire Pressure (incl. spare tire if equipped) Check Battery Voltage (12.65V minimum) Check for Appropriate Fuel Level Warning Lights & Check Control Install Navigation System Map DVD Sound System (incl. CD player & telephone) Record Vehicle/Key Memory Features as per Customer's Preferences using form ZUS3077 Seats/Headrest/Steering wheel (incl. memory function) Oil Level and other Fluid Service Locations, top up if needed Jack & Lug Wrench (secured) and Spare Tire in Trunk Tool Kit Complete* Check Operation of BMW Options and Accessories New Owner Auto Program Video Provide cellular telephone body kit to customer (7 Series) V Complete BMW Assist Agreement (before initialization by techni*jsai5w Program phone numbers for BMW center and BMW Customer Relations into BMW Assist menu. Wallet Key Adapter in Tool Kit (7 Series) CBS Hand-Over Inspection ROAD TEST: „ Transmission (incl. Auto P & display) Park Distance Control (PDC) Opej^t^n/^dSipped ROAD TEST (OPER AI1QM LA OH JSTMENT): - Check/Adjust Tire pressure (incl. spare tire if equipped) Check for Appropriate Fuel Level Program Vehicle/Key memory as per customer’s preferences using form ZUS3077 Enter BMW Assist Phone Numbers per completed Aqreement Check for and correct Check Control Messages BMW Assist: perform test call Warning Liqhts Engine Operation Transmission (incl. auto P & L on 7 Series) Function Selector (incl. instrument panel display) Park Distance Control (PDC) Operation, if equipped ^ ^ Steering (wheel in center position) Foot/Parking Brakes (before and during roadtestjV \ Initialize the Flat Tire Monitor System if equipped wiV Run-Flat Tires Check Handlinq and Wheel Balance l * Absence of Rattles, Squeaks and Wincfccois^^ Cruise Control Operation v Telephone (7 Series) » \ Speaker and Fader Operation (incSbass, treble & balance) On-Board Computer and ton^^isplay (incl. service indicatorandifelk control) Check Operation ofCMW Options and Accessories Windshield WiM/W^kSi^tems lnterior/ExterlC:Mlrrors (incl. dim & memory functions) Seats/Harfdrestgip^eering Wheel (incl. memory function) OWNER’S PORTFOLIO iftN^ENTS (stored in center console): Vehicle Owner's ManVfl S Combined Service/Wa^^ntWRoadside Assistance Booklet Telephone Owni^ Manual (7 Series) Radio code cards'^/ Dealer DireS^^Atlas Roadside As^tance Temporary ID Card Sale^flifcice and Parts Managers’ Business Cards BMW Accessories Booklet Accident Guidelines and Checklists Driver’s Reference Guide BMW Assist reference card Three Keys (incl. wallet key) Purchase Agreement Sales Document Key Memory Programming Checklist Note: Recommend to Customer to Review Vehicle Owner’s Manual, New 1 Owner Audio Program Video, Quick Reference Guide, and 7 Series Battery Switch n driver’s door pocket Review Service Schedule/Warranty/Roadside Assistance Introduce to Service Department AFTER ROAD TEST: Read Out Diagnostic System - Correct Faults as Necessary Program State and/or Emissions Inspection (if required) into service display Install Front License Plate Bracket if needed Stamp the Service Booklet in the QC1 space CHECK AND ADJUST: Doors, Trunklid and Hood CHECK: _ Battery Voltage (12.65V minimum) REMINDER: Please complete and mail the postage paid and pre-addressed VEHICLE CONDITION REPORT. COPY DISTRIBUTION: _ BLUE WHITE SALES SERVICE GREEN _ GOLD SALES CUSTOMER SD92-285 (03/05) Technician:_Date: (Display Vehicle Check) Technician:_Date:. (Delivery Check) Customer: Date:. The BMW Experience 6 Service and Maintenance Transportation Mode Transport Mode minimizes battery current draw while vehicles are in transit to BMW centers. Transport Mode replaces the more traditional battery switch. Transport Mode has been phased in on all BMW models starting from the E39 (5 Series). Transport Mode immobilizes vehicle convenience features. Actual features immobilized vary between vehicle models, but typically include radio operation, interior lights, etc. Transport Mode must be deactivated at QC1. Note: Once deactivated, Transport Mode cannot be reactivated Deactivating Transport Mode To deactivate Transport Mode, connect the vehicle to the DISPIus or GT1. Connect an approved BMW battery charger. For E65 only, select "Diagnosis", then select "Function Selection / Service Functions / Maintenance / Transport Mode / Delete Transport Mode / Test Plan". Then follow the on¬ screen instructions to deactivate Transport Mode. For all other BMW models , select "Diagnosis", then select "Function Selection / Service Functions / Body / Transport Mode / Delete Transport Mode / Test Plan". Then follow the on-screen instructions to deactivate Transport Mode. 7 Service and Maintenance Vehicle and Key Memory This feature provides the flexibility of allowing the owner to customize certain functions of select vehicle systems and automatically identifies users of the vehicle by a key identi¬ fication signal provided by the remote keyless entry system (FZV). VKM coding is done at the time of delivery during the QC I. Vehicle & Key memory is marketed as a combined feature but is actually two separate functions of the select vehicle control systems. Vehicle Memory The owner is provided with a list of available system functions that can be customized to their liking. Prior to delivery, CIP is used to encode the owner’s chosen selections into the appropriate control modules. Key Memory This feature provides the added convenience of identifying users of the vehicle whenev¬ er a lock or unlocked signal is generated via the individual FZV keys. A maximum of four FZV keys can be used with the Key Memory feature. Each of the four keys generate a unigue key identification signal (key number) that is transmitted simultaneously with the lock/unlock signals to the General Module. Key Memory does not respond to Lock/Unlock reguests from the mechanical drivers door lock. Most of the key memory functions reguire the vehicle be configured using the “KEY MEMORY” function of the DISplus or GT1. However, there are a few features that store settings automatically without configuration such as IHKA blower speed and temp set¬ ting. There are features that function as both a Vehicle & Key Memory feature. Example: The Automatic Seat Adjustment feature is encoded as a Vehicle Memory Function with the following possibilities: • when unlocking, • when opening a door after unlocking • or not active at all. If active, the seat positions are stored and reactivated by the Key Memory function for individual users of the car. 8 Service and Maintenance Service Required Preconditions Before configuring Vehicle or Key Memory Functions, connect a battery charger to the vehicle. This will ensure adeguate battery voltage during the VKM configuration. If battery voltage drops below 11.8 volts, the procedure will terminate. Vehicle Memory Configuration Procedure Please refer to Progman section located under the Workshop Applications tab of this book. Vehicle/Key Memory Service Considerations If a Vehicle/Key Memory capable control module becomes defective and needs replace¬ ment, the specific customized data will be transferred over to the new replacement unit during the encoding process. If this is not possible due to extensive control module failure, the owner must be made aware of the situation and requested to provide the options they originally selected. For this reason, it is advantageous to print the selected features as mentioned in the Vehicle & Key Memory configuration procedures. FZV Key Initialization Procedure Also mentioned in the BMW Features section of this manual, If FZV keys need re-initializ¬ ing, make sure they are initialized in the same order. Technician Awareness Vehicle Memory/Key Memory Configuration changes the functionality of the systems. It is recommended that the Vehicle/Key memory selections be reviewed for the vehicle you are working on. There may be an owner selected function activated that is not a common selection, causing misunderstanding of the system's function. 9 Service and Maintenance Service Maintenance Programs There are two different types of service maintenance requirement used in BMW vehicles depending on the model and production date. The two maintenance programs are: • Scheduled Maintenance • Condition Based Service Early BMW vehicles are dependent on a scheduled service maintenance program. This means that when a certain criteria is met, usually an oil change, the vehicle will have to undergo either an extensive oil service or a major inspection. Starting with the E65 (7 Series) the BMW service program utilized is condition based. Condition Based Service (CBS) allows for the servicing of specific vehicle components only when it needs the actual service. Scheduled Maintenance A Service Maintenance Checklist has been developed for early BMW passenger cars that require scheduled maintenances. The checklist incorporates space to record values called for in specific checking operations. These include disc brake pad thickness, tire pressures, and the freeze point tempera¬ tures of the engine coolant and of the windshield washer fluid. Because the vehicle will be visiting the workshop less frequently it is very important that the maintenance and anytime dependent services be carried out thoroughly and cor¬ rectly. Follow the Service Maintenance Checklist for the necessary steps required to properly complete the service. Engine Oil Service Starting with the introduction of the 1999 3 Series (E46), BMW introduced an extended oil change interval of approximately 15,000 miles depending on engine operating condi¬ tions. The engine oil change interval of approximately 15,000 miles was carried over to all 2001 BMW models. (Before this the interval was approximately 7,500 calculated miles). However, engine oil should be changed at least once a year. This revision (annual oil change) is retroactive to earlier model years and is included in the BMW Maintenance Plan. To coincide with the increased oil change interval, BMW also introduced "BMW High Performance Synthetic Oil" SAE 5W-30. BMW recommends the use of BMW High Performance Synthetic Oil SAE 5W-30 or Castrol RS SAE 10W-60 Synthetic. 10 Service and Maintenance BMW Inspection I The next scheduled maintenance procedure performed after an oil service is an Inspection I. The advanced technologies used in engine management systems and improvements in low maintenance engine design have reduced the required maintenance in each inspection service significantly. BMW Inspection 2 The BMW Inspection 2 includes all of the procedures outlined in the Inspection I, but includes additional steps that are only necessary with higher accumulated miles. Condition Based Service Starting with the introduction of the E65, the CBS program does away with the sched¬ uled maintenance program that requires the replacement of components that might not need immediate replacement. Condition Based Service monitors wear and tear on important parts. Its sensors can determine when a component needs to be replaced or upgraded. Even if the degree of wear cannot be gauged directly, such as in the case of the air conditioning microfilter, the system uses algorithms to determine when a service check-up should be performed. 'Made-to-Measure Maintenance' Several parameters provide the information for this system - mileage, temperature, driving style and more. Overall, Condition Based Service maximizes safety and keeps the vehicle on the road longer, as the car is serviced only when it is necessary. You get the most out of your automobile, and are always well informed. Notes: • For the most recent list of approved motor oils and their engine application refer to bulletin SI B11 08 98. • Intervals for services may vary slightly especially if it is a Motorsport model. • Always complete the appropriate maintenance checklist when performing a scheduled maintenance. 11 Service and Maintenance Sample 2005 BMW Service Maintenance Checklist BMW of North America, LLC 2005 3 Series, Z4 (X3 and X5- use 2004 checklist SD92-260) Service Maintenance Checklist Customer’s Name Chassis Number Indicate # Lights illuminated in Service Interval Indicator |g |g |g |g |G |Y 1?J Only operations that pertain to this vehicle will be performed. BMW center Mileage (on Service Interval Ind.) NOTE: Any other requested repairs not listed or covered by the applicable BMW Limited Warranty will be charged to the owner and invoiced separately. Repair Order No. Mileage (on odometer) State and federal statutes require a properly completed copy of this form to be retained in the BMW center’s customer file. / /hj /Us' //Vi /.V S’ /'v
Service menu” for others models
The CBS menu appears with the service items.
The Control Display shows a list of selected service and maintenance procedures, as well
as legally-mandated official inspections.
The service and maintenance procedures are displayed in different colors:
• Green: No service is currently reguired
• Yellow: Service deadline is approaching
• Red: Service deadline has already passed
The service items highlighted in red with the highest priority appear in the bottom part
of the display.
You can scroll through the list of service and maintenance procedures from top to bottom
by turning the Controller from right to left. You can leave the list of service items by press¬
ing the button with the Up arrow symbol.
The service and maintenance items are:
Engine oil
• Front brake pads
• Rear brake pads
Microfilter
• Brake fluid
• Coolant
Spark plugs
• Vehicle check
• State Inspection
Emissions Inspection
To display the service and maintenance item information in the Control Display, turn the
Controller to select the item and confirm your selection by pressing the Controller.
35
Service and Maintenance
CBS Reset
The CBS Reset procedure provides resetting of the individual Condition Based Service
items. The items that require a reset depend on the individual vehicle usage. When one
or more service and maintenance items has been performed, these items must be reset
The reset procedure can be carried out via the instrument cluster or the DISplus/GT 1.
DISPIus/GTI
Using the DISplus/GT 1, the CBS Reset sets the service and maintenance items to 100%
(full service interval) and displays a service counter to indicate how many times these
items have been reset.
The procedure is found under:
Service Functions => Maintenance =>
CBS reset.
Select the CBS Reset => Test Plan =>
CBS reset => Right arrow
Select the specific item that needs to be reset.
The selection list is divided in two parts:
Group 1: Engine oil
Spark plugs
Front/Rear brakes
Group 2: Brake fluid
Microfilter
Vehicle - exhaust emission
Vehicle check
I_1
SCBS_6003 / CBS selection
Selection, scope of CBS reset
m
- Fngino oil - Spark plugs
- Front brake - Rear brake
PI
- Brake fliNd - Microtiller
- Vehicle - exhaust emission
- Vehicle check
With the Group 1 option chosen, the items are dis¬
played for further selection.
The selections are displayed with the remaining period
left until the rest should be performed.
In this example, the engine oil has only achieved 16%
of its scheduled usage; 84%of its “life” remaining.
1 \
Scops ol CBS reset, selection 1
(availability) [%] / (service counter)
(1) Engine od (84) [%]/(2 )
[2] Spark plugs (99 ) [%) / (1 )
p] Front brake (99)[%J/(1 )
[4] Rear brake (99) [%] .'(1)
[5] ~(0)[*)/(0)
[6] Back to selection CBS items
ILOLJlL
d-d 1 ICZ
36
Service and Maintenance
SCBS_6003 / Reset erigine oil
After the specific maintenance item to be reset is
selected from the options, a warning will be displayed
and prompt you if the reset is really the intended action
to be performed.
Select: “Yes” to reset
“No” to cancel and back out
I 'I
2
ATTENTION
Availability > 80 \
Do you really wish to perform reset?
.J.
1
1
1
Instrument Cluster
Resetting the maintenance item using the instrument cluster is different depending on
the model of the vehicle.
E65
To reset a service item using the instrument cluster, press the reset button on the top left
side of the instrument cluster for greater that 10 seconds.
A 4-line menu appears in the speedometer. At the top is the Back function, then the first
three service and maintenance items sorted by priority. In addition, the residual wear or
the remaining time are specified (possibly with a minus sign).
The "!" symbol means that you can reset this service and maintenance item, while a "0"
indicates it is not able to be reset (the first 20% of the service interval is protected against
premature/accidental reset).
1. Service items (in the speedometer)
2. Resetable service item (in the tachometer)
a. Back
b. Vehicle Check
c. Microfilter
d. Brake fluid
e. Back
f. RESET Vehicle Check
You can scroll through the service and maintenance items by pressing the reset button or
the lower axial (FAS) button on the turn signal/high beam switch. When you have selected
a service item, press the reset button for a few seconds to display a 2-line menu in the
tachometer.
The Back function is at the top and the Resetable service and maintenance item is below
it. Now select the service and maintenance item with the reset button (or the axial button)
and press the reset button again for a few seconds.
In a third menu line, the system confirms that the reset was successful. The whole inter¬
val for the service operation is highlighted in the Service Need Display.
37
Service and Maintenance
E60/61/63/64
When one or more operations have been carried out, e.g. front pads have been changed,
these operations must be reset to their full service interval.
There are two options for resetting the service operations:
• Legally required service operations Legally required service operations such as the
Statutory vehicle inspection (HU) and the Statutory exhaust test (AU), can only be
reset in the "Service" menu.
• Maintenance service operations All service operations for the purpose of mainte¬
nance are reset by means of the reset button of the trip distance counter in the
instrument cluster. If the reset button is pressed for longer than ten seconds, the
reset mode opens automatically. "Reset?" is displayed in the lower display window.
In the upper display window, the CBS symbol, e.g. for "engine oil service overdue" will
displayed. Press the reset button until the time/distance-dependent displays in the lower
display window are replaced with dashes. Reset is no longer possible once more than
percent of the interval has expired. A reset lock will be shown in the display with "OK".
1. Reset button for trip counter
2. Upper Display Window
- CBS Symbol
3. Lower Display Window
- Gear Indicator
- Reset Mode
E90/91
To reset the service information data using the cluster:
• KL-15 on and all Variable displays in cluster off (clock should be displayed)
• Press and hold odometer reset button until CBS pictures display in cluster for about
5 seconds then release
• Use the BC button to scroll through till desired resetable picture is displayed.
• “Reset?” is displayed, Press and hold BC button a picture of a small analog clock
runs through its display. When complete, the CBS reset that you chose is reset.
• If you want to insure that the reset was done, you can press the BC button while still
looking at the CBS reset pictogram and the acknowledgment of reset will be shown
with a check mark in a box.
38
Service and Maintenance
CBS Data Correction
The CBS correction vehicle data allows “quick access” to create or change the CBS
data stored in the vehicle. Sometimes the vehicle’s maintenance data will not be plausible
(usually due to coding/programming issues). The correction includes decreasing the use
percentage and number of resets when a reset was mistakenly performed. When the
CBS reset is carried out, the changed data in the tester is automatically transferred to
the vehicle.
Example: A vehicle with only 3,000 miles on the odometer enters the service drive
with the oil service light illuminated. The vehicle obviously does not need
an oil service until roughly 15,000 miles.
The oil service should not be performed and the service maintenance light
should not be reset either. This would make the vehicle undergo a
roughly 18,000 mile service interval. Instead, the CBS data has to be
manipulated or corrected to compensate for the miles already driven.
The procedure for CBS correction is found via:
Service Functions => Maintenance =>
CBS correction, Vehicle data.
The first step is vital to synchronize the correct time and
date from the DISplus/GT 1 with the vehicle.
This is important for time/distance based service items
that are managed by the instrument cluster.
After accepting by pressing