Procedure C
Applies to Chassis Number Ranges "TC30126 - TC30569", "TD50082 - TD50200" and "TE10037" only1. Installing the new BC1 and hard cover
^ Before removing the BC1, using DISPlus/GT1 in "Coding", select "Vehicle Memory", then select "Print List" to record the customer's current Vehicle Memory settings
^ [NEW] "Select "Vehicle Memory", then select "Print List" to record the customer's current Vehicle Memory settings
^ [NEW] "Select "ZCS/FA Coding"/"R50/R53 Series"/"Recoding"/"ZKE"/"Replace Control Unit"/"Read data out of faulty unit"
[NEW] Note:
In order to avoid unnecessary delays in the return of the car to the customer, it is MOST IMPORTANT that this step to "Read data out of faulty unit" is carried out.
If it is omitted, then when the replacement part is installed, the key barcode data will have to be entered manually. If the barcodes tags cannot be located, then the barcodes must be requested overnight from the Technical Hotline with the resulting delay in the return of the vehicle to the customer.
^ Disconnect the battery and remove the BC1 in accordance with TIS repair instruction 61 35 510.
^ Inspect the harness connector for any deposits which may have resulted from the presence of water and clean as necessary using compressed air (please observe necessary safety precautions).
^ Connect all 4 connectors and install the new BC1 in accordance with TIS repair instruction 61 35 510.
^ Install the BC1 cover
^ Do not reconnect the battery at this stage.
2. Cleaning and applying grease to the door connectors and sealing the connectors to the "A" pillars
This modification prevents water entering the door connector and running down the harness into the BC1.
^ Remove the single screw securing the door harness connector to the right hand "A" pillar.
^ Pull the connector partly out of the "A" pillar, slide the locking device rearwards and disconnect the door harness.
^ Inspect the "A" pillar surface finish in the area where it abuts the door harness seal (1). The surface must be flat and free from paint runs, wax runs or any other irregularity. Flatten and/or clean the area accordingly.
^ Pull the connector carefully out of the "A" pillar as far as possible. Release the catches and remove the blue locking slide from the connector.
NOTE:
On some vehicles, the rear section of the connector and harness may be wrapped with sealing material and protective tape. In this event do not attempt to remove the locking slide and skip the next two steps.
^ Inspect the connector pins for any deposits which may have resulted from the presence of water and clean as necessary using compressed air (please observe necessary safety precautions).
^ Apply connector grease (see Parts Information) liberally around and amongst the wires at the back of the connector (1). Also apply grease to the terminals, which are exposed by removal of the locking slide (2), on both sides of the connector. Reinstall the blue locking slide.
^ Apply connector grease liberally to all the connector pins inside the "mouth" of the connector.
^ Reconnect the door harness to the "A" pillar connector and, before sliding the assembly into the "A" pillar, apply grease liberally to the lip of the door harness connector seal (for clarity, the door harness connector is shown disconnected).
^ Apply grease to the retaining screw aperture (1) (shown disconnected for clarity).
^ Slide the connector into the "A" pillar and install the retaining screw.
^ Wipe away any excess grease from the "A" pillar and around the connector seal.
^ Repeat the operation on the left hand "A" pillar connector.
^ Reconnect the battery.
^ Using DISPlus/GT1, code the BC1 (ZKE), then set any Vehicle Memory features that are not at Factory Setting (refer to the "Print List" in step # 2 or additional customer selection).
^ [NEW] Select "ZCS/FA Coding"/"R50/R53 Series"/" Recoding"/"ZKE"/"Replace Control Unit"/"Transfer data to new Control Unit and code the Control Unit"
^ [NEW] Set any Vehicle Memory features that are not at Factory Setting (refer to the "Print List" in step # 2 or additional customer selection).
^ Reset the clock (if necessary) and reinitialize the windows (refer to TIS Repair Instruction 61 35)
3. Electrical functional check
Start the check by sitting in the vehicle with the doors closed and unlocked. Switch on the ignition. Activate and check for correct operation of the following:
^ Lighting system
Side lamps.
Dipped headlamps.
Headlamp flash.
Indicators left and right.
Fog lamps.
Brake lamps.
Interior light (open and close door) and map lights.
Headlamp leveling.
Switch OFF all lights.
^ Wiper system
Front flick wipe.
Rear wiper.
Rear washer.
^ Center switch pack
Lock master switch (lock and unlock).
Door windows - one touch down (left and right).
Door windows - hold switch up to fully close (left and right).
Door windows - drop slightly when doors opened (left and right).
^ Air conditioning and heated rear window (with engine running)
All functions of air conditioning and switch LEDs. Heated rear window (check switch LED only).
^ Locking
Close the doors, hood and tailgate, fully open the RH door window, open the sunroof (if installed), turn off the ignition and lock the vehicle with the key.
With the vehicle unlocked, open the tailgate and check the trunk lamp.
Lock the vehicle with the key and hold the key in the locked position to close the RH window and sunroof (if installed).