100A Fuse In Rear Power Distribution Box Failed, Causing Electrical System Failure (61 13 12)

100A FUSE IN REAR POWER DISTRIBUTION BOX FAILED, CAUSING ELECTRICAL SYSTEM FAILURE

TECHNICAL SERVICE BULLETIN

SERVICE INFORMATION

This Service Information bulletin supersedes SI B61 13 12 dated April 2012. 

SUBJECT

100A Fuse in Rear Power Distribution Box Failed, Causing Electrical System Failure 

SITUATION

Various functions of the electrical system fail. In rare cases, the vehicle cranks but may not start.

CAUSE

The 100-amp fuse (F502) in the rear power distribution box (Z3), mounted on the battery, has failed.

CORRECTION

Locate and repair the wiring harness issue.

• Replace the rear power distribution box (Z3) if the 100-amp fuse (F502) has failed (the fuse is not replaceable separately).

PROCEDURE

1. Perform a vehicle test using the latest ISTA (Integrated Service Technical Application) diagnostic software.
   NOTE: When the ISTA system message displays:

   "Battery voltage only "XX.XX" V. Please connect charger."

   Please note the displayed battery voltage reading in the repair order comments section.

2. If diagnosis leads to a faulty fuse in the rear power distribution box located on the battery, replace the power distribution box. Refer to ISTA Repair Instructions "61 14 010 Removing and installing/renewing power distribution box (on battery)."
3. Inspect the following areas for possible damage that might have caused the fuse to fail.

   Damage found in the 2 areas listed below is not considered warranty. 

4. X2 B+ Jump-starting point:  Check the metal brace located near the jump point terminal for signs of arcing. This can happen when jump-starting or the charging aid contacts the metal brace along with the terminal.
5. B+ Battery cables that run under the vehicle:  Check the battery cables that run under the vehicle from the rear power distribution box up to the engine compartment for damage. This can be the result of underbody damage caused by an outside source. The diagram to the left shows the routing of the cable. If the cable is damaged, it needs to be replaced.

PARTS INFORMATION

Part Number	Description	Quantity
Refer to EPC	Power distribution box, rear	1
Refer to EPC	Repair wire for B+	1 (if needed)

WARRANTY INFORMATION

A. 100-Amp Fuse Replacement: Items #4 and #5 

Fuse replacement for these items are not covered under the terms of the BMW New Vehicle/SAV Limited Warranty or the BMW Certified Pre-Owned program.

B. The 100-Amp Fuse Replacement which is due to a Defect in Materials or Workmanship. 

Covered under the terms of the BMW New Vehicle/SAV Limited Warranty.

Covered under the terms of the BMW Certified Pre-Owned program when the "Causal Part" is not a CPO-excluded item.

Defect Code

Refer to KSD2

Enter the Defect Code for the Causal Part

Labor Operation:	Labor Allowance:	Description:
00 00 006	Refer to KSD2	Performing "vehicle test" (with vehicle diagnosis system - checking faults)
and if necessary, also
61 21 528	Refer to KSD2	Charging battery
and if necessary, also
61 00 006	WT	Performing vehicle diagnosis - test module (Work time)
and/or as necessary
61 00 009	WT	Troubleshooting electrical/electronic system
and
61 14 510	Refer to KSD2	Replacing power distribution box, rear
and if necessary, also
61 99 000	WT	Work time to replace repair wire for B+

Labor operation code 00 00 006 is a Main labor operation. If you are using a Main labor code for another repair, use the Plus code labor operation 00 00 556 instead.

Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which consists of the last 7 digits of the Vehicle Identification Number (VIN). Click on the "Search" button, and then enter the applicable flat rate labor operation in the FR code field.

Work time labor operation codes 61 00 006, 61 00 009 and 61 99 000 are not considered Main labor operation as used above.

The work time (WT) labor operations require individual punch times.