No Crank, No Start, New Starter & Ignition Switch

[nm8shun]

I've owned this 2003 for about two months. It's been an adventure (and I say that unironically). I've enjoyed working on it.

However, I've got a problem that keeps popping up that I thought I had fixed.

1) When purchased it intermittently would not start. No crank, no start, just nothing when the key was turned. Then later it'd start right up.
2) Following advice on threads here and elsewhere, I replaced the Ignition switch. This did not fix it.
3) I changed the starter motor. The motor I took out was clearly a reconditioned unit, so the new motor I put in was at least the third starter in this car. After putting in the new starter, everything ran great until...
4) Today, went to start it, and again - no crank, no start.
5) Ran errands in another car, came home, and it starts again.

I guess the starter or the switch could be faulty. But it seems like there's likely something else that is either burning starters out or otherwise causing problems.

My cheap OBDII scanner only reports a P1415 error (Mass or volume air flow too low) that I think it tied to a tear in the air intake boot (replacement on the way). But I don't think that's related.

Any ideas?

 

[nm8shun]

So I tested the relays inside the DME box (left back of the engine bay). All tested alright. So its not that.

Things I plan to try and track down:
a) Grounding. I'm not sure where all the grounding wires are...but that seems to be a real possibility. However, I've run a voltmeter between negative terminal (in the engine bay) and engine, and was getting 12v. So I don't think its a grounding issue.
b) Is there a starter relay somewhere? I can't seem to find this.
c) I can't (for the life of me) get ISTA running, but I've ordered the Launch X431 (https://www.amazon.com/gp/product/B09XTMPVHN/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1) so hopefully that will generate some real fault codes to try and track this down.

 

[raymond.harper]

I find YouTube quite a good source of information. The Z4 is a BMW that shares many components with the other models in the range so don't just look at Z4 videos. Found this one, scroll to 1 minute 34 seconds. https://www.youtube.com/watch?v=lwIiAW4EJ1Y

 

[Mike6]

Faulty battery, loose connections at battery or starter, poor earthing. Cannot think of much more

 

[nm8shun]

Thanks, Mike6 and raymond.harper.

@raymond.harper, thanks for that link. I've watched that one a bunch of times, then went out to my '03 and was unable to find the IVM module that is on the '06 shown on the video. I can't find an IVM or "integrated control module" on FCP either...do you know where this part is on the '03 Z4? I've searched extensively online and haven't had any luck.

 

[nm8shun]

OK. So further developments.

I've run jumper cables between the negative terminal (under the hood) and the engine (to check for ground), and still no go. I even ran double-jumper cables from battery's negative to engine block and no start. So I think I can cross out the grounding/earthing potential issue.

I have a circuit tester now. Under the hood, circuit is complete from positive to negative terminals, and from positive terminal to engine block. I have also reached it down to the positive cable on the starter and it lights up. So I think the power is reaching the starter. Therefore, I think loose battery connections at battery or starter are also not the cause.

I have not swapped batteries yet, but I'm getting a strong >12v off all terminals (in the trunk and under the hood), so I doubt its that. I've also connected a battery jumper and still no crank no start. So I'm thinking its unlikely to be the battery.

I did get a hold of a scanner specifically for BMWs so I've been able to get much more in depth scans. I don't know al lot about what I'm doing, but did find an error:

27A4 DME: Interface EWS 3.3-DME

Then, I went digging around further in the scanner to try and enable/disable the key. The test function yielded the following:
"The active key (currently inserted in ignition lock) transmits faulty data. In order to indicate the keys already used in this vehicle the active key (currently inserted in ignition lock) must NOT be disabled and must transmit valid data. Use DIFFERENT key."

So, I'm starting to suspect EWS issues. I only have the one key - which doesn't really look like it's BMW-original.

Looking at EWS systems on FCP Euro, these look like >$800 replacements. Any suggestions on what to try before having to try with the big ticket items?

 

[raymond.harper]

https://www.gelautomotive.co.uk/bmw-ews-repair-ews-fault/ https://www.rpmmotorsport.net/pages/ews-3-test-before-replacement

 

[nm8shun]

Thanks @raymond.harper. I've been looking at a few of those kinds of places on this side of the pond. All still expensive, but not $800 expensive.

I think at this point, I'm going to try the cheaper approach that it might be an issue with the key. Just to document my process (in case anyone else runs into this problem)...
1) I've ordered and to try and program a new key. https://www.amazon.com/dp/B08DRD9ZDK?psc=1&ref=ppx_yo2ov_dt_b_product_details
2) I've ordered a new key: https://www.amazon.com/dp/B07MDVWBKK?psc=1&ref=ppx_yo2ov_dt_b_product_details
3) I plan to try one of the following:
[youtube]https://www.youtube.com/watch?v=Ra6OSYmdzg4[/youtube]
[youtube]https://www.youtube.com/watch?v=AJ6enooPkYs&t=770s[/youtube]

If those don't work, I'll have to go down the EWS path. I'll report back.

:headbang:

 

[colb]

Sounds like the EWS has lost its sync with the DME, some code readers have an opton to sync these two modules, BMW Scanner 1.4 can do it on a Laptop. Best of luck with that AK90+ key coder, I had one and couldn't successfully get it to code a new key.
How to video on Youtube here using BMW Scanner 1.4 which uses PASoft
https://www.youtube.com/watch?v=-HM5hpMNvQk
The non start is usually down to the sync between the modules failing so the rolling code in the keys transponder is not recognised so the EWS wont allow the car to fire the car up.

 

[nm8shun]

Thanks for that lead colb. I've got a new 2023 LAUNCH X431 Elite scanner. I'll see if I can get it to do a DME/EWS sync (I could never get my K+DCAN setup to work with my laptop).

 

[bigwinn]

Where you based

I have software that can unlink your ews?

 

[nm8shun]

San Antonio, Texas....I fear a long way from you. I've looked at deleting the EWS and other such options. I might need to look more at that in the long term.

 

[bigwinn]

Never mind!

 

[nm8shun]

Alright. Continuing with the saga.

I connected the Launch X431 today and started digging around.
- Got to DME-EWS Adjustment
* "DME Control Unit and EWS Control Unit Do Not Fit Together!"
- Went into the Data Stream for the EWS
* Key Disabled: No
* Key Identification: Not O.K.

So, it seems as though the EWS and DME are not talking for sure. I don't know if "DME-EWS Adjustment" is supposed to allow for Sync, or if they have to be synced before adjustment. Any advice?

 

[Mike6]

I had fully voltage on my battery but it was dead in terms of amps. New battery solved all my problems. Might be worth trying a different battery just in case

 

[nm8shun]

Thanks @Mike6. I've got another one...I'll give it a try. Although that shouldn't have any impact on EWS-DME communication would it?

 

[colb]

Is there anything in the Special Functions menu on your scanner for syncing the EWS to DME?
BMW Scanner 1.4 comes with a cable and interface and software on a usb stick from ebay sellers, its by far the easiest diagnostics for setting up on a Laptop and its cheap. Worth adding it to your toolbox and giving it a go.
UK seller here
https://www.ebay.co.uk/itm/164592783812?hash=item26527e91c4:g:vW0AAOSwhnZf32G5&amdata=enc%3AAQAIAAAAwHbNV27M4mM24d9WbUI2ZwuDl%2Bm8GhJMjsXgAM71tH%2BM%2Ff8tfa%2FUGH6opH6XeC8%2FRJ5kq6AC0EwMrxSEyzHHEBvqzxbn61s36ZDUM2zSuFgstPhSDYoItClzrpYotiJgubiv7Ii4GEWwK1Q3IPFgLw2fbIXAMBdaIWdEOn7vh0uvfDESXScyPAYiQYM9yZiooZEvqKASDQJayeoTjcEDXsQ4ulHgpTYc%2FhFwOixzPTkh9fbrZrtu5yVmQjE8lCnrMQ%3D%3D%7Ctkp%3ABk9SR8a0i97gYg No doubt you will find a USA seller on USA ebay.

 

[nm8shun]

@colb. I couldn't find anything on my scanners to sync DME to EWS. But, I ordered a BMW Scanner 1.4.0 at your suggestion yesterday (thank you, BTW). It should be here early next week. I'll give it a try and report back.

 

[nm8shun]

Just reporting in.

I haven't gotten the BMW Scanner 1.4, but was able to get my K+DCAN and laptop working. I have a hard time getting INPA in English, but was able to use ISTA and in its DMW/EWS area, I was able to get thing synced, and (hooray!) it starts again.

Thanks for the help and guidance everyone!