Engine Does Not Start (54.18/108)

ENGINE DOES NOT START

TECHNICAL SERVICE BULLETIN

SUBJECT

Model 211.065/070/076/082/083/265/282/283 

All Model Years 

Engine Does Not Start 

SERVICE INFORMATION

If you receive customer reports in the above model vehicles of the engine not starting, the starter cable harness lug may be providing insufficient contact. The following procedure must be followed.

1. Disconnect ground cable from battery, as per WIS document AF54.10-P-0003T (sedan) and AF54.10-P-003TA (wagon).
2. Remove footwell paneling in passenger footwell, as per WIS document AR68.20-P-2070T.
3. Disconnect starter cable harness on the vehicle under side from (F32) prefuse box (Fig 1 , 3).
   Fig 1: Starter Cable Harness Lug On The Vehicle Under Side

   
4. Perform a visual inspection of the contact surfaces of the starter cable harness and of the prefuse box, clean the contacts and coat with a preserving agent.
   NOTE: If the starter cable harness lug cannot be properly connected to the terminal point on the front prefuse box (F32) (outside part of passenger footwell), this may cause pitting of the contacts (Fig 2 & 3).
   Fig 2: Pitting On Starter Cable Harness Lug

   
   Fig 3: Pitting On Bottom Part (Flange) Of Front Prefuse Box Cap (F32)

   
   NOTE: If there is damage to the cap of the starter cable harness, in the form of a burnt or pitted surface, replace with a new cap.
5. Connect starter cable harness to the prefuse box. Torque the M8 cable connection nut to 14 Nm.
   NOTE: Ensure that the damping mat is not caught between the body and the cap (Fig 4 ). This tilted installation position may cause contact problems between the cap and the terminal point.
   NOTE: Ensure that the battery cable in the interior of prefuse box is not under tension (Fig 5 , 2). If the cable is under tension it can bend and/or misalign the terminal point in the interior of the prefuse box. A tilted installation position can also lead to contact problems in this case. Fig 5 shows the correct installation position of the battery cable.
   Fig 4: Insulation Mat

   
   Fig 5: Battery Cable At Front Prefuse Box (F32) In Passenger Footwell

   

PARTS INFORMATION

Qty.	Part Name	Part Number
As required	Cap, upper	A211 545 04 83(1)
As required	Flange, lower	A211 545 11 83(1)
(1) Parts are in a critical supply situation and will be limited, please see the PAC weekly status report on parts availability status and delivery expectations. This report is located on the PAC website.

IN CASE OF WARRANTY

Operation:  Cable connection - footwell circuit 30, check/correct (02-3982)

Damage Code	Operation Number	Time (hrs.)	Model Indicator (s)
54290 38	02 3982	1.4 hrs.	T0, U0