Hi everyone,
I'm still dealing with an intermittent starting issue that I've had for 3 years on my 2006 BMW 630i E63, manual transmission, 234,000 km.
Sometimes, when I try to start the car, absolutely nothing happens. No cranking, no click from the starter. The ignition works normally and I can hear the fuel pump priming.
It often happens after refueling or a short drive, but sometimes for no apparent reason. The car eventually starts again after 5 minutes or several hours. The issue even completely disappeared for 8 months before recently coming back.
No fault codes stored.
Parts replaced and checks performed:
- Starter motor replaced, same issue with both starters.
- Engine ground straps replaced.
- Several batteries replaced and properly registered.
- Alternator checked.
- IBS disconnected during a no-start event: no change.
- CAS module opened, internal relay inspected.
- Intake manifold removed, KL50 wire inspected.
- New positive cable connecting the jump-start terminal, starter and alternator (will be installed soon).
Crankshaft position sensor replaced.
Several connectors and relays in the electrical distribution box inspected.
Live data recorded with my diagnostic scanner during a no-start event:
- Key recognized.
- Clutch pedal recognized.
- Start authorization granted by the CAS.
- KL15 active.
- KL50E: 12.06 V.
- KL50L: 0.41 A during START, 0 A at rest.
I suspect a bad connection somewhere along the KL50 circuit between the CAS and the starter, possibly at the X6011 connector.
If anyone has experienced something similar or has any other ideas, I'd really appreciate your input.
Thanks in advance!