Attachment I

735i and L7 - Sealing and Rerouting of the Oxygen Sensor Harness


References are made to the drawings on Attachment III.

Note: The purpose of these steps is to weatherproof the connections found in the oxygen sensor wiring.


1. Raise vehicle on lift.

2. Remove the two plastic nuts retaining the protection plate for the oxygen sensor wiring harness.

3. Unclip the oxygen sensor connector and remove the protection plate.

4. Discard the protection plate and reinstall the plastic nuts.

EXISTINGWIRE HARNESS ROUTING FIGURE 1:

5. Cut wire tie at point A Figure 1.

6. Remove the plastic nuts at points A and B in Figure 1.

7. Reinstall these nuts in the reverse order so that the one with attachment points for the wire ties is at point B in Figure 1.

8. Disconnect the oxygen sensor connector. Clean the connector and wires entering the connector with solvent and blow dry.

MODIFIED WIRE HARNESS ROUTING FIGURE 2:

9. Reroute the wiring harness so that it crosses over the transmission cross member as shown in Figure 2.

10. Reconnect the connector partially (about 3mm). Apply sealing paste P/N 11 12 1 262 571 around the connector to fully weatherproof it and then press together the connector completely. Excess sealing paste will be pushed out. Do not wipe off.

FIGURE 3:

11. Apply sealing paste to both sides of the connector sealing the area where the wires enter the connector as shown in Figure 3 point A. Make sure areas are clean before sealing.

12. Push sealing paste into wiring protection sleeve as shown in Figure 3 points B, C & D. Make sure these areas are clean before sealing.

13. Apply sealing paste where the wires enter the oxygen sensor as shown in Figure 3 point E. Areas must be clean before application.

MODIFIED WIRE HARNESS ROUTING FIGURE 2:

14. Secure the wiring harness to the plastic nut at point B in Figure 2 with wire tie P/N 61 13 1 243 092. Make sure that the harness will be free from any moving components.
15. Install a splash shield P/N 11 78 1 278 560 onto the oxygen sensor so the front of the sensor is protected from road splash.