Attachment II

535i and 635CSi - Sealing of the Oxygen Sensor Harness Only


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. Disconnect and clean the connector and wiring harness with solvent and blow dry.

5. 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:

6. 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.

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

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

9. Clip the wiring harness connector onto the protection plate.

10. Reinstall the protection plate.
11. Install a splash shield P/N 11 78 1 278 560 onto the oxygen sensor so that the sensor is protected from road splash.