Oxygen Sensor - Long Cable Design
87bmw10GROUP 11 Engine
Bulletin Number 11 13 86 (1324) Page 1 of 4
Montvale, NJ February 1987 Technical Dept.
SUBJECT: Oxygen Sensor Service
MODEL: 535i, 635CSi, 735i/L7 (E23) produced prior to 9/86
Situation: As of 9/86 production, all 3.5 liter-engined vehicles are equipped with a long cable oxygen sensor. The connector to the wiring harness is now located in the engine compartment, which makes maintenance and troubleshooting much easier.
To achieve uniformity on all 3.5 liter-engined vehicles produced prior to 9/86, only the longer-cable version should be installed in these cars when an oxygen sensor is replaced.
NOTE: The oxygen sensor itself is unchanged, the only difference is in the length of the cable.
Parts
Information: Part Number Description Quantity
11 78 1 716 156 Oxygen sensor with long cable 1
61 13 1 373 584 Wire tie (for 635CSi only) 2
NOTE: Use up stocks of oxygen sensors with short cable (P/N 11 78 1 286 638) on the 325/e/es models.
Service
Procedure: General Note: Rerouting and attachment of cables has to be done in such a way that there is no possibility of chafing against any metal.
1. Remove protection plate (where applicable) and splash shield.
2. Disconnect plug and remove oxygen sensor.
NOTE: On cars where the special oxygen sensor sealing kit has been installed (see S.I. 11 03 86 (1182) dated February 1987), cut into the shrink tubing with a knife at the edge created by the two connectors where joined. Leave the shrink tubing on the engine harness side.
3. Cut the wire ties holding the harness to the body. Guide the harness back to the engine compartment.
4. Install the new oxygen sensor (P/N 11 78 1 716 156). Route the oxygen sensor cable with new wire ties the same way the harness had been routed before.
NOTE: On the 635CSi, two new wire ties (P/N 61 13 1 373 584) have to be installed.
5. Reinstall protection plate (where applicable) and splash shield.
FIGURE 1:
6. Route harness and oxygen sensor cable to the upper engine compartment as follows:
a. 535i, 635CSi (Manual Transmission)
- Use a wire tie to attach harness and oxygen sensor cable to the lower white spiral conduit (see Figure 1).
FIGURE 2:
FIGURE 3:
- Guide the cables upward between heater hose and firewall. Attach them to the heater hose with a wire tie (Figure 2 for 535i; Figure 3 for 635CSi).
- Connect the plug and attach it to the wiring harness with two wire ties (Figures 2 and 3).
FIGURE 4:
b. 535iA, 635CSiA, 735iA, L7 (Automatic Transmission)
- Attach harness and oxygen sensor cable to the lower part of the transmission dipstick tube with a wire tie (Figure 4).
FIGURE 5:
- Guide the cables upward and attach them at the top part of dipstick tube with a wire tie (Figure 5 shows 735iA as an example).
FIGURE 2:
FIGURE 3:
FIGURE 5:
- Connect plug and attach it to the wiring harnesses at the firewall as shown in Figure 5 for 735iA and L7; and as shown in Figure 2 for 535iA and Figure 3 for 635CSiA.
Warranty
Status: When a warrantable repair is performed (under the provisions of the BMW 5 Year/50,000 Mile Emissions Warranty) which requires the oxygen sensor to be replaced, an additional labor operation and labor allowance may be claimed:
Labor operation: 00 50 095
Labor allowance: 5 Flat Rate Units
Defect code: 11 78 00 79 00
If replacement is part of a normal maintenance, the additional costs are to be charged to the customer.