Section A
Section A: VANOS accumulator shutoff valve wiring harness installation - applies to M5 and Z8 vehicles produced up to 8/31/00.1. Disconnect the battery.
2. Remove the air intake duct (intake air silencer upper section, air mass meter, bellows) for cylinder banks 1 and 2.
3. Remove intake manifold as outlined in repair manual group 11 section 11 61 050.
4. Separate plug connections:
(1) VANOS connector, cylinder bank 2
(2) Oil switchover valve connector, generator wire terminal 61, thermal oil level sensor
(3) Corrugated tubing
5. Remove the fabric tape (water proofing tape for corrugated tubing) from end of wire harness (2).
6. Carefully unclip and raise the wiring duct covers located next to the fuel rail on both cylinder banks 1 and 2.
Important:
If any of the cover retaining clips break off when removing the wiring duct covers they must be replaced. New covers are included in kit part number 11 36 7 832 855.
7. Remove E box cover.
8. Remove wire ties (1)
(1) Wire ties
(2) Crimp connector X6461
(3) Bellows connecting wiring duct for cylinder bank 1 and 2
(4) Bellows connecting wiring duct for cylinder bank 1 and E box
9. Remove the fabric tape (water proofing tape for corrugated tubing) from end of wire harness (1).
(1) Fabric water proofing tape located inside the end of the corrugated tubing.
10. Thread the additional wire harness (2) red-violet and brown wires through the corrugated tubing (1) until distance (a) has been reached.
(2) Additional wire harness included in parts kit
(a) = 175 mm (approx. 7 inches)
Installation Notes:
Use a piece of slightly bent welding or tie wire to assist in carefully threading the wires through the corrugated tubing.
Attach the brown wire to the partially threaded red-violet wire with tape and carefully thread both wires through the corrugated tubing until distance (a) has been reached.
11. Route the red-violet wire through bellows (3) and (4) into the E box.
12. Plug the red-violet wire into the DME connector, module 2, pin 8.
Note:
If the connector on the end of the red-violet wire is damaged during the threading process it should be repaired using the 100 mm (4 inch) piece of red-violet wire with the new connector included in the parts kit. To perform this repair, cut off 100 mm of the damaged red-violet wire and attach new wire section using a butt connector (PN 61 13 8 353 747) and shrink tubing (PN 61 13 1 379 833) found in BMW electrical repair kit number IV.
13. Using electrical tape secure the red-violet wire in the E box and pull back any excess length of wire into the wire duct for cylinder bank 2.
14. Cut ground wires - 1 x brown, cross section 2.5 mm and 2 x black-brown, cross section 0.5 mm - directly at crimp connector X6461 (green or blue protective cap). See illustration S11 01 004 item (2) above.
15. Slide shrink tubing (PN 61 13 1 379 833) onto the brown 2.5 mm ground wire. Plug the brown 2.5 mm ground wire, the two black-brown 0.5 mm wires and new brown 0.75 mm into butt connector (PN 61 13 8 353 748) and crimp connection.
16. Install shrink tubing on butt connector as shown.
17. Reinstall 3 wire ties as shown (1).
18. Wrap butylene tape (water proofing tape) around the end of the corrugated tubing (1) to assure a proper seal.
Note:
When reinstalling wire harness bellows boots, items (3) and (4), insure that the double lip seal connections at the ends are installed properly to avoid leaks.
19. Reinstall the E box cover.
20. Reinstall wiring duct covers on both cylinder banks.
21. Reinstall intake manifold as outlined in repair manual group 11 section 11 61 050.