12 51... Exchanging plug-in contact of coolant temperature sensor (S65)

WARNING: This page is about a different car, the 2011 BMW M3, 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Necessary preliminary tasks

Read out the fault memory of the DDE control unit.
Switch off ignition.
Follow instructions for disconnecting and connecting BATTERY .
Remove INTAKE AIR MANIFOLD .
Remove SECONDARY-AIR PUMP .
Disconnect BATTERY EARTH LEAD and cover.
Remove INTAKE PLENUM .

Carefully open locks on cable duct.

Fig 1: Locating Cable Duct Locks

G00524419

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully lift the front of the upper part of the cable duct by approx. 10 cm and secure, e.g. with panel wedge set 00 9 310 or a screwdriver.

Fig 2: Securing Duct In Lifted Position Using Special Tool 00 9 310

G00524420

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock connector (1) from coolant temperature sensor and pull off.

Fig 3: Identifying Coolant Temperature Sensor Connector

G00524421

Courtesy of BMW OF NORTH AMERICA, INC.

The cable repair kit consists of:

Length of corrugated tubing (1) 60 mm.
Heat-shrink tubing (2).
Chamber 1, brown cable.
Chamber 2, yellow/green cable.
Crimp connectors (3).

Fig 4: Identifying Cable Repair Kit Components

G00524422

Courtesy of BMW OF NORTH AMERICA, INC.

Cut lines of engine wiring harness for coolant temperature sensor according to the repair kit (1) and strip insulation.

Fig 5: Identifying Repair Kit

G00524423

Courtesy of BMW OF NORTH AMERICA, INC.

Connect cable ends of repair kit and engine wiring harness with crimp connectors (1).

Crimp the crimp connectors with suitable pliers.

Fig 6: Connecting Cable Ends Of Repair Kit And Engine Wiring Harness With Crimp Connectors

G00524424

Courtesy of BMW OF NORTH AMERICA, INC.

Pull heat-shrink tubing (1) over the crimped cable ends.

Bond heat-shrink tubes watertight with hot-air blower.

IMPORTANT: Make sure that no cables are damaged by the hot air blower!

Fig 7: Pulling Heat-Shrink Tubing Over Crimped Cable Ends

G00524426

Courtesy of BMW OF NORTH AMERICA, INC.

Insert wiring harness in cable duct and secure with cable strap. Close cable duct again.

Fig 8: Inserting Wiring Harness In Cable Duct And Securing With Cable Strap

G00524425

Courtesy of BMW OF NORTH AMERICA, INC.

Delete fault memory of DDE control unit.

Assemble engine.