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  1. #1
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    Palo Alto, CA, United States
    Member No: 13136 stukreit is an unknown quantity at this point stukreit's Avatar
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    Yes | No

    Wiring diagram under the intake manifold? (528i)

    Has anyone r&r'd the intake manifold? I took it off to replace
    the plastic water lines directly under it. I need help reattaching the
    10-odd connectors there. Turns out there's no clear documentation
    on this and the connectors are anonymously 2 and 3 pin modulars.

    Btw, both hard lines were completely weakened and cracked where they
    enter the engine. The minor water loss was simply going to continue
    to get worse and worse. I'm surprised that more people aren't
    dealing with this as our e39's approach their second decade and
    are deep into their second 100k miles.

    Stuart
    Palo Alto


  2. #2
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    Ooltewah, TN, United States
    Member No: 119706 Bmw540san is on a distinguished road Bmw540san's Avatar
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    Yes | No

    Most connectors usually only fit their other

    respective end. You shouldn't have problems reconnecting them. If there are similar ones you should always mark them before disconnecting.
    You may also end up with extra connectors that were not used from factory due to changes in model years.
    The rubber lines you're talking about aren't really common problem, although you're right, age and heat will eventually create a problem



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  3. #3
    Registered Member
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    Member No: 13136 stukreit is an unknown quantity at this point stukreit's Avatar
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    Yes | No

    There is some keying, but most are identical

    And no, I cavalierly removed connectors thinking that there'd be
    documentation to get me back, but its worse than the old days,
    because there doesn't seem to be color coded wires anymore, or if
    there is, its very well hidden in the weatherproof boot. Not like
    the old days. I may need to go find a wreck to go photograph.

  4. #4
    Eurodavid
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    Yes | No

    Re: Most connectors usually only fit their other

    BMW540san,

    This may sound ignorant, but which plastic water lines under the manifold is stukreit referring to? I have had my manifold off on my 1996 528i (as you all well know) and am I sitting here trying to figure out what he is talking about when he is saying "plastic water line".

    Eurodavid

    P.S. stukriet, I know this is after the fact, but when I did mine, I took 2 mins and put strips of paper w/ numbers on them (taped) so I knew which connectors went where. Doesn't help you now, I know, but next time it pays to slow down a bit and mark things. I know this sounds crazy, but just start plugging things in where it looks like they went (and keep track by markings). The EGR stuff is really the only thing you should have a problem with as all those connectors look the same. At that many miles, the other connectors have a natural settled in place where they went & which connector they went into. Besides, lol, you'll know what's what when starting the car and/or begin seeing the immediate idiot lights (or codes being thrown).


  5. #5
    Registered Member
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    Yes | No

    Euro, rubber has probably hardened so much by

    now that he's probably mistaken it for plastic.



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  6. #6
    Registered Member
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    Palo Alto, CA, United States
    Member No: 13136 stukreit is an unknown quantity at this point stukreit's Avatar
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    Yes | No

    Re: Most connectors usually only fit their other

    Hose #6, #8. I have a picture of how badly decomposed they were
    at the double-o-ring interface to the block:

    http://realoem.com/bmw/showparts.do?model=DM63&mospid=47585&btnr=11_2638&hg=11&fg=35

    closest thing to a diagram. I'll try to annotate:

    http://realoem.com/bmw/showparts.do?model=DM63&mospid=47585&btnr=12_0988&hg=12&fg=28

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