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Pelican Technical Article:

Radiator Outlet Temperature Sensor Replacing

Nick Czerula

Time:

1 hour1 hr

Tab:

$60

Talent:

**

Tools:

Torx driver, flathead screwdriver

Applicable Models:

X3 E83 (2004-06)
X3 E83 facelift (2007-10)

Parts Required:

Engine coolant, radiator outlet temperature sensor

Hot Tip:

Work with a cool engine

Performance Gain:

Repair faulty sensor or remedy coolant leak

Complementary Modification:

Replace radiator hose

BMW X3 cooling system components include:

Radiator, coolant overflow tank and tank bracket on radiator support.

Belt driven coolant pump bolted to the front of the engine block.

Electric cooling fan, DME controlled.

Electrically heated thermostat.

Automatic transmission cooler or heat exchanger (if equipped).

Heater valve and heater core (for climate control).

Coolant level sensor inside expansion tank.

Coolant temperature sensor at cylinder head.

Coolant hoses and lines.

The radiator outlet temperature sensor, located in the right side radiator hose, monitors coolant temperature as it leaves the radiator. The sensor reading is used by the engine management system (DME) to determine when the electric cooling fan is activated. The DME uses other inputs as well to control cooling fan operation and speed: Coolant temperature at the cylinder head and AC operation.

The radiator outlet temperature sensor can fail electrically; a fault code will be stored and the MIL (malfunction indicator lamp) will be illuminated. The sensor can also leak coolant from the sensor sealing O-ring. I have replaced this sensor and soon after developed a leak at the lower radiator hose. If it's in your budget, replace the lower radiator hose also as preventative maintenance. Replacing the radiator outlet temperature sensor is a snap and can be done working above the engine on the right side of the radiator.

In this article I will describe how to replace the radiator outlet temperature sensor. Be sure to work with a cool engine and confirm the cooling system lacks pressure before opening the cooling system.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Drain the cooling system. See our tech article on draining and filling your cooling system. Not necessary but recommended by BMW. Most times if you place a drain pan under the sensor you catch what spills. Leave the reservoir cap on to prevent a major amount of coolant escaping.

I prefer to remove the radiator fan when replacing the sensor, it allows better access. It is not necessary. The fan comes out quick, so it is worth it.

The radiator outlet temperature sensor (red arrow) might be the cause of a hard to find coolant leak.
Figure 1

The radiator outlet temperature sensor (red arrow) might be the cause of a hard to find coolant leak. The sensor is mounted in a plastic section of the right side radiator hose. There is a sealing O-ring that normally prevents leaks in the system. Over time, this O-ring fails and creates a coolant leak. At first, it will be a small leak and you may notice a small amount of coolant under the right side of your vehicle or the coolant reservoir coolant level slowly dropping. This photo shows the beginning of a failing O-ring. You can see coolant seeping out through the sensor mounting bung (note wet area around sensor). If you have a small, yet hard to locate coolant leak, start by inspecting this sensor.

Start by removing the four T25 Torx fasteners (red arrows) for the fresh air intake duct.
Figure 2

Start by removing the four T25 Torx fasteners (red arrows) for the fresh air intake duct. Next you will unclip the five air filter housing retaining clips. Lift them up and unhook from the lid of the intake air housing. Start with the two near the mass air flow sensor. Then release the front clips.

Once you release all the clips, lift the intake air duct (blue arrow) and pull it out of the air filter housing lid (red arrow) then remove it from the radiator support.
Figure 3

Once you release all the clips, lift the intake air duct (blue arrow) and pull it out of the air filter housing lid (red arrow) then remove it from the radiator support.

Place a drain pan under the right side of the front bumper, below the sensor (red arrow).
Figure 4

Place a drain pan under the right side of the front bumper, below the sensor (red arrow).

Working at the radiator outlet temperature sensor, disconnect the electrical connector by pressing the wire release tab (red arrow) and pulling the connector straight off.
Figure 5

Working at the radiator outlet temperature sensor, disconnect the electrical connector by pressing the wire release tab (red arrow) and pulling the connector straight off.

To remove the sensor from the hose, squeeze the plastic locking tabs on the sensor (red arrows) and pull the sensor out of the radiator hose.
Figure 6

To remove the sensor from the hose, squeeze the plastic locking tabs on the sensor (red arrows) and pull the sensor out of the radiator hose. Be prepared to catch any excess dripping coolant in a container when you pull the sensor out of the hose. I like to keep my drain pan under the area of the hose.

To install the new sensor, lubricate the sensor O-ring (red arrow) with clean engine coolant.
Figure 7

To install the new sensor, lubricate the sensor O-ring (red arrow) with clean engine coolant. Then push it into the radiator hose until both plastic mounting tabs engage. Then connect the electrical connector and reassemble the splash shield. Fill and bleed the cooling system.

If you suspect the sensor is good and the wiring or voltage to be faulty, disconnect the electrical sensor as noted above.
Figure 8

If you suspect the sensor is good and the wiring or voltage to be faulty, disconnect the electrical sensor as noted above. Using a DVOM check the voltage to the sensor. Pin 1 (yellow arrow) should have 5 volts. Pin 2 should have close to zero volts (green arrow). If your voltage readings do not match, you may have a faulty wire or control module. Consult the most current wiring diagram for your vehicle. You can also measure across the sensor terminals (red arrows), as the temperature of the sensor increases, resistance should decrease. You can test this by placing the sensor in hot water with a DVOM set in OHMs.

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Page last updated: Fri 12/2/2016 03:07:50 AM