Automatic A/c-Heater Systems: Removal & Installation BMW 5 series E39

REMOVAL & INSTALLATION

Remove glove box. Remove screws and pull off trim on right and left sides of center console. Disconnect wiring from left and right sides of A/C-heater control unit. Remove screws and fold down ventilation duct. Press down retainer and pull out A/C-heater control unit from right side. To install, reverse removal procedure.

For removal and installation procedure, see CABIN AIR FILTER article.

Disconnect harness connector and unclip motor with gearbox from plenum housing. To install, reverse removal procedure.

Drain coolant, and disconnect heater hoses. Disconnect coolant hose at auxiliary water pump. Disconnect pump wiring. Remove nuts and lift out heater control valve and pump. Remove clamp and bolt. Remove auxiliary water pump assembly. To install, reverse removal procedure.

1. Disconnect negative battery cable. On vehicles with coolant overflow tank in rear of engine compartment, remove hose from overflow tank and disconnect tank level sensor electrical connector. Remove mounting bolts and move to side.
2. Unclip wire harness protective cover from rear of bulkhead and cut wire ties as necessary. Unhook blower motor housing cover retaining strap and remove cover. Disconnect electrical harness connectors from blower motor. Remove blower motor retaining strap from blower motor. Remove blower motor from cowl opening. To install, reverse removal procedure.

Removal & Installation (IHKR II & IHKR III Only)

Remove screw from carpeted trim panel from left side of center console and remove trim panel. Disconnect harness connector from resistor pack. Remove resistor pack from heater housing. To install, reverse removal procedure.

Removal & Installation (IHKR I & IHKA Only)

1. Remove glove box. Remove carpeted trim panel from right side of center console. Remove trim cover at left side of glove box. Remove ventilation air duct retaining screws and pull air duct down and outward.
2. Disconnect harness connectors from control module and blower motor final stage unit. Move wire harness to allow for final stage unit removal. Remove mounting screws from final stage unit and remove unit from heater assembly. To install, reverse removal procedure.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Loosen hose clamp. Remove nut and air cleaner. Cut wiring straps, and disconnect compressor clutch lead. Disconnect suction hose and pressure hose. Cap all openings.
2. Raise vehicle on hoist, and remove engine splash shield. Loosen compressor mounting bolts, remove drive belt and remove compressor. To install, reverse removal procedure.

Loosen hose clamp. Remove nut and air cleaner. Cut wiring straps and disconnect switch lead. Remove compressor temperature switch. To install, reverse removal procedure.

Removal & Installation (IHKR System)

1. Remove radio. Reach in through radio opening and push tabs outward toward steering wheel then remove control panel to allow clearance to disconnect electrical harness connectors and cables from back of unit.
2. Squeeze retaining tab together and remove cable end from operating lever. Repeat for 2 other cables. To install, reverse removal procedure.

Removal & Installation (IHKA System)

1. Remove radio. Squeeze retainer on left side of control panel through radio opening and pull out control panel from left side.
2. Detach cable and wiring harness connectors. Remove blower switch, ensuring catch lever and spring do not slide out. Remove screws and control panel.
3. Lift cover retainers and remove sensor blower cover. Disconnect wiring connector, and remove sensor blower. Remove control panel cover. To install, reverse removal procedure.

Removal & Installation (IHKR System Only)

1. Remove glove box. Remove carpeted trim cover at center console. Remove plastic trim cover at left of glove box. Remove control panel. See «CONTROL PANEL»(ref-137491-S28325746672002030600000) . Disconnect cables from air distribution levers.
2. Install cables. To complete installation, reverse removal procedure.

Discharge A/C system using approved refrigerant recovery/recycling equipment.

Scheme 7

Scheme 8

1. Pull off rubber trim along engine compartment firewall. Remove wiring and drain hose from expansion tank. Remove expansion tank, and set it aside. DO NOT bend coolant hose.
2. Cut 5 wiring straps along firewall. Tie up wiring harness and, if necessary, carefully bend down fuel lines.
3. Unfasten screws and remove cover plate by lifting upward. Unfasten nut (1), screws (2) and stud bolt (3). Stud bolt is secured with Loctite. If necessary, preheat with hot air blower.
4. Remove glovebox. Remove screws and remove trim by pulling forward out of rear clip. Lift out clip and remove cover.
5. Unfasten screws and lift out ventilation duct.
6. Remove all plugs from control unit and lift up wiring harness. On automatic air-conditioning system, also remove plug from output stage.
7. Unfasten screws and remove cover.
8. Unfasten screw and lift out twin tube. During installation, replace O-rings.
9. Unfasten screws and lift out expansion valve. During installation, replace O-rings.
10. Lift out evaporator.

Remove screw and pull off trim on left side of center console. Disconnect wiring, and lift out evaporator sensor. To install, reverse removal procedure.

Remove center console. Disconnect sensor harness connector and carefully pry sensor from heater core housing. To install, reverse removal procedure.

1. Drain coolant, and discharge A/C system using approved refrigerant recovery/recycling equipment. Remove instrument panel. See «INSTRUMENT PANEL»(ref-137491-S41627360682002030600000) . Remove rubber trim along engine compartment firewall. Remove wiring and drain hose from expansion tank. Remove expansion tank, and set it aside. DO NOT bend coolant hose.
2. Cut wiring straps (on firewall). Tie wiring harness and, if necessary, carefully bend down brake and fuel pipes. Remove screws and pull up cover. Disconnect 3 heater hoses from heater valve assembly. Remove 5 bolts and nut from heater valve assembly (engine compartment side).
3. Remove 3 bolts from heater valve assembly. Lift out left and right side ventilation ducts. Remove heater valve assembly. To install, reverse removal procedure.

1. Drain coolant. Remove center console. Remove glove box. Remove 3 bolts from heater assembly. Remove 2 bolts and lift out right holder. Remove front ventilation drive motor. Disconnect both temperature sensors.
2. Remove screws, loosen wire straps and clips, and remove cover. Remove 8 bolts and heater pipes. Remove heater core from right side. To install, reverse removal procedure. Use NEW "O" rings on heater pipes.

Removal

1. Disable air bag system. Using Torx TX30 bit with long shank, remove air bag module Torx screws from rear of steering wheel. Lift off air bag module enough to unplug wiring connector from rear of module. Place air bag module in a secure area, away from work area (preferably in trunk).
2. Position module with trim cover pad facing upward. Remove steering wheel nut and washer. Mark position of steering wheel on shaft, and remove steering wheel using puller. Remove center console. Remove glove box. Pry top of instrument cluster out slightly.
3. Pull cluster up to steering column and then fold down. Press tabs next to connectors and disconnect cluster wiring. Remove instrument cluster, and set it aside. Disconnect connector for radio speaker, if necessary. Remove left and right rubber door seals.
4. Remove "A" pillar trim on left and right side. Disconnect wiring harnesses as necessary. Remove screws from left and right sides of instrument panel. Disconnect air ducts as necessary. Carefully remove instrument panel.

Installation

To install instrument panel, reverse removal procedure. Tighten air bag module Torx screws and steering wheel hub nut to specification. See TORQUE SPECIFICATIONS . Activate air bag system and ensure air bag system is functioning properly. See SYSTEM OPERATION CHECK in AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

1. Pull off rubber trim along engine compartment firewall. Remove wiring and drain hose from expansion tank. Remove expansion tank, and set it aside. DO NOT bend coolant hose. Cut 5 wiring straps along firewall.
2. Remove screws and pull up cover. Cut sensor lead 1 1/4" (32 mm) away from sensor. Strip insulation rubber about 1 1/2" (38 mm) away from sensor. Remove outside temperature sensor.

1. Place small diameter shrink tubing over each wire. Place large diameter shrink tubing over insulation rubber. Connect ends of NEW sensor to existing wiring. Solder ends of wiring.
2. Slide small diameter shrink tubing over solder points. Apply heat to shrink tubing using heat gun. Slide large diameter shrink tubing over solder points. Apply heat to shrink tubing using heat gun. Install outside temperature sensor.