A/c Heater Systems - Automatic: Removal & Installation BMW 7 series E38 facelift

REMOVAL & INSTALLATION

Remove radio by bending flaps out to expose screws. Remove screws and remove radio. (Scheme 23) Remove additional control on right of radio (if necessary). Depress clip behind trim panel through radio opening at top of Multi-Information Display (MID). Remove MID and push A/C-heater control panel from rear and out of trim panel. (Scheme 24) Remove A/C-heater control panel. To install, reverse removal procedure.

Scheme 23

Scheme 24

Drain engine coolant. Loosen 3 hose clamps 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. (Scheme 25) To install, reverse removal procedure.

Scheme 25

Removal & Installation (Front)

Disconnect negative battery cable. Remove upper instrument panel cover. See INSTRUMENT PANEL. Unclip ventilation duct. Unclip and remove blower motor cover. (Scheme 26) Remove blower motor screws. Disconnect blower motor electrical connectors. Remove blower motor. (Scheme 27) To install, reverse removal procedure.

Scheme 26

Scheme 27

Removal & Installation (Rear)

1. Disconnect negative battery cable. Remove screw at left and right sides of console. Move carpeting aside. Remove 2 driver's side console screws. Unclip carpeting at rear of console. Pull carpeting backward to remove from clips. Remove left and right screws from rear of console.
2. Unclip rear console tray. Remove 6 rear console screws. Lift front of center console forward. Remove front of center console. Remove console wood tray screws. Move wood tray forward and remove. (Scheme 28)
3. Disconnect electrical connector under wooden tray. Pull wiring harness connector holder backward. Remove center console screw next to shift lever. Lift rear center console and loosen left and right screws. Push rear fan forward out of holder. Remove fan. (Scheme 29) To install, reverse removal procedure.

Scheme 28

Scheme 29

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.

1. Remove front bumper.
2. Disconnect plug connection (1). Turn plug (2) in direction of arrow and remove from air duct at front (4). Feed cable loom (3) out of fixtures. (Scheme 30)
3. Remove screws (1). Remove air duct at front (2). (Scheme 31)
4. Remove nuts (1). Remove condenser fan with fan cowl (2) in direction of arrow. (Scheme 32)
5. To install, reverse removal procedure. Ensure Bowden cable guide (3) is correctly seated. (Scheme 31)

Scheme 30

Scheme 31

Scheme 32

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. 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 wiring straps along firewall. Remove screws and pull up cover. Remove nut, 2 screws, and stud. Disconnect wiring harness from A/C-heater control unit. Cut and discard wire straps. Set wiring harness aside.
3. Remove glove box. Remove 3 screws and trim panel. Pull clip out and remove cover. Remove screws and air duct. Remove evaporator cover. Remove screw and lift out pipe. Remove expansion valve and evaporator. (Scheme 33) To install, reverse removal procedure.

Scheme 33

1. Drain engine coolant. Pry off engine cover clips. Remove engine cover screws. Remove engine cover. Disconnect 3 heater hoses at firewall. (Scheme 34) Blow out heater core with compressed air. Remove center console.
2. Remove lower steering column panel and footwell trim. Remove left footwell air duct. Remove heater core bracket bolts. Place bracket aside. Remove heater core pipe bolts. Remove heater core pipes. Remove 5 heater core cover bolts. (Scheme 35) Remove heater core. To install, reverse removal procedure. Use new "O" rings on heater pipes.

Scheme 34

Scheme 35

Removal

1. Disable air bag system. Using a Torx bit with a long shank, remove air bag module screws from rear of steering wheel. Lift off air bag module enough to unplug wiring connector from rear of module. Place air bag module, with trim cover pad facing up, in trunk.
2. Remove steering wheel nut and washer. Mark position of steering wheel on shaft, and remove steering wheel using puller. Disconnect wiring and gas cylinder rod from left side of glove box. Pull off trim, detach clips and remove glove box.
3. Remove center console. (Scheme 28) Pry top of instrument cluster out slightly. 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. Remove radio (if necessary).
4. Remove rubber door seal. Remove "A" pillar trim on left and right side. Disconnect wiring harnesses. If necessary, open lock tabs on some connectors to disconnect harnesses. Lift out speaker balance control, and disconnect wiring. Remove screw, and pull off trim, and lead at glove box light.
5. Remove dashboard trim plate and 3 bolts on top of dash. Cut straps retaining heater wiring harness to dash (located in instrument cluster opening). Disconnect wiring to vent duct potentiometers. Remove bolts and instrument cluster. (Scheme 36)

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.

Scheme 36

Open hood for engine compartment. Remove screw attaching filter cover to filter housing. Remove 3 clips attaching filter to housing and remove filter. (Scheme 37) To install, reverse removal procedure.

Scheme 37