Heating and Air Conditioning - Repair BMW X3 E83

64 11... Installing servodrive

Installation

If necessary, align shaft of flap(s) to be actuated to position of servodrive to be installed.

Scheme 1

64 11 208 Replacing heater core

Necessary preliminary tasks: Remove microfilter housing. Remove INSTRUMENT PANEL TRIM .

Coolant emerges when coolant hoses are detached. Have a suitable collecting container ready. Catch and dispose of escaping coolant. Observe country-specific waste-disposal regulations.

Detach hot water hoses (1) from heater and blow coolant out of heater core.

Scheme 2

For purposes of clarity, the following operations are shown on the removed heater core.

Pull out temperature sensor (1) and unclip wiring harness (2) from holder.

Scheme 3

Installation: Ensure correct lead routing.

Release screw (1) and remove bracket (2) from double pipe. Unclip retainers (3) and lift off cover for heating element (4).

Scheme 4

Installation: First insert lugs (5).

Remove retainers (1) and remove double pipe (2) towards top. Raise heater core (3) at front and remove.

Scheme 5

Installation: Replace sealing rings, coat with anti-friction agent and make sure sealing rings and lines are correctly seated.

After installation: VENT COOLING SYSTEM and check for water leaks.

64 11 213 Removing and installing/replacing heater - A/C unit fan

Special tools required

1. 51 3 057

Necessary preliminary tasks

E46 and E83

Remove heater bulkhead. Refer to 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD .

64 11 227 Replacing output stage/switch for heater - A/C system blower

Necessary preliminary tasks

1. Remove servodrive of right fresh-air/recirculated-air flap, see «Removing and installing/replacing servodrive for right fresh-air flap»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-807-removing-and-installingreplacing) .

Scheme 6

Release catch (1) and pull output stage (2) out of heater.

Scheme 7

Disconnect plug connection (1) and remove output stage (2).

64 11 377 Removing and installing control panel for heater - A/C system (replacing, automatic air conditioning)

Special tools required

1. 64 1 020

Necessary preliminary tasks

1. Remove «CENTER FRESH-AIR GRILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing)
2. Remove ignition key from ignition switch
3. Pull fuse 63 from distribution box in glovebox

Release screws (1).

Unclip control panel for heater - A/C system (2) with special tool 64 1 020 at retaining points (3) all round and pull back.

Unlock associated plug connections and disconnect.

Remove control panel for heater - A/C system (2).

Scheme 8

Replacement

Carry out programming/coding . Programming/coding is performed with BMW scan tool.

Special tools required

1. 64 1 020

1. Remove «CENTER FRESH-AIR GRILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing)
2. Remove ignition key from ignition switch
3. Pull fuse 63 from distribution box in glovebox

Release screws (1).

Unclip control panel for heater - A/C system (2) with special tool 64 1 020 at retaining points (3) all round and pull back.

Unlock associated plug connections and disconnect.

Remove control panel for heater - A/C system (2).

Scheme 9

Replacement

Carry out programming/coding . Programming/coding is performed with BMW scan tool.

1. Remove «center fresh-air grill»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing) .
2. Remove «GLOVEBOX»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-16-361-replacing-right-glovebox) .

Disconnect Bowden cable (1).

Scheme 10

Disconnect Bowden cable from mountings (1) and feed out.

Installation

Make sure Bowden cable can move freely.

If necessary, perform function test prior to assembly.

Scheme 11

Special tools required

1. 64 1 020

Necessary preliminary tasks

1. Remove center fresh air grill, refer to «64 22 162 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing)
2. Remove ignition key from ignition switch.
3. Pull fuse 63 from distribution box in glovebox.

Release screws (1). Unclip control panel for heater - A/C system (2) with special tool 64 1 020 at retaining points (3) all round and pull back.

Scheme 12

Unlock associated plug connections and disconnect.

Remove control panel for heater - A/C system (2).

Replacement

Carry out programming/coding. Programming/coding is performed with BMW scan tool.

64 11 807 Removing and installing/replacing servodrive for right fresh-air flap

Necessary preliminary tasks

1. Remove right glovebox with housing. See «51 16 360 REMOVING AND INSTALLING RIGHT GLOVE BOX»(ref-202198-S23693868412005102600000) .

Scheme 13

Release screws (1) and remove servomotor (2) complete with bracket.

Scheme 14

Disconnect plug connection (1).

Disengage actuating lever (2) and remove bracket with servomotor (3).

Scheme 15

Replacement

Release lock (1) and remove servomotor (2) from holder.

Installation

Scheme 16

Lug (1) must be adapted to fit in counterpiece (2) on holder.

64 11 992 Removing and installing/replacing solar sensor

Special tools required

1. 64 1 020

Necessary preliminary tasks

1. Remove instrument panel trim, refer to «51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-45-030-removing-and-installing)

Lever out solar sensor (1) with special tool 64 1 020 in direction of arrow.

Scheme 17

Feed wiring harness of solar sensor (1) out of retainers of instrument panel trim (2).

Remove solar sensor (1) from instrument panel trim (2).

Special tools required

1. 51 3 057

Remove HEATER BULKHEAD .

1. Remove «SWITCH UNIT IN CENTER CONSOLE»(/bmw/x3/e83-2003-2006/remont/horns/#general-electrical-system-repair-instructions__61-31-057-removing-and-installingreplacing) .

Remove temperature sensor (1) and disconnect plug connection (2).

Scheme 18

Necessary preliminary work

1. Remove «ACTUATOR DRIVE FOR VENTILATION FLAPS»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair)

Unlock actuator drive (1) and feed out towards side. Disconnect plug connection.

Scheme 19

Installation note

If necessary, align shaft for defroster flaps and drive.

Scheme 20

Replacement

Servomotors must be re-addressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis system.

Service functions

1. Body
2. Heating and air conditioning function
3. Flap motors
4. Re-address flap motors

1. Remove «GLOVEBOX»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-16-361-replacing-right-glovebox)

Unhook adjusting lever (1).

Scheme 21

Disconnect plug connection (1). Unlock actuator drive (2) and feed out towards rear.

Scheme 22

If necessary, align shaft for footwell flap and drive (see illustration).

Scheme 23

Replacement

Servomotors must be re-addressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis system.

Service functions

1. Body
2. Heating and air conditioning function
3. Flap motors
4. Re-address flap motors

1. Remove «trim panel for pedal mechanism»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-45-185-removing-and-installingreplacing) .
2. Remove «lower section of steering column trim»(/bmw/x3/e83-2003-2006/remont/steering-column/#steering-column) .

Note. Heater is removed for purposes of clarity.

Release screw (1).

Unclip adjusting clasp (2) and feed out servomotor (3).

Scheme 24

Replacement

Servomotors must be readdressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis system.

Service functions

1. Body
2. Heating and air conditioning function
3. Flap motors
4. Readdress flap motors

1. Remove «trim panel for pedal mechanism»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-45-185-removing-and-installingreplacing) .
2. Remove «lower section of steering column trim»(/bmw/x3/e83-2003-2006/remont/steering-column/#steering-column)

Note. Heater is removed for purposes of clarity.

Release screw (1).

Unclip adjusting clasp (2) and feed out servomotor (3).

Scheme 25

Replacement

Servomotors must be readdressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis system.

Service functions

1. Body
2. Heating and air conditioning function
3. Flap motors
4. Readdress flap motors

1. Remove «trim panel for pedal mechanism»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-45-185-removing-and-installingreplacing)

Note. Left footwell heating duct removed for purposes of clarity.

Pull out evaporator temperature sensor (1) and disconnect plug connection (2).

Installation

Ensure evaporator temperature sensor (1) is correctly seated.

Scheme 26

1. Remove «MICROFILTER HOUSING»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair)
2. Remove «INSTRUMENT PANEL TRIM»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-45-030-removing-and-installing)

Recycling

Coolant emerges when coolant hoses are detached.

Have a suitable collecting container ready.

Catch and dispose of escaping coolant.

Observe country-specific waste-disposal regulations.

Detach hot water hoses (1) from heater and blow coolant out of heater core.

Scheme 27

Note. For purposes of clarity, the following operations are shown on the removed heater core.

Pull out temperature sensor (1) and unclip wiring harness (2) from holder.

Installation

Ensure correct lead routing.

Scheme 28

Release screw (1) and remove bracket (2) from double pipe.

Unclip retainers (3) and lift off cover for heating element (4).

Installation

First insert lugs (5).

Scheme 29

Remove retainers (1) and remove double pipe (2) towards top.

Raise heater core (3) at front and remove.

Installation

Replace sealing rings, coat with anti-friction agent and make sure sealing rings and lines are correctly seated.

Scheme 30

After installation

1. «VENT COOLING SYSTEM»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54__17-00-039-venting-cooling-system) and check for water leaks

1. Remove «servodrive for right fresh-air flap»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-807-removing-and-installingreplacing) .

Release catch (1) and pull output stage (2) out of heater.

Scheme 31

Disconnect plug connection (1) and remove output stage (2).

Scheme 32

1. Remove complete «GLOVEBOX»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-16-361-replacing-right-glovebox)

Move rotary knob (1) into position illustrated.

Scheme 33

Disconnect plug connection (1).

Unlock servo-drive (2) and remove towards bottom.

Scheme 34

Installation

If necessary, align shaft for defrosting flaps and drive (see illustration).

Scheme 35

64 11 273 Replacing water valve for heater

Coolant emerges when coolant lines are detached. Have a suitable collecting container ready.

Catch and dispose of emerging coolant.

Observe country-specific waste-disposal regulations.

Disconnect plug connection (1).

Disconnect coolant hoses (2) from water valve and remove.

Installation

Observe direction of flow.

Scheme 36

Installation

Make sure rubber mounts (1) are correctly seated in mountings (2).

Scheme 37

After installation

1. Fill and «VENT COOLING SYSTEM»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54__17-00-039-venting-cooling-system) and check for leaks

64 22 135 Removing and installing/replacing left fresh-air grill

Special tools required

1. 00 9 341

Fit special tool 00 9 341 at side as illustrated.

Scheme 38

Lever out left fresh-air grill (1) all round and remove in direction of arrow.

64 22 136 Removing and installing/replacing right fresh-air grill

Special tools required

1. 00 9 318

Unclip right fresh-air grill (1) with special tool 00 9 318 and remove in direction of arrow.

Scheme 39

Installation

Catches (1) on fresh-air grill (2) must not be damaged or missing.

Scheme 40

64 22 162 removing and installing/replacing center fresh-air grill

Special tools required

1. 64 1 020

Necessary preliminary tasks

1. Remove switch for hazard warning system/central locking, refer to «61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING FLASHERS/CENTRAL LOCKING»(/bmw/x3/e83-2003-2006/remont/horns/#general-electrical-system-repair-instructions__61-31-079-removing-and-installingreplacing)

Fit special tool 64 1 020 at lower attachment points (1).

Scheme 41

Lever out center fresh-air grill (2) and pull back.

Unclip Bowden cable (3) and remove center fresh-air grill (2).

64 31 010 Replacing microfilter for interior ventilation

Turn toggle (1) through approx. 90 ° and remove cover (2) towards front.

Scheme 42

Remove microfilter element (1).

Scheme 43

1. Remove MICROFILTER.
2. Remove cable duct cover.

Release screws (1).

Remove lines from cable duct (2).

Feed microfilter housing (3) upwards in direction of arrow.

Scheme 44

Installation

Make sure water drain hoses (1) are correctly seated.

Scheme 45

64 31 010 Replacing microfilter for interior ventilation (Version 1)

Note on cleaning

Spray microfilter housing from inside with BMW pollen filter housing cleaner (observe instructions for use).

COMPLY with notes and instructions on handling cleaning agents!

Wipe away excess fluid.

This kills off germs, bacteria and fungi that cause smells.

The smell that results on the plastic parts of the microfilter housing is eliminated.

Sourcing reference: BMW Parts

Department

Unlock screw caps (1), raise lid (2) and remove microfilter element.

Scheme 46

64 31 010 Replacing microfilter for interior ventilation (Version 2)

Turn toggle (1) through approx. 90 ° and remove cover (2) towards front.

Scheme 47

Remove microfilter element (1).

Scheme 48

64 50... Air conditioner test (R 134a)

Before A/C efficiency test, satisfy following conditions

1. Provide a MoDiC or DIS.
2. Provide a thermometer with separate gauge.
3. Compressor load (intake air temperature of approx. 50 °C)

Re 1

Connect MoDiC or DIS to car and display evaporator temperature.

Re 2

Position a thermometer with a separate gauge approx. 5 cm below the roofliner at the height of the B-pillar. Lay gauge outwards out of vehicle interior.

Re 3

Heating up vehicle interior

1. A/C button is not activated during heating up.
2. Close all windows and doors.
3. Set recirculated air mode.
4. Select air distribution mode for footwell and defrosting.
5. Maximum temperature setting.
6. Maximum fan stage.
7. Run engine at approx. 2000 RPM.

A/C efficiency test

Turn on A/C compressor at a vehicle interior temperature of 50° Celsius.

After 2 -3 minutes, evaporator sensor temperature must be 10° Celsius.

Draw off a/c system if this temperature is not reached. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) . Measure amount of refrigerant drawn off.

If drawn-off quantity does not correspond to specified an quantity: replenish refrigerant.

If refrigerant quantity is correct fill a/c system. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Note. A/C systems with uncontrolled compressors only: If necessary, then continue troubleshooting by pressure measurement.

64 50... Leak-testing with leak tester device

Carry out leak-testing with a leak tester device from the workshop equipment catalog following the device manufacturer's operating instructions.

If leaks not to be localized are already identified during evacuation, the A/C system must nevertheless be filled. Then test for leaks with leak tester device.

Note. Refrigerant is heavier than air. Therefore always conduct the leak test below the lines and components to be tested. Shield lines and components against strong blasts of air (wind, drawing off).

Tighten down loose lines, mark leaks.

Then draw off draw off A/C system and seal off or repair leakage points. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Then refill A/C system and test for leaks. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

64 50... Safety instructions for handling refrigerant r 134a

The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the A/C system, it is absolutely essential to draw off the refrigerant.

Do not weld or solder on filled A/C systems or in rooms into which R 134a may have leaked. Exposure to flames or high temperatures "GREATER THAN EQUALS TO" 50°C) may give rise to toxic decomposition products (fluorine gas). For this reason, do not smoke either.

R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant operating instructions.

Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the refrigerant circuit. R 134a acting on the skin can cause frostbite. Wash off thoroughly with cold water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact lenses if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you experience problems after inhaling R 134a fumes.

As a gas, R 134a is colorless, odorless and heavier than air. If it gets into the atmosphere, this may result especially in workshop pits in an imperceptible danger of asphyxiation or in cardiac palpitations. Ventilate rooms adequately; if necessary, turn on installed extractor systems.

For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from refrigerant circuit) before each filling of the A/C system.

R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and drier bottle immediately with plugs.

With replacement parts, the plugs may only be removed immediately before the lines are connected.

In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of the damage.

If an A/C system has been completely drained by leakage, accident or repair, the drier element must be replace as excessive moisture may have entered the system.

Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat sources (max. 45 °C). Also avoid exposing them to mechanical stress (e.g. by dropping).

In the event of fire, carbon dioxide (CO2), extinguishant powder and a sprayed water jet are deemed to be suitable extinguishants. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).

64 50... Safety precautions when handling refrigerant oil (for refrigerant r 134a)

Recycling

Dispose of drawn-off refrigerant oil as hazardous waste.

Observe country-specific waste-disposal regulations.

Absorb escaping refrigerant oil with fluid-binding material.

Notify the relevant authorities if larger amounts of refrigerant oil are discharged into above-ground water supplies, drainage systems or subsoil.

64 50 009 Drawing off, evacuating and filling a/c system (r 134a)

Restart engine only when A/C system has been correctly filled.

Note. Draw off, evacuate and fill A/C System in accordance with the operating instructions of the relevant service station.

E60 only

If necessary, to connect service station, use manufacturer's adapter for high-pressure connection (red).

Instructions for drawing off A/C system

To help separation of refrigerant and refrigerant oil, run engine at low speed (800-1200 RPM) and with A/C system turned on for a few minutes.

The limits the entertainment of refrigerant oil while it is drawn off.

Drawn-off refrigerant oil must be changed and reintroduced via the service station.

If at the end of the drawing -off procedure the service station moisture indicator shows that the drawn-off refrigerant is excessively moist, clean the refrigerant in accordance with the service station operating instructions.

Recycling

Dispose of drawn-off refrigerant oil as hazardous waste.

Observe country-specific waste-disposal regulations.

Instructions for evacuating off A/C system

The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the A/C system. This enables subsequent system filling with refrigerant.

A decrease in the vacuum level indicates a leak in the refrigerant circuit. Refer to 64 50... LEAK-TESTING WITH LEAK TESTER DEVICE .

Instructions for filling A/C system

Before filling with refrigerant, top up the refrigerant oil entrained during drawing off.

Depending on the type of component replaced on the A/C system, it may be necessary to top up the refrigerant oil, even if no measurable losses have occurred during drawing off. Read and comply with the A/C system manufacturer's notes in this regard and the operating instructions of the relevant service station.

Information on the required refrigerant fill quantity for the entire A/C system is contained on the rating plate (1) in the engine compartment.

Scheme 49

If necessary, refer to HEATING AND AIR CONDITIONING - TECHNICAL DATA for fill quantities.

Installation

Reseal refrigerant filler necks on vehicle with sealing caps.

Special Tools

1. 00 9 030
2. 32 1 270

Attention!

1. Always use new O-rings each time A/C connections are opened (refer to Electronic Parts Catalogue) They must not be coated. Use special tool 00 9 030 to install sealing rings without damaging them.
2. Open the refrigerant circuit for as short of a period as possible.
3. Close all components and lines in the refrigerant circuit and return parts immediately following the removals at openings with special tool 32 1 270 to prevent penetration of moisture or foreign objects.
4. If the refrigerant circuit was closed at the openings with special tool 32 1 270 but it remains open for more than 24 hours, the dryer insert for the air conditioning must be replaced.

I. Part replacement as preliminary work fur further repair work and based on gradual leakage

(minor leak, e.g. hairline crack)

Procedure

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally top up with new refrigerant oil according to components replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 10 ml Capacitor: 20 ml Desiccant insert / dryer flask: 20 ml Each replaced refrigerant line: 10 ml Capacitor with integrated dryer: 40 ml Safety pressure switch and gasket: no additional refrigerant oil
4. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C system

II. Part replacement due to sudden leakage

(major leak, e.g. pipe break due to accident)

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally replace with new refrigerant oil according to parts replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 35 ml Capacitor: 35 ml Desiccant insert / dryer flask: 55 ml Each replaced refrigerant line: 35 ml Capacitor with integrated dryer: 55 ml Safety pressure switch and gasket: no additional refrigerant oil
4. Evacuate and fill «A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 53... Instructions for replacement of air conditioning capacitors and radiator/coolers

This is not damage.

Radiators, cooler or capacitors are not to be replaced in this case.

Note. Deformations can be bent back with a standard fin comb.

Scheme 50

Damage to lines carrying media or on the flat pipe require replacement of the radiator/or air conditioning condenser (picture 2-6).

64 50... Leak detection with forming gas

Note. Leak detection with forming gas replaces the leak detection that is restricted in EU countries using UV.

Observe national regulations in all other countries!

Read and comply with the manufacturer's operating instructions provided with the special tool particularly with regard to accident prevention, health protection and environmental protection.

Only the basic procedure is described in the following!

Note. Determine the customer's use behavior prior to leak detection!

Certain user behaviors can lead to a loss of refrigerant from the refrigerant circuit even if there is no leak. This may occur if the customer has not used the air conditioning for a period of more than six months. This may cause O-rings to harden and refrigerant may escape. In this case, it will be sufficient to top up the refrigerant circuit and switch the air conditioning on for approximately 10 minutes while the engine is running.

1. If components of the refrigerant circuit are contaminated, clean the engine compartment. Otherwise, the sensor head of the leak detector will become contaminated. Comply with notes and instructions on handling high pressure cleaner.
2. Remove «center fresh-air grill»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing)
3. Remove drive belt from A/C compressor
4. Drain off air conditioning system
5. Fill the air conditioning system with forming gas
6. Set pressure to 5 bar

To reach components of the refrigerant circuit with the leak detector, it may be necessary to remove the following parts, depending on the vehicle

1. Covers
2. Trim panels
3. Air duct
4. Intake silencer
5. Bulkheads

With some vehicles, the air flaps of the automatic air flap control (LKS) must be opened.

Forming gas consists of 95% nitrogen and 5% hydrogen. The leak detector will detect hydrogen. If this is leaking from the refrigerant circuit even though the pressure remains, the leak detection bears no results.

Maximum approved pressure: 10 bar

Do not start the engine during the entire procedure!

Scheme 51

Notes for handling the leak detector

1. Sensor head must always stand vertical to the surface to be tested.
2. Sensor head must always be aligned to the centre of the point to be tested. Slowly guide the sensor head around the point (e.g. connection point, sealing surface, etc.).
3. The optimal distance (A) between sensor head and surface to be checked must permanently be approximately 1 mm, maximum distance (B) at points that are difficult to access approximately 5 mm.
4. Test speed may not exceed 2 cm per second.

Note. If the leak detector indicates a leak, remove the sensor head from the leak for approximately 10 seconds. Then check if the leak is still indicated at the same point. Repeat the procedure up to three times to ensure that a leak is actually present at this point.

Note. If a leak is detected in the refrigerant circuit, the remaining points must also be tested! Multiple leaks may be present in the refrigerant circuit.

Note. Replace the leaking component. Relieve the pressure from the refrigerant circuit prior to replacement.

Scheme 52

Overview of points to be checked in test sequence

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Capacitor: Damage caused by stone chipping, etc. is the most frequent cause of capacitor leaks (1): Visual inspection in the area of the ornamental grille (2) and air inlet grille, centre (3). Check damaged points first. Check the remainder of the capacitor. .
2. Connection point capacitor - refrigerant line Check the connection point between the connection at the capacitor (1) and refrigerant lines (2).
3. Expansion valve: Check the connection point between the expansion valve (1) and refrigerant lines (2).
4. A/C compressor: Check the following components on the A/C compressor: High-pressure connection Low pressure connection Pressure relief valve Radial shaft seal of the magnetic coupling: Turn the magnetic coupling several times by hand during the leak detection.
5. Filler neck Blow out the filler neck (1) prior to testing.
6. Refrigerant pressure sensor Check the sealing surface between the refrigerant pressure sensor (1) and the refrigerant line (2).
7. Refrigerant lines: Perform visual inspection Check damaged points first. Check bending points at points marked with an arrow. Leaks occur especially frequently at these points. Check the remainder of the refrigerant line.
8. Evaporator

Compliance with the following settings is absolutely required

Scheme 60

1. Air recirculation function On
2. Lowest blower speed
3. Lowest temperature
4. Set the air distribution to ventilation (air may only flow out of the «center fresh-air grill»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-162-removing-and-installingreplacing) )

Position sensor head (1) in air duct of middle fresh air grille (2) as illustrated and move slowly from inside to outside above and below air flap (3). Carry out this operation on the left and right fresh air grilles.

Following the completed leak detection

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 50... Leak detection with ultraviolet additives (UV additives) (BMW leak-testing case)

Use only BMW-approved UV additives (e.g. TRACER).

Only the basic procedure is described in the following!

Note. Fill the hose system of the hand pump completely with UV additive PRIOR to use Use the UV additive exclusively for refrigerant oil approved by BMW Do not operate the air conditioning system while the hand pump is connected or in use The air conditioning system must always be filled with an adequate amount of refrigerant to enable the leak-detecting agent to be properly distributed

Before actually testing for leaks, check the entire refrigerant circuit using the UV leak detection lamp to ensure that no UV additive is already in the area of the refrigerant circuit.

If already illuminated areas are found, carefully clean the area in question with the cleaning agent contained in the case.

On initial use

Connect hand pump (1) to additive cartridge (2) and hose piece (3).

Scheme 61

On initial use

Attach vent valve (1) to quick-release coupling (2).

Turn handle (3) on hand pump to advance the piston until a small amount of UV additive emerges. This vents the hose system.

Scheme 62

Attach quick-release coupling (1) to low-pressure connection (2) of air conditioning system.

Turn handle on hand pump (3) until the required amount of UV additive is added.

The quantity of UV additive to be added is dependent on the amount of refrigerant in the refrigerant circuit

Scheme 63

1. Air conditioning systems with refrigerant filling up to 900 g: one graduation mark (4) on additive cartridge
2. Air conditioning systems with refrigerant filling in excess of 900 g: two graduation marks (4) on additive cartridge

Note. After filling, remove quick-release coupling (1) and if necessary use the cleaning agent contained in the special tool case to clean up the UV additive.

Further tasks

1. Start engine
2. Run air conditioning system at highest stage for 5 - 10 minutes in order to ensure adequate distribution of dye in the system
3. Turn off engine.
4. Check all air conditioning system components for possible leaks
5. Possible leaks show up in luminous green

Complete accompanying information label (1) with the relevant data and attach in an easily visible position next to the filling capacity information label (2).

Scheme 64

64 50... Safety informations for handling refrigerant oil

Protective measures/rules of conduct

1. Wear safety goggles
2. Wear oil-resistant protective gloves
3. Do not smoke!
4. Observe country-specific safety regulations.

First aid measures

1. If swallowed: Do NOT induce vomiting, unless expressly instructed to do so by medical personnel. Do not administer anything to an unconscious person through their mouth. Consult a doctor immediately if larger quantities of this substance are swallowed. Loosen tight-fitting items of clothing (e.g. collar, tie, belt or similar).
2. Eye contact: Remove contact lenses if worn. In the event of eye contact, rinse eyes for at least 15 minutes with plenty of water. It is essential to use WARM WATER. Consult a doctor.
3. Skin contact: In the event of skin contact, rinse immediately with plenty of water. Remove contaminated clothes and shoes. Wash affected clothes before wearing again. Clean shoes thoroughly before reusing. Call for a doctor .
4. After inhalation: If inhaled, take the person affected outside into fresh air immediately and keep them under supervision. Call for a doctor . If breathing difficulties are experienced, administer additional oxygen. If the person affected stops breathing, administer the kiss of life.

Catch and dispose of emerging refrigerant oil.

Observe country-specific waste disposal regulations.

64 50... Safety informations for handling tetrafluorethane refrigerant R134a

1. Wear safety goggles
2. Wear oil-resistant protective gloves
3. Do not smoke!
4. Observe country-specific safety regulations.

1. Eye contact: In the event of contact with the eyes, rinse immediately with plenty of running water and consult an ophthalmologist.
2. Skin contact: In the event of contact with skin, remove affected clothing immediately and rinse with plenty of water.
3. After inhalation: If refrigerant vapors are inhaled in greater concentrations, remove the person affected to an area of fresh air and keep them under supervision. Consult a doctor. If breathing problems are experienced, breathe additional oxygen. If the person affected is breathing with difficulty or has stopped breathing, incline the person's head at the neck and administer the kiss of life.

64 51 522 Removing and installing or replacing expansion valve

Necessary preliminary tasks

1. Draw off A/C system. Refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A)»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) .
2. Remove heater bulkhead. Refer to «51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-71-080-removing-and-installingreplacing) .

Unfasten nut.

Scheme 65

Installation

Tightening torque 64 53 10AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Unfasten screws.

Detach refrigerant lines in direction of arrow.

Scheme 66

Installation

Replace sealing rings.

Tightening torque 64 53 2AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

If necessary, pull lock (1) in direction of arrow and feed out flap (2).

Scheme 67

Unscrew nut (1).

Scheme 68

Installation

Replace sealing rings.

Tightening torque 64 53 11AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Detach double pipe (2) in direction of arrow and lay to one side.

Unfasten screws.

Scheme 69

Installation

Replace sealing rings.

Tightening torque 64 53 9AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Pull out expansion valve in direction of arrow.

1. 00 9 030
2. 32 1 270

Attention!

1. Always use new O-rings each time A/C connections are opened (refer to Electronic Parts Catalogue) They must not be coated. Use special tool 00 9 030 to install sealing rings without damaging them.
2. Open the refrigerant circuit for as short of a period as possible.
3. Close all components and lines in the refrigerant circuit and return parts immediately following the removals at openings with special tool 32 1 270 to prevent penetration of moisture or foreign objects.
4. If the refrigerant circuit was closed at the openings with special tool 32 1 270 but it remains open for more than 24 hours, the dryer insert for the air conditioning must be replaced.

(minor leak, e.g. hairline crack)

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally top up with new refrigerant oil according to components replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 10 ml Capacitor: 20 ml Desiccant insert / dryer flask: 20 ml Each replaced refrigerant line: 10 ml Capacitor with integrated dryer: 40 ml Safety pressure switch and gasket: no additional refrigerant oil
4. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C system

(major leak, e.g. pipe break due to accident)

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally replace with new refrigerant oil according to parts replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 35 ml Capacitor: 35 ml Desiccant insert / dryer flask: 55 ml Each replaced refrigerant line: 35 ml Capacitor with integrated dryer: 55 ml Safety pressure switch and gasket: no additional refrigerant oil
4. Evacuate and fill «A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 51... Leak-testing condenser

Special tools required

1. 00 9 030
2. 64 5 121
3. 64 5 122
4. 64 5 123

1. Drain off «A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)
2. Detach refrigerant lines from condenser

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

E70 only

Tightening torque 64 53 3AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 70

Fit and secure sealing adapter 64 5 123 to connection of low-pressure line.

Fit and secure test adapter 64 5 122 to connection of high-pressure line.

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

E70 only

Tightening torque 64 53 3AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 71

Connect special tool 64 5 122 to special tool 64 5 121 .

Scheme 72

Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5 121 (connecting hose).

Note. Testing apparatus must be leakproof. Ambient temperature and temperature of vehicle must not change during the test procedure. Do not move the vehicle during this period

Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.

Check leak-tightness of testing apparatus and of connection to refrigerant line.

Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar over a test period of 1.5 hours.

If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the condenser unit.

After leak-testing

1. Replace sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging them.
2. Assemble A/C system
3. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C system

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Remove «HEATER BULKHEAD»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-71-080-removing-and-installingreplacing) .

Unfasten nut.

Scheme 73

Installation

Tightening torque 64 53 10AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Release screws.

Detach refrigerant lines in direction of arrow.

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 2AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 74

If necessary, pull lock (1) in direction of arrow and feed out flap (2).

Scheme 75

Slacken nut (1).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 11AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Detach double pipe (2) in direction of arrow and lay to one side.

Scheme 76

Release screws.

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 9AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Pull out expansion valve in direction of arrow.

Scheme 77

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 51 590 Removing and installing/renewing evaporator

Remove HEATING ELEMENT .

Remove output stage/switch for heater - A/C system blower .

Withdraw temperature sensor (1).

Disconnect plug connection (2).

Unclip linkage (3) at actuator drive.

Scheme 78

Unlock and remove actuator drive (1) and disconnect plug connection.

Release screw (2).

Unlock plate (3) (see detail) and remove.

Installation note

First insert tabs (4).

Unclip wiring harness.

Scheme 79

Twist cam disc (1) until microswitch (2) is unclipped and can be pulled off.

Scheme 80

Release screws on blower housing.

Lift off blower housing (1) and feed out double pipe (2).

Installation note

Ensure correct cable routing.

Scheme 81

Unclip clamps (1) and remove lower housing section (2).

Scheme 82

Remove evaporator (1).

Only replace

expansion valve .

Scheme 83

If necessary, clean or straighten cooling fins with slat comb.

64 52... Instructions for compressor replacement

1. Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with base).
2. Return faulty compressors in their original packaging only.

1. Switch on A/C system
2. Set all air vents in instrument cluster to "OPEN"
3. Start engine and let it stabilize at idle speed
4. Set blower output to min. 75% of max. blower output
5. Switch on A/C system and run for at least 2 minutes at idle speed (risk of damage at higher speed!)

When evacuating the air-conditioning system, refrigerant oil is also extracted and collected in the oil separator of the service station.

Scheme 84

After evacuation, the refrigerant must be filtered in the service station as the oil separator could still contain a liquid refrigerant/oil mixture. The filtering process gasifies the refrigerant completely and only the previously bound refrigerant oil remains in the oil separator. Measure and note down this quantity of refrigerant oil

refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Transfer the refrigerant oil remaining in the previous compressor via the filler plug completely into a measuring container.

Scheme 85

Measure the amount of refrigerant oil collected from the previous compressor.

Scheme 86

Depending on its design, the new compressor is filled at the factory with 120 to 200 g refrigerant oil. Open filler plug and pour entire contents of compressor into a clean container.

Scheme 87

Installation

If necessary, replace gasket.

Observe tightening torque, 64 52 2AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

From this refrigerant oil, pour the same amount (as drained from the previous compressor) + 10 g extra into a clean measuring container and pour again into the new compressor.

Scheme 88

Remaining refrigerant oil can be poured into service station tank

refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Otherwise the excess refrigerant oil must be disposed of correctly.

On account of its hygroscopic properties, refrigerant oil must not be stored in open containers.

The refrigerant oil drawn off from the oil separator of the service station and from the previous compressor must not be reused and must be correctly disposed of.

Scheme 89

After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the previously drawn off refrigerant oil into the system again

refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Scheme 90

Installation

If A/C system is opened for more than 24 hours: Replace drier bottle/drier insert.

1. 00 9 030
2. 32 1 270

Attention!

1. Always use new O-rings each time A/C connections are opened (refer to Electronic Parts Catalogue) They must not be coated. Use special tool 00 9 030 to install sealing rings without damaging them.
2. Open the refrigerant circuit for as short of a period as possible.
3. Close all components and lines in the refrigerant circuit and return parts immediately following the removals at openings with special tool 32 1 270 to prevent penetration of moisture or foreign objects.
4. If the refrigerant circuit was closed at the openings with special tool 32 1 270 but it remains open for more than 24 hours, the dryer insert for the air conditioning must be replaced.

(minor leak, e.g. hairline crack)

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally top up with new refrigerant oil according to components replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 10 ml Capacitor: 20 ml Desiccant insert / dryer flask: 20 ml Each replaced refrigerant line: 10 ml Capacitor with integrated dryer: 40 ml Safety pressure switch and gasket: no additional refrigerant oil
4. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C system

(major leak, e.g. pipe break due to accident)

1. «DRAW OFF»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) heating and air conditioning system, then determine drawn-off amount of refrigerant
2. Carry out part replacement
3. Replace removed refrigerant oil and additionally replace with new refrigerant oil according to parts replaced: Compressor: refer to «NOTES ON COMPRESSOR REPLACEMENT»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-52-instructions-for-compressor-replacement) Evaporator: 35 ml Capacitor: 35 ml Desiccant insert / dryer flask: 55 ml Each replaced refrigerant line: 35 ml Capacitor with integrated dryer: 55 ml Safety pressure switch and gasket: no additional refrigerant oil
4. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C SYSTEM

64 53 550 Removing and installing or replacing capacitor for the heating and air conditioning system

Note. Follow Instructions for opening and replacing parts in refrigerant circuit. If Air conditioning system is opened for more than 24 hours: Replacing desiccant insert for air conditioning system

1. «DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this job item
2. Remove «RADIATOR»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54)

Release screws (1) and remove refrigerant lines.

Installation note

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Replace all sealing rings and moisten with refrigerant oil.

Scheme 91

Release screw (2) and remove the spacers (3).

Release retaining clip (4) and remove capacitor (5).

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)
2. Fill and «VENT COOLING SYSTEM»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54__17-00-039-venting-cooling-system) and check for leaks

64 52 523 Replacing A/C system compressor (M54, M57)

Special tools required

1. 32 1 270

Follow Instructions for opening and replacing parts in refrigerant circuit.

If A/C system is opened for more than 24 hours

Replace dryer bottle/insert

All

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Remove front underbody protection

Only M57

1. Remove pressure pipe

M54 only

1. Release coolant expansion tank, disconnect plug connection and place coolant expansion tank to one side

Version with Dynamic Drive

Do not release pressure lines on active stabilizer.

Press lock (1) on distributor (2) and detach vent line (3) in direction of arrow.

Installation

Make sure vent line (3) is correctly seated in distributor (2).

Lower stabilizer on front axle.

Scheme 92

Version with Dynamic Drive

Release nuts (1) and (2).

Remove retaining fixture (3).

Installation

Make sure retaining fixture (3) is correctly seated.

Scheme 93

All

Disconnect plug connection (1).

Release screws (2).

Detach refrigerant lines (3) in direction of arrow.

Installation

Tightening torque 64 52 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Replace all sealing rings and moisten with refrigerant oil.

Scheme 94

All

Note. Secure A/C compressor (2) against falling out.

Release bolts (1).

Feed out A/C compressor (2) in direction of arrow.

Scheme 95

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 53... Notes on replacing drier bottle or drier insert

The drier bottle or drier insert does not have to be replaced at regular service intervals in a functioning, leakproof A/C system.

However, the drier bottle or drier insert must be replaced without fail in the event of

1. fouling of the refrigerant by filings/shavings (e.g. when the compressor is clamped)
2. a leaking A/C system or loss of refrigerant
3. the refrigerant circuit being opened for a period exceeding 24 hours, e.g. during repair work.

64 53 510 Removing and installing/replacing dryer bottle for air conditioner

Note. The time value given for this work operation does not include drawing off, evacuating and filling the A/C system!

Drain off air conditioner. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Necessary preliminary tasks

1. Release fluid reservoir for windscreen washer system and place to one side, refer to «61 71 061 REPLACING FLUID RESERVOIR FOR WINDSHEILD WASHER SYSTEM»(/bmw/x3/e83-2003-2006/remont/horns/#general-electrical-system-repair-instructions__61-71-061-replacing-fluid-reservoir)
2. Partially detach front right wheel arch trim, refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH TRIM»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-71-040-removing-and-installingreplacing)

Release screws (1) and remove refrigerant lines (2).

Scheme 96

Installation

Replace all sealing rings.

Slacken screws (1) and lift out dryer bottle (2) in direction of arrow.

Scheme 97

Disconnect plug connection (3).

Installation

Make sure dryer bottle is securely seated.

64 53 520 Replacing safety pressure switch

Note. The time value given for this work operation does not include drawing off, evacuating and filling the A/C system!

Drain off air conditioner. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .

Note. If A/C system is opened for more than 24 hours: Replace desiccant insert for A/C system, refer to 64 53 510 REMOVING AND INSTALLING/REPLACING DRYER BOTTLE FOR AIR CONDITIONER .

Necessary preliminary tasks

1. Release fluid reservoir for windscreen washer system and place to one side. Refer to «61 71 061 REPLACING FLUID RESERVOIR FOR WINDSHEILD WASHER SYSTEM»(/bmw/x3/e83-2003-2006/remont/horns/#general-electrical-system-repair-instructions__61-71-061-replacing-fluid-reservoir) .

Disconnect plug connection (1). Release safety pressure switch (2), tightening torque 64 53 13AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Scheme 98

This is not damage.

Radiators, cooler or capacitors are not to be replaced in this case.

Note. The deformations can be bent back with a standard fin comb.

Damage to lines carrying media or on the flat pipe require replacement of the radiator/or air conditioning condenser (picture 2-6).

Scheme 99

Note. Follow Instructions for opening and replacing parts in refrigerant circuit. If Air conditioning system is opened for more than 24 hours: Replacing desiccant insert for air conditioning system

1. «DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this job item
2. Remove «RADIATOR»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54)

Release screws (1) and remove refrigerant lines.

Installation note

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Replace all sealing rings and moisten with refrigerant oil.

Release screw (2) and remove the spacers (3).

Release retaining clip (4) and remove capacitor (5).

Scheme 100

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)
2. Fill and «VENT COOLING SYSTEM»(/bmw/x3/e83-2003-2006/remont/cooling-system-mechanical/#cooling-system-repair-instructions-m54__17-00-039-venting-cooling-system) and check for leaks

64 53 510 Removing and installing/replacing dryer flask for heating and air conditioning system

Note. Follow Instructions for opening and replacing parts in refrigerant circuit. If air conditioning system is opened for more than 24 hours: Replace desiccant insert for heating and air conditioning system.

1. «DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this job item
2. Release fluid reservoir for windscreen washer system and place to one side

Release screws (1) and remove refrigerant lines (2).

Installation note

Replace all sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 101

Partially remove front right wheel arch cover .

Slacken screws (1) and remove the dryer flask (2) towards top.

Disconnect plug connection (3).

Installation note

Make sure dryer flask is securely seated.

Scheme 102

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)
2. If necessary, top up fluid reservoir for windscreen washer system

64 53 641 Replacing line from compressor to condenser (N47)

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Remove intake filter housing

Release screw (1).

Remove refrigerant line (2).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 52 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 103

Expose refrigerant line up to connection on condenser.

Release screw (1).

Remove refrigerant line (2) and feed out completely.

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 2AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 104

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C SYSTEM

64 53 645 Replacing line from condenser to desiccant bottle (N47)

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Remove intake filter housing
3. Remove fluid reservoir for windscreen washer system

Release screw (1) and remove refrigerant line (2).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 105

Release screw (1) and remove refrigerant line (2).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 106

1. Evacuate and «FILL A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

64 53 681 Replacing line from desiccant bottle to evaporator (N47)

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. If necessary, «Remove microfilter housing»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair)
3. Remove acoustic cover at front
4. Remove fluid reservoir for windscreen washer system

Release screws (1) and remove refrigerant line.

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 6AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 107

Expose refrigerant line up to desiccant bottle connection.

Release screw (1).

Remove refrigerant line (2) and disconnect associated plug connection.

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Replacement

Modify safety pressure switch .

Scheme 108

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C System

64 53 701 Replacing line from evaporator to compressor (N47)

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Remove intake filter housing
3. Remove acoustic cover at front
4. Partially remove pressure pipe

Release screw (1).

Remove refrigerant line (2).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 52 1AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 109

Expose refrigerant line up to connection on expansion valve.

Release screw (1).

Remove refrigerant line (2) from holder (3) and feed out completely.

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 2AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 110

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C System

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation
2. Release fluid reservoir for windscreen washer system and place to one side

Disconnect plug connection (1).

Release safety pressure switch (2).

Tightening torque 64 53 13AZ . Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES

Scheme 111

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C System
2. If necessary, top up fluid reservoir for windscreen washer unit

64 53... Replacing valve insert for refrigerant line

Note. The special tool is available under BMW order number: 81 34 0 427 679 from the BMW workshop equipment catalogue.

1. «DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) are not included in the time value given for this work operation

Twist valve insert out of filler neck (2) with remover (1).

Installation

Screw in valve insert hand-tight only.

Scheme 112

1. «EVACUATE AND FILL»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C System
2. Check leak-tightness of valve insert with soapy solution

In event of leakage

1. «EVACUATE»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) A/C system
2. Check sealing faces on line and valve insert for damage, replace line or valve insert if necessary
3. If necessary, carry out «LEAK DETECTION»(/bmw/x3/e83-2003-2006/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-leak-detection-with-ultraviolet)

See also:
• INSTRUMENT PANEL TRIM
• VENT COOLING SYSTEM
• 51 71 080 REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD
• 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• GLOVEBOX
• SWITCH UNIT IN CENTER CONSOLE
• trim panel for pedal mechanism
• lower section of steering column trim
• INSTRUCTIONS
• 61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING FLASHERS/CENTRAL LOCKING
• HEATING AND AIR CONDITIONING - TECHNICAL DATA
• HEATING AND AIR CONDITIONING - TIGHTENING TORQUES
• RADIATOR
• 61 71 061 REPLACING FLUID RESERVOIR FOR WINDSHEILD WASHER SYSTEM
• 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH TRIM
• Removing and installing/replacing servodrive for right fresh-air flap
• CENTER FRESH-AIR GRILL
• ACTUATOR DRIVE FOR VENTILATION FLAPS
• 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A)
• HANDLING REFRIGERANT OIL
• 64 50... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R 134a
• 64 50... LEAK-TESTING WITH LEAK TESTER DEVICE
• TETRAFLUORETHANE REFRIGERANT R134A
• NOTES ON COMPRESSOR REPLACEMENT
• dryer bottle/insert
• HEATING ELEMENT
• LEAK DETECTION