A/c-Heater System: Removal & Installation BMW Z3 E36 рестайлинг

REMOVAL & INSTALLATION

Note. Drier bottle or drier insert does not have to be replaced at regular service intervals in a functioning, leakproof A/C system. However, they must be replaced without fail in the event of: Fouling of refrigerant by filings/shavings (for instance when compressor is seized). Leaking A/C system or loss of refrigerant. Refrigerant circuit being opened for a period exceeding 24 hours.

1. Remove both wiper arms. Remove rubber seal (1) from beside protective grill (2). (Scheme 1) Remove rubber seal from protective grill. Unfasten all expanding rivets and remove protective grill.
2. Unfasten clips and remove hoses. (Scheme 2) Carefully blow air into intake line to remove residual water from heater core.
3. Remove screws from heater. (Scheme 3)
4. Remove trim from instrument panel. Unfasten screws on reinforcement pipe and cut cable tie. (Scheme 4)
5. Unfasten screws and remove front bracket. (Scheme 5)
6. Unfasten left and right screws and remove reinforcement pipe.
7. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
8. Unfasten nuts for evaporator connection in engine compartment. (Scheme 6)
9. Unfasten screws from bracket (1) and remove bracket. (Scheme 7) Unfasten screw (2) and take double pipe off expansion valve. Remove left and right drain hoses (3).
10. Unfasten screws (1) and place air bag control unit to one side. (Scheme 8) Unfasten screws (2), remove bracket and lift out A/C-heater unit.
11. To install, reverse removal procedure. Replace "O"rings. Tighten screws on double pipe to specification. See «TORQUE SPECIFICATIONS»(ref-98957-S35257280572004030500000).
12. Evacuate, charge, and leak test A/C system. Fill and bleed cooling system.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Remove lower left trim for instrument panel. Unclip regulator for evaporator and remove connector. (Scheme 9)
2. Unfasten screw and unclip left footwell air outlet. Unfasten screws and remove connector.
3. Press actuator drive slightly downwards and unclip actuating lever.
4. To install, reverse removal procedure. Press actuating lever into shaft until it is heard to engage, then tighten down actuator drive.

Scheme 9

Remove windshield wiper assembly. Unfasten clamping straps and remove fan cover. (Scheme 10) Remove fan resistor. (Scheme 11) Disconnect fan electrical connector. Unclip fan retaining bracket. Lift out blower motor. To install, reverse removal procedure.

Scheme 10

Scheme 11

1. Unclip radio covers (3), if so equipped, and remove. (Scheme 12) Press unlocking hooks (1) into radio on left and right sides. Pull out radio carefully with hooks. Remove harness connector.
2. Remove shift lever. Remove screws on left and right side of console. Lift out parking brake rubber gaiter. Pull finisher strip (1) about 0.2 inch (5 mm) backwards and remove upwards. (Scheme 13)
3. Lift off finisher caps (1) and unfasten left and right screws. (Scheme 14) Unfasten screws inside top of radio opening.
4. Unclip shift-lever cover. Remove insulation sheet. Carefully press switches downward and remove from trim. Disconnect harness connector. On Z3, release screws and remove clock. On M Roadster, loosen union nut of external temperature display and clock through radio aperture and press display out forwards. On all vehicles, mark connectors and pull off.
5. Unfasten left and right screws. Unclip heater controls and slide inwards. (Scheme 15)
6. Lift center console at rear a little while pulling towards rear until guides at front are fed out. Disconnect plug connection and light for cigarette lighter. On Z3, disconnect plug connection for clock/on-board computer. On all vehicles, push center console forwards at an angle and guide over parking brake lever. Remove center console from vehicle.
7. To install, reverse removal procedure. On M Roadster, to install clock and outside temperature display, larger distance between edge and threading of union nut faces display. Install display vertically and brace union nut while tightening.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Removal & Installation (M Coupe & Roadster)

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Remove front splash guard.
3. Remove compressor drive belt.
4. Release push-button (1). (Scheme 16) Remove fluid tank (2) towards top and place to one side.
5. Release expansion rivet (1). (Scheme 17) Lift out air duct on right (2).
6. Disconnect harness connector (1) in direction of arrow. (Scheme 18) Loosen screws (2). Remove lines (3 and 4).
7. Secure compressor against falling out. Remove screws and remove A/C compressor.
8. To install, reverse removal procedure. Replace sealing rings. Ensure air duct is correctly seated in mount. Ensure fluid tank is correctly seated in lower mount. Tighten lines and screws to specification. See «TORQUE SPECIFICATIONS»(ref-98957-S35257280572004030500000).
9. Evacuate, charge, and leak test A/C system.
10. If replacing compressor, observe the following break-in procedure: Set all air vents in instrument cluster to open. Start engine and let it stabilize at idle speed. Set blower output to a minimum of 75 percent of maximum blower output. Switch on A/C system and run for at least 2 minutes at idle speed. Risk of damage at higher speed.

Scheme 16

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Scheme 18

Removal & Installation (Z3)

Information is not available from manufacturer at this time.

Removal & Installation (Seiko-Seiki)

1. If necessary, remove underbody protection and drive belt.
2. Remove compressor. See «COMPRESSOR»(ref-98957-S09557308842004030800000).
3. Grip drive plate with special tool (64 5 020) and remove screw (1). (Scheme 19) Remove drive plate.
4. Spread and remove circlip. Remove pulley with a standard three-arm extractor tool. Only fit extractor lugs to joint between magnet coil and pulley to prevent damage to pulley.
5. Spread and remove circlip. (Scheme 20) Disconnect harness connector (2) and remove solenoid coil. Unscrew bolt (1).
6. To install, reverse removal procedure. Carefully drive pulley onto bearing seat with special tool (33 1 020). Check for correct clearance "A" between drive plate and pulley. If necessary, adjust using shims. Clearance should be.020-.031 inch (0.5-0.8 mm). (Scheme 21) Note position of circlips. Bevelled side must point out.

Scheme 19

Scheme 20

Scheme 21

Removal & Installation (Nippondenso)

1. If necessary, remove underbody protection. Remove drive belt.
2. Grip drive plate with special tool (64 5 090) and remove screw (1). (Scheme 22) Remove drive plate.
3. Spread and remove circlip. Remove pulley.
4. Spread and remove circlip. (Scheme 20) Remove screw (1). Disconnect harness connector (2) and remove solenoid coil.
5. To install, reverse removal procedure. Note position of circlips. Bevelled side must point out. Check for correct clearance "A" between drive plate and pulley. If necessary, adjust using shims. Clearance should be.020-.031" (0.5-0.8 mm). (Scheme 21)

Scheme 22

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect A/C hoses for evaporator core in engine compartment. (Scheme 6)
2. Remove lower instrument panel covers. Disconnect A/C pipes from firewall to evaporator core by removing the A/C pipe holder screws and sliding pipes upward with pressure plate. (Scheme 7)
3. Loosen screws and remove evaporator cover. (Scheme 23) Remove evaporator by sliding sideways out of case. Remove expansion valve from evaporator core. (Scheme 24) Drain refrigerant oil from evaporator and measure amount.
4. To install, reverse removal procedure. Replace oil in evaporator with the same amount that was drained. Replace all "O" rings and coat them with refrigerant oil before installation. Evacuate, charge, and leak test A/C system.

Scheme 23

Scheme 24

Remove lower left trim for instrument panel. Unclip regulator for evaporator and remove connector. (Scheme 9) Unclip plug connection from bracket and disconnect. Remove evaporator sensor. (Scheme 25) To install, reverse removal procedure.

Scheme 25

Disconnect heater hose clips. Remove heater hoses. (Scheme 2) Blow out coolant from heater core with compressed air. Remove lower left instrument panel trim. If necessary, remove knee bolster. Remove center console. See CENTER CONSOLE. Disconnect heater hoses from heater core. Remove footwell air duct. Remove heater core screws. Slide out heater core. To install, reverse removal procedure.