Heating and Air Conditioning - Repair BMW Z4 E85/E86

Scheme 1

Scheme 2

64 11... INSTALLING SERVODRIVE

Installation

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

Scheme 3

64 11... Removing and installing/replacing trims on control panel for heater - A/C system

Necessary preliminary tasks

1. Remove control panel for heater - A/C system. Refer to «64 11 377 REMOVING AND INSTALLING (REPLACING) CONTROL PANEL FOR HEATER - A/C SYSTEM»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-377-removing-and-installing) .

Unclip trims on heater - A/C system control panel (1) and (2) and remove in direction of arrow from instrument panel trim (3).

Scheme 4

Installation

Make sure guides (4) are correctly positioned.

Make sure trims (1) and (2) are correctly seated in instrument panel trim (3).

64 11 205 REMOVING AND INSTALLING OR REPLACING HEATER

Necessary preliminary tasks

1. Draw off refrigerant from A/C system. Refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) .
2. Detach lower section of steering spindle from steering column. Refer to «STEERING SPINDLE LOWER SECTION»(/bmw/z4/e85e86-2002-2005/remont/suspension-front/#suspension-front__steering-spindle-lower-section) .
3. Remove trim for instrument panel. Refer to «51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-030-removing-and-installing) .

Release hose clamps (1) and detach coolant hoses (2).

Scheme 5

Installation

Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (M54 / M56) .

Release screws (3) and detach refrigerant lines (4) in direction of arrow.

Installation

Replace sealing rings.

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

Make sure bulkhead grommet is correctly seated.

Necessary preliminary tasks

1. Disconnect all necessary cable ties on support tube.
2. If necessary, disconnect plug connections.

Installation

Make sure wiring harnesses are correctly routed.

Remove screws (1) and (2).

Scheme 6

Installation

Tightening torque 51 71 13AZ.

Release screws (1).

Scheme 7

Pull out current distributor (2) downwards and place to one side.

Installation

Make sure guide (3) is correctly seated in mounting (4).

Unscrew nuts (5).

Installation

Tightening torque 19.5 Nm.

Unscrew nuts (1).

Scheme 8

Installation

Tightening torque 19.5 Nm.

Release screws (1).

Scheme 9

Installation

Tightening torque 19.5 Nm.

Release screws (1).

Installation

Insert screws (1) slightly.

Tighten down screws (1) in sequence (A1-A4) to specified tightening torque 4 Nm.

Scheme 10

Detach support tube (2) and remove from vehicle.

Remove heater (1) in direction of arrow.

Scheme 11

Installation

If necessary, replace seal (2) and seals between heater (1) and bulkhead.

Make sure condensate drain grommet (3) is correctly seated in mounting.

Make sure heater (1) is correctly seated in condensate drain grommet (3).

64 11 208 REPLACING HEATER CORE

Necessary preliminary tasks

1. Remove heater.

Release screw (1).

Scheme 12

Installation

Tightening torque = 10 +/- 2 Nm (64 53 3AZ).

Remove adapter plate (2).

Release screws (3).

Installation

Tightening torque = 1.0 +/- 0.3 Nm (64 11 1AZ).

Remove bulkhead adapter (4).

Withdraw heater element (5) in direction of arrow.

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

Necessary preliminary tasks

1. Remove right glovebox with housing.
2. Remove right footwell channel.
3. If necessary, remove servodrive for footwell flap.

Loosen screws (1).

Scheme 13

Detach current distributor (2) in direction of arrow and lay to one side.

Installation

Make sure guide (3) is correctly seated in mounting (4).

Release screws (1), (2) and (3).

Scheme 14

Remove carrier for current distributor (4).

Unlock plug connections (1), (2) and (3) and disconnect.

Scheme 15

Feed out wiring harness (4) and lay to one side.

Installation

Make sure wiring harness (4) is correctly routed.

Loosen screws (1).

Scheme 16

Installation

Tightening torque = 1.5 +/- 0.3 Nm (64 11 2AZ).

Take out fan for heater/air conditioner (2) in direction of arrow and remove to bottom right.

Installation

Make sure fan for heater/air conditioner (2) is correctly seated.

64 11 225 REPLACING CONTROLLER FOR HEATER - A/C FAN

Necessary preliminary tasks

1. Remove radio receiver.
2. Remove right glovebox with housing.

Unclip right footwell channel (1).

Scheme 17

Installation

Make sure right footwell channel (1) is correctly seated in retainer (2).

Unclip right footwell channel (1) and remove in direction of arrow.

Scheme 18

Installation

Make sure right footwell channel (1) is correctly seated in retainer (2).

Unlock plug connection (1) and disconnect.

Scheme 19

Release screw (2).

Installation

Tightening torque = 1.0 +/- 0.3 Nm (64 11 3AZ).

Pull out controller for heater - A/C fan (3) in direction of arrow.

Installation

Make sure controller for heater - A/C system fan (3) is correctly seated in housing of heater - A/C system.

64 11 377 REMOVING AND INSTALLING (REPLACING) CONTROL PANEL FOR HEATER - A/C SYSTEM

Special tools required

1. 00 9 317

Necessary preliminary tasks

1. Remove radio receiver. Refer to «51 45... REMOVING AND INSTALLING/REPLACING RADIO CUTOUT TRIM»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-removing-and-installingreplacing-radio) and «65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#audio-navigation-anti-theft-and-restraints-repair__65-11-080-removing-and-installingreplacing) .

Lever out cover (1) with special tool 00 9 317 and remove.

Scheme 20

Installation

Make sure cover (1) is correctly seated.

Unlock plug connections (1) and disconnect.

Scheme 21

Loosen screws (2).

Scheme 22

Press out heater - A/C system control panel (2) in direction of arrow (A) and remove through opening (B).

Replacement

Carry out coding/programming.

Observe following IDC specifications

Scheme 23

1. Programming
2. Coding
3. Car & Key Memory
4. CD "CIP"

64 11 806 Removing and installing/replacing servodrive for fresh-/recirculated-air flap

Necessary preliminary tasks

1. Remove trim for instrument panel, bottom right. Refer to «51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL, BOTTOM RIGHT»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-181-removing-and-installingreplacing) .

Unlock plug connection (1) and disconnect.

Scheme 24

Press lock (2) and pull out servodrive for fresh-/recirculated-air flap (3) in direction of arrow.

Installation

Follow repair instruction "Installing servodrive". Refer to 64 11... INSTALLING SERVODRIVE .

64 11 829 Removing and installing/replacing servodrive for ventilation flaps (automatic A/C)

Necessary preliminary tasks

1. Remove right glovebox with housing. Refer to «51 16 367 REMOVING AND INSTALLING RIGHT GLOVE BOX WITH HOUSING (WITH ACTIVE KNEE PROTECTION)»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-367-removing-and-installing) .

Press lock (1) and pull out servodrive for ventilation flaps (2) in direction of arrow.

Scheme 25

Unlock plug connection (3) and disconnect.

Installation

Follow repair instruction "Installing servodrive". Refer to 64 11... INSTALLING SERVODRIVE .

64 11 839 Removing and installing/replacing servodrive for footwell flap (automatic A/C)

Necessary preliminary tasks

1. Remove right glovebox with housing. Refer to «51 16 367 REMOVING AND INSTALLING RIGHT GLOVE BOX WITH HOUSING (WITH ACTIVE KNEE PROTECTION)»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-367-removing-and-installing) .

Unlock plug connection (1) and disconnect.

Scheme 26

Press lock (2) and pull out servodrive for footwell flap (3) in direction of arrow.

Installation

Follow repair instruction "Installing servodrive". Refer to 64 11... INSTALLING SERVODRIVE .

64 11 856 Removing and installing/replacing servodrive for central kinematics (heater - A/C control)

Operation is described in

1. Removing servodrive for defrosting flap (automatic A/C). Refer to «64 11 875 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP (AUTOMATIC A/C)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-875-removing-and-installingreplacing) .

64 11 872 Removing and installing/replacing servodrive for blending flap

Necessary preliminary tasks

1. Remove controller for heater - A/C fan. Refer to «64 11 225 REPLACING CONTROLLER FOR HEATER - A/C FAN»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-225-replacing-controller-for) .

Unlock plug connection (1) and disconnect.

Scheme 27

Press lock (2) and pull out servodrive for blending flap (3) in direction of arrow.

Installation

Follow repair instruction "Installing servodrive". Refer to 64 11... INSTALLING SERVODRIVE .

64 11 875 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP (AUTOMATIC A/C)

Necessary preliminary tasks

1. Remove trim panel for pedal assembly. Refer to «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unclip wiring harness (1) and slide to one side.

Scheme 28

Unfasten plug connection (2) and disconnect.

Press lock (3) and pull out servodrive for defrosting flap (4) in direction of arrow.

Installation

Follow repair instruction "Installing servodrive". Refer to 64 11... INSTALLING SERVODRIVE .

64 11 943 Replacing evaporator temperature sensor

Necessary preliminary tasks

1. Remove AIRBAG module for driver's knee protection. Refer to «REMOVAL & INSTALLATION (DRIVER-SIDE)»(ref-170474-S40488558022005011000000) .
2. Remove radio receiver. Refer to «51 45... REMOVING AND INSTALLING/REPLACING RADIO CUTOUT TRIM»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-removing-and-installingreplacing-radio) and «65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#audio-navigation-anti-theft-and-restraints-repair__65-11-080-removing-and-installingreplacing) .
3. Remove cover. Refer to «64 11 377 REMOVING AND INSTALLING (REPLACING) CONTROL PANEL FOR HEATER - A/C SYSTEM»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-377-removing-and-installing) .

Unlock plug connection (1) and disconnect.

Scheme 29

Unlock socket housing (2) and remove.

Unclip left footwell channel (4).

Scheme 30

Installation

Make sure left footwell channel (4) is correctly seated in retainer (3).

Unclip left footwell channel (1) and remove.

Installation

Make sure left footwell channel (1) is correctly seated in retainer (2).

Pull out holder (1) with evaporator temperature sensor (2) in direction of arrow.

Scheme 31

Installation

Make sure evaporator temperature sensor (2) is correctly seated in holder (1).

Make sure holder (1) is correctly seated in heater - A/C housing.

64 11 949 Replacing temperature sensor for heater

Necessary preliminary tasks

1. Remove radio receiver. Refer to «51 45... REMOVING AND INSTALLING/REPLACING RADIO CUTOUT TRIM»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-removing-and-installingreplacing-radio) and «65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#audio-navigation-anti-theft-and-restraints-repair__65-11-080-removing-and-installingreplacing) .

Turn temperature sensor for heater (1) in direction of arrow through approx. 90° and remove.

Scheme 32

Installation

Make sure temperature sensor for heater (1) is correctly seated.

Unfasten plug connection (2) and disconnect.

64 11 991 Removing and installing/replacing sensor for automatic recirculated air control

Necessary preliminary tasks

1. Remove radiator cover. Refer to «REMOVING RADIATOR COVER»(/bmw/z4/e85e86-2002-2005/remont/cooling-system-mechanical/#cooling-system-repair__removing-radiator-cover) .

Unlock plug connection (1) and disconnect.

Scheme 33

Feed out sensor for automatic recirculated air control (2) in direction of arrow and remove.

Installation

Make sure sensor for automatic recirculated air control (2) is correctly seated.

Scheme 34

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

Remove cap (1).

Scheme 35

Without cup holder

Lever out cover (2) and remove.

With cup holder

Extend cup holder (2).

All

Loosen screws (1).

Scheme 36

Withdraw fresh air grill (2) in direction of arrow.

Replacement (with cup holder)

Release screw (1).

Scheme 37

Detach cup holder (2) in direction of arrow and feed out.

Installation

Make sure cup holder (2) is correctly seated in guide (3).

64 22 161 Removing and installing/replacing center fresh-air grill

Special tools required

1. 00 9 341
2. 64 1 020

Move actuator for center fresh-air grill (1) into illustrated position.

Scheme 38

Turn control wheels for center fresh-air grill (2) in direction of arrow to zero position.

Release locks (1) with special tool 64 1 020 on left and right on center fresh-air grill (2).

Scheme 39

If necessary, gently pretension center fresh-air grill (2) beforehand with special tool 00 9 341 so as to facilitate access to lock (1).

Lever out center fresh-air grill (2) with special tool 00 9 341 and remove in direction of arrow.

Installation

Turn control wheels for center fresh-air grill (2) into zero position.

Scheme 40

Feed guide (1) of center fresh-air grill (2) into mounting (3).

Make center fresh-air grill (2) is correctly seated.

Scheme 41

64 31 010 Replacing microfilter for interior ventilation

Necessary preliminary tasks

1. Remove trim for instrument panel, bottom right. Refer to «51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL, BOTTOM RIGHT»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-181-removing-and-installingreplacing) .

Unlock cover (1), slide in direction of arrow and remove towards bottom.

Scheme 42

Installation

Make sure guides (2) are correctly seated in rails (3).

Pull out microfilter for interior ventilation (1) in direction of arrow.

Scheme 43

Installation

Make sure microfilter for interior ventilation (1) is in correct installation position (flow direction).

Scheme 44

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 fill quantity: replenish refrigerant. Refer to HEATING AND AIR CONDITIONING - TECHNICAL DATA .

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

64 50 ... LEAK-TESTING WITH LEAK TESTER DEVICE

Follow safety precautions when handling refrigerant. Refer to 64 50... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R 134a .

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 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.

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 EQUAL 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)

Action to be taken after contact with refrigerant oil

1. After contact with eyes, rinse thoroughly with plenty of water and take out contact lenses (if worn). Then seek immediate medical attention.
2. After contact with the skin, wash body parts affected with plenty of soap and water.
3. Do not induce vomiting if oil is swallowed, seek immediate medical attention.
4. If inhaled, introduce the person affected to fresh air. Seek medical attention if problems persist.

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)

Follow safety instructions for handling refrigerant R 134a. Refer to 64 50 ... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R 134a .

Follow safety instructions for handling refrigerant oil. Refer to 64 50 ... SAFETY PRECAUTIONS WHEN HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134a) .

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

Note. Draw off, evacuate and fill the 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 internment 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 45

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

Installation

Reseal refrigerant filler necks on vehicle with sealing caps.

Scheme 46

64 51 001 Cleaning evaporator

Special tools required

1. 64 1 490

Note. For information on cleaning agent and rinsing again, refer to Service Information.

For information on spraying equipment, refer to Service Information, Special Tools and Equipment.

1. Close all air vents.
2. Switch heating - A/C system to recirculated-air mode.
3. Cover carpet in work area.

Recycling

Carry out the cleaning operation in a suitable washing bay as the emerging cleaning agent escapes through the drain openings in the transmission tunnel.

After completing cleaning, allow car to drip-dry for approx. 5 minutes.

Necessary preliminary tasks

1. Remove controller for heater - A/C fan, refer to «64 11 225 REPLACING CONTROLLER FOR HEATER - A/C FAN»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-225-replacing-controller-for)

Install special tool 64 1 490 (spraying equipment).

Secure guide (1) in place of controller with screw (2).

Scheme 47

Tightening torque 64 11 3AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Insert spray lance (2) through guide opening (1).

By moving spray lance (2) back and forth, spray a uniform amount of cleaning agent onto evaporator.

Note. Set heating - A/C system to footwell ventilation and fresh-air mode. Open windows/doors.

Start car and run heating - A/C system at maximum fan power for approx. 5 minutes in order to dry evaporator.

In order to eliminate the last remnants of cleaning agent, repeat this procedure shortly before handover to the customer.

64 51 522 Removing and installing or replacing expansion valve

Necessary preliminary tasks

1. Draw off refrigerant from A/C system. Refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) .
2. Follow instructions on replacing dryer bottle. Refer to «64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-53-notes-on-replacing) .

Release screw (1).

Scheme 48

Installation

Tightening torque 64 53 5AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Release screws (2).

Detach refrigerant lines (3) in direction of arrow and press slightly to one side.

Installation

Replace sealing rings.

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

Release screw (1).

Detach adapter plate (2) in direction of arrow.

Scheme 49

Installation

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

Make sure bulkhead grommet (3) is correctly seated in all-round groove of adapter plate (2).

Release screws (1).

Scheme 50

Installation

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

Carefully detach bulkhead grommet (2) from bulkhead and fold down in direction of arrow.

Detach expansion valve (1) in direction of arrow.

Scheme 51

Installation

Replace sealing rings.

Unclip frame (2) from bulkhead and insert in groove (3) of bulkhead grommet (4).

Make sure bulkhead grommet (4) is correctly seated.

64 51 591 Removing and installing/replacing evaporator

Necessary preliminary tasks

1. Remove heater. Refer to «64 11 205 REMOVING AND INSTALLING OR REPLACING HEATER»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-205-removing-and-installing) .
2. Remove bulkhead adapter. Refer to «64 11 208 REPLACING HEATER CORE»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-11-208-replacing-heater-core) .

Feed out cable (1).

Scheme 52

Unclip retainers (2).

Release screw (1).

Scheme 53

Unclip fastening clips (2).

Detach upper housing (3) in direction of arrow and lay to one side.

Release screws (1).

Scheme 54

Installation

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

Remove expansion valve (2).

Installation

Replace sealing rings.

Remove retainer (3).

Remove evaporator (4) in direction of arrow.

Scheme 55

64 52 ... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT

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

Scheme 56

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 57

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

Scheme 58

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 59

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 60

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 61

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 62

Installation

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

64 52 523 Replacing compressor for air conditioner

Necessary preliminary tasks

1. Draw off refrigerant from A/C system. Refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) .
2. Remove fluid tank for windshield washer system. Refer to «61 71 061 REPLACING FLUID RESERVOIR FOR WINDSHIELD WASHER SYSTEM»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-71-061-replacing-fluid-reservoir) .
3. Remove front underbody protection. Refer to «51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-490-removing-and-installingreplacing) .
4. Remove A/C compressor drive belt. Refer to «11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (M52 / S52 / M52TU / M54 / M56)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-28-050-replacing-ac-compressor) .

Disconnect plug connection (1).

Scheme 63

Loosen screws (2).

Detach refrigerant lines (3) in direction of arrow.

Installation

Replace sealing rings.

Tightening torque = 20 Nm.

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

Release screw (1) and remove A/C compressor (2) downwards.

Scheme 64

Installation

Tightening torque = 21.4 Nm.

Scheme 65

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 DRIER FLASK FOR AIR CONDITIONER

Necessary preliminary tasks

1. Draw off refrigerant from A/C system. Refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating) .
2. Follow instructions on replacing dryer bottle. Refer to «64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-53-notes-on-replacing) .

Installation

Observe gap between top edge of dryer bottle (1) and top edge of holder (2)

Scheme 66

1. A=30mm

Note. If the A/C system remains open for longer than one hour, the refrigerant lines must be sealed off with seal plugs.

In event of warranty application, seal line openings with plugs of new dryer bottle.

Loosen screws (1).

Scheme 67

Detach refrigerant lines (2) in direction of arrow and press slightly to one side.

Installation

Replace sealing rings.

Tightening torque = 20 Nm.

Release screws (3) slightly.

Pull out dryer bottle for A/C system (4) towards top.

64 53 551 Removing and installing or replacing condenser for A / C system

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

1. Drain off air conditioner, refer to «64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-50-009-drawing-off-evacuating)

Note. If A/C system is opened for more than 24 hours: Replacing drier insert for A/C system, refer to 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER FLASK FOR AIR CONDITIONER .

Necessary preliminary tasks

1. Remove radiator, refer to «17 11 000 REMOVING AND INSTALLING RADIATOR (M54)»(/bmw/z4/e85e86-2002-2005/remont/cooling-system-mechanical/#cooling-system-repair__17-11-000-removing-and-installing)

After installation

1. Fill and vent cooling system and check for leaks, refer to «17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (M54)»(/bmw/z4/e85e86-2002-2005/remont/cooling-system-mechanical/#cooling-system-repair__17-00-009-checking-cooling-system)

Release screws (1).

Scheme 68

Installation

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

Disconnect refrigerant lines (2).

Installation

Replace sealing rings.

Pull out condenser for A/C system (3) in direction of arrow.

Installation

Make sure A/C condenser (3) is correctly seated.

Release screw (1).

Scheme 69

Release expansion rivet (2).

Take off holder (3).

Installation

Make sure guides (4) are correctly seated in holders (3).

See also:
• STEERING SPINDLE LOWER SECTION
• 51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM
• 17 00... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM
• 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (M54 / M56)
• HEATING AND AIR CONDITIONING - TIGHTENING TORQUES
• 51 45... REMOVING AND INSTALLING/REPLACING RADIO CUTOUT TRIM
• 65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER
• 51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL, BOTTOM RIGHT
• 51 16 367 REMOVING AND INSTALLING RIGHT GLOVE BOX WITH HOUSING (WITH ACTIVE KNEE PROTECTION)
• 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY
• REMOVING RADIATOR COVER
• HEATING AND AIR CONDITIONING - TECHNICAL DATA
• 61 71 061 REPLACING FLUID RESERVOIR FOR WINDSHIELD WASHER SYSTEM
• 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION
• 11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (M52 / S52 / M52TU / M54 / M56)
• 17 11 000 REMOVING AND INSTALLING RADIATOR (M54)
• 17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (M54)
• 64 11 377 REMOVING AND INSTALLING (REPLACING) CONTROL PANEL FOR HEATER - A/C SYSTEM
• 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134a)
• 64 11... INSTALLING SERVODRIVE
• 64 11 875 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP (AUTOMATIC A/C)
• 64 11 225 REPLACING CONTROLLER FOR HEATER - A/C FAN
• 64 50... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R 134a
• 64 50 ... SAFETY PRECAUTIONS WHEN HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134a)
• 64 50 ... LEAK-TESTING WITH LEAK TESTER DEVICE
• 64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT
• 64 11 205 REMOVING AND INSTALLING OR REPLACING HEATER
• 64 11 208 REPLACING HEATER CORE
• 64 52 ... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT
• 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER FLASK FOR AIR CONDITIONER