Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

EBA – 01 29 9 750 867
BMW Installation Instructions

All installation work is described and shown as for left- hand-drive cars. On right-hand-drive models, certain installation tasks have to be carried out in the same relative positions on the opposite side of the car.

Tools required:

Socket wrench, 8 mm
Phillips screwdrivers, Nos. 1 and 3
Centre punch
Drill
Drill bits, 3.7 mm, 4 mm, 6.4 mm, 8 mm
Cranked ring spanners, 10 mm, 17 mm
Open-ended spanners, 10 mm, 17 mm
Side cutters
Steel ruler
Marking tool
Metal cutting saw
Flat file
Pin


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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Remove water tank (1).

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Remove the left and right headlight covers.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Take out plug connection (1) for front turn indicator from holder (2) at left and right, and disconnect.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Release nut (1 … 2) left and right. Completely turn off the indicator on the left and right.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Remove nuts (1…2) at left and right.

Take out the complete turn indicator at left and right.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Remove the screws (1) from the left and right grille sections.

Take off the grille.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Remove screws (1) from left and right headlight. Pull off cover. Detach plug. Remove headlights.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Place the drilling template (1) for the left twin headlights from the installation kit on the support frame of the left headlight.

Bring line (2) in alignment with the headlight centre. Mark with centre punch. Drill 6.4 mm dia. hole.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Secure the holder (1) with M 6 x 10 screws, spring washer and nut.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Insert motor (1) (marked “L”) with bushing (2) in holder (3) and secure with toothed lock washer and nut. Place seal (4) on shaft.

Note: align the longitudinal axis (5) of the motor cross- section vertically to the support frame.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Insert shaft bearing (1) with bushing (2) in holder (3) and secure with toothed lock washer and nut.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Install idler lever (1) with hexagon (2) on motor shaft. Note: the position of the idler lever is 45° above horizontal.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Pull off the headlight rings (1…2).

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Push on the trim rings from the installation kit. Trim ring stamped 05 for left low-beam headlight. Trim ring stamped 07 for left high-beam headlight. Trim ring stamped 06 for right low-beam headlight. Trim ring stamped 08 for right high-beam headlight.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

When installing:

Projections (1) on all headlight rings must locate in slot (2).

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Attach linkage (1) to idler levers (2…3).

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Attach wiper blades to wiper arms.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Install wiper arms with spring washer and nut. Attach caps (1).

Carry out work on right headlights as for left headlights.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Drill 3.7 mm dia. hole for control unit mounting in front right bulkhead. A = 40 mm B = 6 mm

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Run the wiring harness from the installation kit along the existing wiring harness from the water-tank installation point to the control unit installation point and the right twin headlight, and from there to the left twin headlight, and secure in position. Insert rubber sleeve in cutout.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Secure the control unit and the earth (ground) cable (1) from the additional wiring harness with a self-tapping screw.

Install headlights and make the connections between the wiper motors and the wiring harness.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Make up the hose according to the diagram. 1 = T-piece A = 5 cm B = 20 cm C = 20 cm

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Attach windshield-washer and headlight-washer pump to water tank.

Attach the made-up hose to connection (1) at the water- tank and to connection “B” of the pumps.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Cut two 17 cm lengths of hose.

Attach hoses to connection “D” of the windshield- washer and headlight-washer pumps.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Make up hose as in diagram.

    1. = T-piece
    2. = Valve
    3. = Valve
    4. = 40 cm
    5. = 110 cm
    6. = 30 cm
    7. = 5 cm

A = Connection to water tank
B = Connection to right headlight spray jets
C = Connection to left headlight spray jets

Run the made-up hose from the water tank location to the installation point for the right headlights, and from there to the installation point for the left headlights (along the existing wiring harnesses), and secure.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Connect plug (1) to plug for the washer system from the main wiring harness.

Connect plug (2) (3 violet/black cables) to the plug connection of the headlight cleaning pump (3). Connect plug (4) (2 brown/black cables) to plug (5) of the headlight cleaning pump (3).

Connect plug (6) (blue and brown cable) to plug of the windshield washer pump (7).

Connect plug with grey/white cable from the additional wiring harness to the plug with grey/white cable tied back on the main wiring harness. Attach windshield-washer hose to connection A. Attach headlight cleaning hose to connection B. Install water tank.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Insert the water level sensor and connect the cable.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Make cutouts for wiper arms in the left radiator grille section.

A = 60 mm
B = 30 mm
C = 70 mm

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Make cutouts for wiper arms in the right radiator grille section.

A = 60 mm
B = 15 mm
C = 70 mm

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Make hole in grille for mounting the spray jets.

Place drilling template for low-beam headlight on grille.

Mark the point to be drilled and drill holes.

Note: double panel.

Outer panel hole dia. 8 mm

Inner panel hole dia. 4 mm

Drill holes at the left grille section as shown and in the same relative position on the right grille section.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Place drilling template for high-beam headlight on grille.

Mark the point to be drilled and drill holes.

Note: double panel.

Outer panel hole dia. 8 mm

Inner panel hole dia. 4 mm

Drill holes at the left grille section as shown and in the same relative position on the right grille section.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Install clips for spray jets and radiator grille.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Secure spray jets with self-tapping screws. Attach hoses to spray jets and refit grille.

Checking operation:

Add watter, and antifreeze if necessary. Turn the ignition key to position I and switch on the parking lights. Operate the windshield washer switch: the headlight cleaning system must run for about 5 seconds and then switch itself off. Check wiper blade adjustment while the system is running. About 30 seconds must elapse before the headlight cleaning system can be operated again. Install all parts and components removed during installation work.

Adjust the spray jets by inserting a pin.

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Drilling template for radiator grille, low-beam headlights

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Installation kit for headlight cleaning system BMW 6 Series (E24) CS models (from 5/82 on)

Drilling template for radiator grille, high-beam headlights

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