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Headlight Cleaning System BMW 7 Series E32 from September 1990

EBA – 01 29 9 786 007
BMW Installation Instructions

Specialised knowledge is required.

Installation time: approx. 2 hours – this may vary, depending on the condition of the vehicle and its fittings.

Note

Instructions and illustrations are given for left-hand drive models. Various work stages must be carried out for right-hand drive models in mirror-image fashion.

Tools and materials required

Drill
Twist drill bit, dia. 5 mm, 8 mm
Stepped drill bit, 4 – 30 mm
Double-ended offset ring spanner, 10 – 11 mm, 12 – 13 mm, 18 – 19 mm A/F
Regular screwdriver
Phillips screwdriver
Ratchet with 1/2″ drive
1/2″ extension
1/2″ six-point socket, 10 mm NF
Torque wrench
Hose-clip pliers
Socket wrench, 8 mm
Allen key, 4 mm A/F
Round file
Hammer
Centre punch
Universal knife
Drilling templates
Petroleum ether
Cleaning cloth

Special tool:

Contents

Chapter

  1. Disconnecting Battery
  2. Removing and Disassembling Bumper
  3. Installing Spray Nozzles
  4. Fitting Hose Retainers
  5. Laying Hoses
  6. Installing Relay
  7. Setting and Checking Operation
  8. Installing Intensive Cleaning System

1. Disconnecting Battery

Note

The error memories are erased when the battery is disconnected.

Print out error memories.

F 32 65 589

To disconnect battery, remove cover (1) from rear seat base. Release negative cable from earth (ground) support.

If necessary, disconnect subsidiary battery.

2. Removing and Disassembling Bumper

F 32 61 014

Using a regular screwdriver (2), press lug of strip (1) down.

F 32 61 015

Remove strip (1) in direction indicated by arrow.

F 32 64 148

Note on installation

Ensure that clips and lugs of strip (1) are correctly seated in bumper.

F 32 64 149

Take out screws (arrowed).

Remove bumper as indicated with the aid of a second person.

F 32 61 117

If necessary, withdraw plug (1) from fog lamp and plug (2) from temperature sensor.

F 32 61 118

Using a screwdriver, press down lug (1) of section (2) on left and right and remove section in direction indicated by arrow. Unscrew licence-plate screws and remove licence plate.

F 32 61 119

Remove securing screws (1) from fog lamp.

Lift out fog lamp in direction indicated by arrow.

F 32 61 018

Remove split rivets (arrowed) from upper panelling.

F 32 61 019

View of split rivet

Tip

Press inside section of split rivet upwards and pull rivet upwards and out.

F 32 61 020

Remove screws from bumper reinforcement (arrowed) on both sides.

F 32 61 120

Lift out foam inlays (1) in direction indicated by arrow.

F 32 61 022

Caref ully remove plastic towing-eye covers in direction indicated by arrow.

F 32 61 121

Turn bumper round and remove split rivets (arrowed).

F 32 61 122

Lift out bumper reinforcement completely from bumper in direction indicated by arrow.

3. Installing Spray Nozzles

F 32 61 025

Glue template (1) for headlight spray-nozzle opening to panelling.

Note

Templates for left and right-hand sides are marked.

F 32 61 026

Prepare opening with a round file. Remove template.

Remove possible remnants of adhesive with petroleum ether.

F 32 61 027

Turn bumper round and glue template (1) for fog-lamp spray-nozzle opening to panelling.

Note

Templates for left and right-hand sides are marked.

Drill through centre of bore hole with 5 mm dia. twist drill bit. Then increase bore diameter to specified size with stepped drill bit.

Remove template.

Remove possible remnants of adhesive with petroleum ether.

Install bumper reinforcement in bumper and secure with screws.

Refit foam inlays. Insert split rivets. Install fog lamps.

Note on installation

The left and right-hand fog lamps are marked.

F 32 61 028

Insert spray nozzles for fog lamps (1) from below and tighten plastic nuts (2) firmly.

F 32 61 029

Note on installation

The lug of the spray nozzle (arrowed) must snap into place in the opening of the middle bumper reinforcement.

F 32 61 123

Coat sealing ring (1) with Vaseline and fit on valve (2). Insert valve into fog-lamp spray nozzle (3).

F 32 61 124

Insert split nut (1).

Insert lower section (2) of fog-lamp spray nozzle, fit plastic nuts (3) and tighten.

4. Fitting Hose Retainers

F 32 61 125

Fit six hose retainers (1) as shown in illustration.

5. Laying Hoses

F 32 61 126

Note

Ensure that all hoses are laid without any twists or kinks and that all hose connections are fitted correctly .

Cut hose (1) for headlight spray nozzle to length of 1600 mm, attach to lower section (3) with hose clip (2) and close clip with hose-clip pliers.

Lay hose to left-hand side as shown in illustration.

Push hose with hose clip onto distributor connection (4) as shown in illustration and tighten clip.

The distributor connection is fitted in mirror-image fashion in 750i models.

F 32 61 127

Cut hose (1) to length of 480 mm and push onto distributor connection (2) with hose clip as shown in illustration and tighten clip.

F 32 61 128

Lay hose to lower section of headlight spray nozzle (1).

Push hose with hose clip onto lower section of headlight spray nozzle and tighten clip.

F 32 61 129

Cut hose (1) for fog-lamp spray nozzle to length of 1480 mm, push onto valve (2) with hose clip and tighten clip.

Lay hose to left-hand side as shown in illustration. Secure hoses with cable strap (3).

F 32 61 130

Push hose (1) with hose clip onto distributor (2) and tighten clip.

Note

The distributor connection is installed in mirror-image fashion in 750i models.

F 32 61 131

Cut hose (1) to length of 320 mm, push onto distributor (2) with hose clip and tighten clip.

Push hose onto valve (3) with hose clip and tighten clip. Secure hoses with cable strap (4) .

F 32 61 132

Fit sealing rings (1) onto connecting piece (2).

Insert connecting piece (2) into distributor (3) up to stop.

F 32 61 133

Cut two hose pieces to lengths of 90 mm, push onto locations I and II with hose clips and tighten clips.

F 32 61 134

Push hoses with connecting piece (1) onto distributor connections as shown in illustration and secure with hose clips.

Note

In 750i models, lay hoses with connecting piece to right side of bumper.

F 32 61 135

Cut two hoses to lengths of approx . 500 mm, push onto locations Ill and IV of connecting piece (1) with hose clips and tighten clips.

Note

Location III = Connection for main headlights

Location IV = Connection for fog lamps

F 32 61 056

Release tied-back plug-in connection in area marked by arrows and lay to installation location in engine compartment (front left).

Note

The plug-in connections are on the right in 750i models. Refit and secure bumper with the aid of a second person.

Notes on installation

To avoid mixing up the connecting hoses (headlights/fog lamps), mark hoses and lay into engine compartment.

Tightening torque of bumper screws = 48 Nm.

F 32 64 150

The height of the bumper can be adjusted by turning the hexagon socket-head screw (arrowed).

Reattach licence plate with screws.

F 32 61 136

Refit side bumper sections (5).

Take bumper strip (4) from installation kit and install.

Insert headlight spray nozzle (1) with sealing ring (2) and secure with sheet-metal screw (3).

F 32 61 058

Fit cover (1) with spacer element (2) onto bumper and secure with countersunk-head screw (3).

F 32 61 093

Insert sealing ring (1) into fluid tank (2).

F 32 61 062

Install fluid tank on left-hand side in engine compartment.

Note on installation

The lug on the tank base must be inserted into the opening in the bodywork (arrowed).

Feed hoses for main headlight and fog-lamp cleaning to installation location of pump (ensure that hoses are free of twists and kinks) and cut to length.

F 32 61 137

Take fluid tank, push hoses onto twin pump (1) and secure with hose clips.

2 – Connection for fog lamps

3 – Connection for headlights

F 32 61 144

Glue foam-rubber spacer element (1) to fluid tank as shown in illustration.

F 32 61 138

Insert split nuts (1).

Install fluid tank and secure with two sheet-metal screws.

F 32 61 139

Install twin pump (1) in fluid tank and connect plug (2).

750i models

F 32 61 081

Removing right air-filter housing

Release hose strap (arrowed). Remove hoses (1) and (2).

Release electrical connection (3) and remove.

Note

All work here is carried out on the right side of the vehicle.

F 32 61 082

Release air-filter fixture (arrowed). Lift air-filter housing up and out.

F 32 61 083

Release hose strap.

Withdraw hoses from connector (1).

Take hose (2) out of hose retainers (3) and (4).

F 32 61 084

Release electrical connections ( 1) and (2) on pumps. Loosen screw (arrowed).

Remove supply tank.

F 32 61 085

Remove spring nuts (arrowed). Take out heat shield.

F 32 61 086

Lift out pumps (1) and (2) with hose and gaskets (3) and (4).

Note on installation

Install pump (2) with hose and gasket (3) in new supply tank. Install pump (1) and gasket (4) in second supply tank.

F 32 61 087

Remove caps (1) and (2) and filter (3).

F 32 61 088

Take supply tank (1) and stop coupling (2) from installation kit and fit together.

Install pump (3), intensive cleaning system, hose (5) and gasket (4) in fluid tank.

Note in installation

Refit heat shield.

Install fluid tank in engine compartment and screw down.

F 32 61 140

Take second supply tank (3) from installation kit and install gasket (1) and twin pump (2) in specified order.

F 32 91 090

Install gasket and pump for windscreen-washing system in fluid tank.

F 32 61 097

Push hoses onto twin pump (1) and secure with hose clips. Connect cable plug (4) to twin pump.

2 – Connection for main headlights

3 – Connection for fog lamps

Note on installation

Select hose length in such a way as to ensure that the hoses are not twisted or kinked once the fluid tank has been installed in the engine compartment.

F 32 61 141

Install fluid tank in engine compartment (front right) and secure with fastener (1).

Note on installation

The lug on the tank must be inserted into the opening in the bodywork.

F 32 61 142

Connect hose as shown in illustration and secure with hose clips.

6. Installing Relay

F 32 61 066

Open cable tray (1) in engine compartment (front left) and fit headlight-cleaning module (2) in position (3).

Refit cover.

Insert strainer in fluid tank. Secure cap.

Fill tank with cleaning fluid conforming to manufacturer’s specifications and close cap.

Note

Filling capacity 7.5 I.

7. Setting and Checking Operation

Reconnect battery.

Check setting of fog lamps.

Carry out test on headlight-cleaning system for correct operation.

Actuate automatic windscreen washing or intensive cleaning with vehicle lights switched on.

F 32 61 067

Adjust headlight spray nozzles with special tool (1).

F 32 61 115

To ensure that the headlights are cleaned to optimum effect, adjust the headlight spray nozzles so that the jets of water contact the headlights at the points marked (see illustration).

A = 30 mm

B = 22 mm

C = 18 mm

D = 11 mm

8. Installing Intensive Cleaning System

730i, 735i models

F 32 61 098

Take out engine-compartment light (1) from engine hood.

Withdraw electrical connection (2) and remove engine-compartment light.

F 32 61 099

Remove pin (1) and clip (2) with a small screwdriver. Remove panelling (engine hood).

F 32 61 100

Release hose clip (1) with pliers.

Withdraw hose (2) from windscreen spray nozzle.

Withdraw electrical connection from heated windscreen spray nozzle.

F 32 61 101

Using pliers, press together windscreen spray nozzle (1) at point shown (2) and remove in direction indicated by arrow.

F 32 61 008

Take windscreen spray nozzle (1) from installation kit and fit in engine hood.

Note on installation

The spray nozzle must snap audibly into place.

F 32 61 102

Lay hose (1) along length of existing hose (2) as shown in illustration.

F 32 61 009

Push hoses (1) and (2) onto heated windscreen spray nozzle. Secure hoses (1) and (2) with clips (arrowed).

F 32 61 010

Insert plug (1) of heated windscreen spray nozzle into plug-in contact (2) of power-supply cable.

Note

The power-supply cable is laid to the installation location as standard.

F 32 61 103

Lay hose (1) into engine compartment as shown in illustration and secure with hose retainer (2).

F 32 61 104

Push hose with hose clip onto pump and tighten clip.

Note on installation

Select hose length in such a way as to ensure that the hoses are not twisted or kinked once the fluid tank has been installed in the engine compartment.

F 32 61 105

Attach cap (1) and label (2) to opening of fluid tank. Fit gasket (3) in tank.

F 32 61 106

Install pump (1) in fluid tank (3).

Connect cable plug (2) to pump.

Fit fluid tank (3) (intensive cleaning) onto fluid tank (4) (windscreen-washing system).

Ensure that tank locks into place correctly.

F 32 64 046

Open fuse box on left-hand side in engine compartment by folding bracket back.

Remove cover (arrowed).

F 32 61 107

Fit relay with catch (1) in position (2). Close fuse box.

F 32 64 214

Remove steering wheel and panelling.

Vehicles not fitted with airbags

Using a small screwdriver, lever BMW emblem out in direction indicated by arrow.

F 32 64 215

Unlock steering-wheel lock.

Unscrew nut (1) and remove with washer (2).

Mark position of steering wheel to steering spindle. Remove steering wheel.

F 32 65 247

Loosen screws (arrowed) and remove upper and lower sections of steering-column panelling (1).

F 32 65 248

Vehicles fitted with airbags

The steering wheels must not be removed from vehicles which have been fitted with airbags.

Loosen screws (arrowed) and remove lower section of steering-column panelling (1).

F 32 65 036

Open parcel shelf on left-hand side and release holding strap (arrowed).

F 32 61 108

Loosen screws (1) and remove panel (2) towards front.

F 32 61 109

Withdraw cable plug (1).

Take wiring harness out of steering column.

F 32 61 110

Remove control lever (1) (windscreen-washing system) from steering column and replace with control lever from installation kit.

Note on installation

Carry out test on system for correct operation.

Reinstall all parts which have been removed in reverse sequence.

F 32 61 116

To ensure that the windscreen is cleaned to optimum effect, adjust the windscreen spray nozzles so that the jets of water contact the windscreen at the points marked (see illustration).

A = 305 mm
B = 490 mm
C = 435 mm
D = 250 mm
E = 320 mm
F = 355 mm
G = 550 mm
H = 178 mm
I = 60 mm
J = 80 mm

Note on installation

On right-hand drive models, adjust points of contact of water jets in mirror-image fashion.

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