Automatic Air Conditioning BMW 7 Series E32 (M60)

EBA – 01 29 9 787 198
BMW Installation Instructions

Automatic Air Conditioning BMW 7 Series E32 (M60)

Specialised knowledged is required.

Installation time: Approx. 12 hours – this may vary, depending on the condition of the vehicle and its fittings. The installation instructions must be issued to the customer.

The air conditioner must be installed only at a workshop which has the necessary special tools and suitable equipment required for evacuating and filling the system.

Installation of the air conditioner reduces the capacity load by approx. 26 kg.

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.

Do not remove the plugs of any part of the refrigerant system until just before assembly, as the system may be damaged by penetrating moisture.

Installation of the air conditioner is possible only in conjunction with appropriate special fittings (see parts microfiche)

Important

The coil springs of the front suspension struts must be replaced after installation of the air conditioner (see repair instructions).

Important remarks concerning operation of the air conditioner

  1. The condensate produced at the vaporizer is discharged below the vehicle, and may be up to 2 l/h, according to air humidity.
  2. The air conditioner must be put into operation at least once a month (especially in the cold season), otherwise there is the danger that the compressor shaft seal will dry out, thus allowing refrigerant to escape.
  3. In the event of any malfunction of the air conditioner – e.g. if no cold air is produced by the system when it is on – it must be switched off and a BMW service department for air conditioners must be consulted.

Addresses of BMW service departments for air conditioners: see “BMW Service” register.

Tools and Materials Required

Regular screwdriver
Phillips screwdriver
Torx screwdriver T 25
1/2″ torque wrench
1/2″ ratchet
1/2″ extension
1/2″ drive socket, 12, 13, 17, 22, 24 mm A/F
1/4″ ratchet
1/4″ extension
1/4″ drive socket, 6, 8, 10, 13 mm A/F
Allen key, 4, 6 mm A/F
Hammer
Chisel
Punch
Cranked ring spanner, 6, 10, 13, 17, 19, 22 mm A/F
Open-jawed spanner, 11, 13, 15, 19, 22, 30, 32 mm A/F
All-purpose knive
Touch-up pencil
Drill
Twist drill bit, 3 mm, 4.5 mm, 6 mm, 25 mm dia.
Loctite 242
Refrigerator oil Brush
Soap Air gun
Stepped drill bit, 5 – 40 mm dia.

Ser. No.     Illustration     Designation

I                F 32 72 075    Special Torx tool
II               F 32 64 263    Test device BMW No. 170 000
III              F 32 64 264    Adapter BMW No. 170 003
IV              F 30 64 109    BMW No. 115 020

Automatic Air Conditioning BMW 7 Series E32 (M60)

Automatic Air Conditioning BMW 7 Series E32 (M60)

Automatic Air Conditioning BMW 7 Series E32 (M60)

Automatic Air Conditioning BMW 7 Series E32 (M60)

Contents

Chapter

  1. Reparatory Work
  2. Installing Right and Left Condensate Drain
  3. Preparing Heater/Air Conditioner for Installation
  4. Installing Heater/Air Conditioner
  5. Converting Front Bumper
  6. Installing Drier Canister
  7. Installing Condenser
  8. Installing Compressor
  9. Installing Refrigerant Lines
  10. Preparing and Installing Instrument Panel
  11. Inserting Relays
  12. Final Work

1. Preparatory Work

  • Print out error memory
  • Disconnect battery/ies
  • Remove steering wheel and steering column panelling
  • Remove instrument cluster
  • Remove foot pedal panelling
  • Remove panelling, bottom left
  • Remove glove compartment
  • Remove air grille
  • Remove right and left A-column panelling
  • Remove centre console
  • Remove instrument panelling
  • Remove lower engine panelling
  • Remove front bumper
  • Remove air-mass flow sensor with air filter
  • Remove windscreen fluid tank
  • Drain refrigerant
  • Remove radiator and fan shroud
  • Remove heater

2. Installing Right and Left Condensate Drain

F 34 64 088

Automatic Air Conditioning BMW 7 Series E32 (M60)

Cut out carpet at pre-marked areas (arrows).

F 34 64 089

Automatic Air Conditioning BMW 7 Series E32 (M60)

Mark bore areas (1, 2) according to specified dimensions.

A = 175 mm

B = 165 mm

Drill bore areas (1, 2) with twist drill bit (dia. 4.5 mm) and enlarge to dia. 25.

Burr edges of bore holes and coat with primer.

F 34 64 090

Insert rubber grommet (1) Install funnel (2).

Align funnel (2) as shown in illustration and mark bore area (3). Drill bore area (3) with twist drill bit (dia. 3 mm).

Coat edge of bore hole with primer. Install funnel (2). Insert Phillips screw (4) and tighten.

3. Preparing Heater/Air Conditioner for Installation

F 34 64 084

Pull off foam seal (arrow) from heater and install on heater/air conditioner.

F 32 64 541

Note

The condensate drains (1) are marked R (right) and L (left). Attach condensate drains (1) as shown in illustration to heater/air conditioner.

Install sheet-metal nuts (2)

Fit tab washers (3) as shown in illustration to condensate drains (1). Insert coil (4).

F 34 64 323

Unscrew hexagon nuts (4) on right and left of removed heater. Remove brackets (1) and washers (3) and screw out silent blocks (2).

F 34 64 084

Screw brackets (2) on right and left side, together with silent blocks (3), washers and hexagon nuts (1), to heater/air conditioner.

F 34 64 400

Slide control unit (1) onto heater/air conditioner in direction indicated by arrows.

Attach connector of heater/air conditioner wiring harness to control unit, ensuring that colours match, and lock in place.

4. Installing Heater/Air Conditioner

F 34 64 324

Important

After installation, the three refrigerant connections (1) must pass through the rubber sleeve (2).

Seal connection (3) with silicon.

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The condensate drains must be placed in the funnels.

Install heater/air conditioner in reverse sequence of removal of heater. Clip tab washer (arrow) onto right and left funnels.

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Release hexagon nuts (1) on right and left sides of heater/air conditioner.

Align bracket (2) with tapped hole (3) and tighten hexagon nut (1).

Place bracket (2) and holder (4) on tapped hole (3). Insert hexagon screw (5) with washer and tighten.

5. Converting Front Bumper

F 34 64 016

Peel off protective films from adhesive surfaces.

Position insulating mat (1) in bumper as shown in illustration and press to secure.

Press insulating mat (2) in bumper on adhesive surface of insulating mat (1).

Note

The insulating mats (1, 2) have the following designations after the part numbers:

L = Left bumper side

R = Right bumper side

Note on installation

After mounting the bumper, press the adhesive surfaces of the insulating mat (2) to secure.

6. Installing Drier Canister

F 34 64 354

Remove plastic cover (1) in engine compartment on right and insert split nuts (2) in openings.

F 32 64 546

Remove protective plugs from drier canister (1)

Place safety pressure switch (2) with 0-ring in drier canister (1) as shown in illustration.

Tightening torque of safety pressure switch (2): 12 Nm.

F 32 64 552

Insert drier canister (1) as shown in illustration. Insert and tighten hexagon screws (2).

F 62 64 379

Attach connectors (1) to plug-in connections of safety pressure switch, ensuring colours match.

7. Installing Condenser

F 32 64 185

Insert rubber grommets (1) as shown in illustration into condenser holder.

F 34 64 341

Important

Install fan (1) in such a manner that the resistor (2) is positioned at the point shown in the illustration.

Position fan (1) on condenser (3) as shown in illustration.

F 32 64 570

Insert fit screws (1) from the fan side.

Insert washers (2) and self-locking hexagon nuts (3) and tighten.

F 34 64 343

Push sheet-metal nuts (1) onto condenser lugs (2).

F 32 64 569

Insert silent blocks (1) in crossmember.

F 32 64 543

Install condenser (3) in vehicle as shown in illustration. Align condenser (3), insert hexagon screws (1) in standard openings (2) and tighten.

8. Installing Compressor

F 32 64 563

Remove Allen screw (1) and hexagon screw (2). Remove washer (3).

Remove sensor (4).

F 32 64 562

Remove hexagon nut (1). Remove retaining plate (2).

Remove guide tube (3) of oil dipstick.

F 32 64 561

Important

In order to avoid damaging the vehicle, before dismantling the support bracket (5) the engine must be supported.

Remove hexagon screws (1).

Remove hexagon nut (2) and washer (3). Take out earth cable (4).

Remove support bracket (5).

F 32 64 564

Remove hexagon nuts (1). Remove silent blocks (2).

F 32 64 565

Note

The removed support bracket (1) is replaced by support bracket (2) from the installation kit.

F 32 64 550

Insert guide tube (1) in support bracket (2) as shown in illustration.

F 30 64 109

Important

When inserting the support bracket (1), take care not to damage the seal of the guide tube (2).

Insert preassembled support bracket (1) as shown in illustration.

Secure support bracket (1) with hexagon screws M8x50 (one) and M8x30 (three).

F 32 64 544

Place compressor (1) in mount (2) as shown in illustration. Insert hexagon screws M8X90 (3) and secure.

F 32 64 549

Models with oil line

Remove holder (1).

Saw off ridge as shown in illustration and drill hole, dia. 6 mm.

Belt tightener – installation overview

F 32 64 545

Automatic Air Conditioning BMW 7 Series E32 (M60)

1 = Ribbed V-belt
2 = Tensioning roller (preassembled)
3 = Tensioning wheel
4 = Hexagon screw M8X20-Z1
5 = Protective cap
6 = Fit screw M8X60
7 = Washer
8 = Adjustment lever
9 = Hexagon screw with washer M8X30-Z1 1O = Hexagon screw with washer M6X30-Z1
11 = Belt tightener
12 = Hexagon screw M8X30
13 = Spring washer 88
14 = Washer
15 = Hexagon nut MB

F 32 64 551

Insert tensioning roller (1) with belt tightener (2) and hexagon screw (3) .

F 32 64 552

Place adjustment lever (1) in belt tightener (2). Secure hexagon screws (3-4).

F 34 64 540

Remove engine belt. Install ribbed V-belt (1).

F 32 64 173

The tensioner (arrow) must be placed centrally on a tooth. Test V-belt and adjust if necessary. Tighten all securing screws.

9. Installing Refrigerant Lines

F 32 64 363

Cut pre-marked insulating mat ( 1) out of engine compartment partition.

Models with anti-theft alarm system

F 34 64 365

Pull insulating mat forward (1). Remove hexagon screws (2).

Pull out cable connector and remove horn (3) with holder.

F 34 64 366

Insert double tube with rubber grommet (1) as shown in illustration.

F 34 64 367

Withdraw filler plugs out of heater/air conditioner.

Place 0-rings (1, 2) on double tube (3) and insert double tube (3) in heater/air conditioner.

Secure and tighten self-locking hexagon nut (4) M8X-SW12. Tightening torque of hexagon nut (4): 24 Nm.

F 34 64 030

In order to make it easier to pull through the refrigerant lines (1, 2), rub rubber grommet with soap (3).

Pull refrigerant lines (1, 2) through rubber grommet (3) as shown in illustration.

F 34 64 368

Pass refrigerant lines (1, 2) through opening (3) as shown in illustration.

F 34 64 369

Important

When the plugs (1) are unscrewed, pressure escapes from the condenser (2).

Unscrew plug (1) carefully.

F 34 64 370

Fit 0-rings on refrigerant lines (1, 2).

Coat threaded fittings (3) on condenser (4) with refrigerant oil. Attach refrigerant lines (1, 2) and tighten union nuts (5, 6) by hand. Insert rubber grommet (7) in opening.

F 34 64 371

Align refrigerant lines (1, 2) and tighten union nuts (3,4) . When tightening union nuts, hold lower hexagons (5, 6) in position.

Tightening torque of union nuts (3, 4): 17 Nm.

F 34 64 372

Remove plug and insert refrigerant line (1) with 0-ring in drier canister (2).

F 32 64 547

Unscrew plug from compressor and coat thread with refrigerator oil.

Insert refrigerant lines (1, 2) with 0-rings (3) in compressor . Insert Allen screws (4), align refrigerant lines (1, 2) and secure Allen screws (4).

F 32 64 553

Insert insertion nut (1) in openings. Secure refrigerant line (4) with clamps (3) and hexagon screws (2).

F 34 64 418

Remove plugs from drier canister (1) and insert refrigerant lines (2, 3) with 0-ring in drier canister (1).

F 34 64 419

Push bracket over stud bolt. Install and secure self-locking hexagon nut M8 SW 12 (arrow).

F 34 64 080

Insert refrigerant lines (1, 2) with 0-rings in connections (3, 4). Place bracket (5) on stud bolt.

Install and secure self-locking hexagon nut M8 SW 12. Tightening torque of hexagon nut: 24 Nm.

10. Preparing and Installing Instrument Panel

F 34 64 080

Remove centre fresh air grille. Note on installation

The new centre fresh air grille ( 1) with adjuster wheel must be properly seated in the air duct (2).

Ensure that the connecting cables (3) are not wedged in or caught.

F 34 64 081

Pull new cable straps (1) at inaccessible points through mount (2) and secure with adhesive tape.

F 34 64 094

Note on installation

Guide lug (1) of instrument panel must be seated in sheet-metal opening (2).

Reinstall instrument panel in reverse sequence of removal. Place wiring harnesses in cable straps.

F 34 64 095

Attach 3-pole connector (1) of electrically adjustable air vent (2) to corresponding mating connector of heater/air conditioner wiring harness (3).

Models with radio

F 34 65 032

The holders for the radio are marked according to heater and vehicle version (right-hand/left-hand drive models).

Install appropriate holder (1) for the radio on heater/air conditioner.

F 34 64 099

Attach connector (1, 2) on control unit from installation kit. Press lock (3) into place.

F 32 64 257

Remove fuse box cover.

If necessary, insert 7.5 A fuse (arrow).

11. Inserting Relays

F 32 64 375

The respective relays are identified by means of relay numbers cast in the housings, or by means of the connector pin assignment on bottom of relay (see illustration).

AW 1 378 297 (operating current.rnlay) corresponds to connector pin assignment K19/K22.

1 391 397 (operating current relay with diode) corresponds to connector pin assignment K21.

1 388 364 (1 382 353) (double NO relay) corresponds to connector pin assignment K33.

Note on installation

The plug-in station table must be strictly adhered to, as the relays are of differing design.

AW 1 378 297 indicates a selection table that contains relays of three different manufacturers but of identical design.

Selection table 1378 297

Manufacturer Relay number
Bosch 1 378 238
SWF 1 378 301
Wehrle 1 378 300

F 34 64 482

Insert relay K19 1 378 297 (air conditioning compressor) in distribution box.

If necessary, insert relay K 8 1 378 302 (auxiliary water pump) in distribution box.

F 34 64 480

Automatic Air Conditioning BMW 7 Series E32 (M60)

Insert relays in relay box in accordance with the following table.

Cable colour plug-in station IK33 IX 51 (Motronic air conditioner signal)

Relay number 1388 364 (1 382 353)

RD/GY
GN/BUYE
BK/BUYE
BK/GY/WH

Cable colour plug-in station II K21 I X52 (auxiliary fan stage 1) relay number 1391 397

BUWH/YE
BK/GY
RD/GN
GN/BUYE

Cable colour plug-in station Ill K22 I X53 (auxiliary fan stage 1) relay number 1 378 297

RD/GN GN/BUYE BL BK/GR/YE

12. Final Work

F 32 64 554

Automatic Air Conditioning BMW 7 Series E32 (M60)

Insert temperature switch (2) with seal in radiator.

Attach connector (1) – cable colours green/black, brown, and violet/grey – to temperature switch (2). Attach connector – cable colour black/white – to mating connector of air conditioning compressor.

F 34 64 544

Automatic Air Conditioning BMW 7 Series E32 (M60)

Fill cooling system in accordance with repair instructions, and check for leaks.

Fill air conditioner (see capacity plate for refrigerant and capacity). Place cover (1) on heater/air conditioner.

Replace coil springs of front suspension struts (see BMW repair instructions).

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