Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

EBA – 01 29 9 787 200
BMW Installation Instructions

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

(These installation instructions are to be issued to the customer)

Specialised knowledge is required.

Installation time is approx. 11 hours, though this may vary according to condition and fittings of vehicle.

The retrofitting of the independent heating I independent ventilation system is only possible in conjunction with specific BMW special equipment (see BMW parts microfiche or BMW Service Information No. 6106 88 (861)).

Instructions and illustrations are given for left-hand drive models.

In the Federal Republic of Germany, all fittings installed after initial registration must undergo !.nspection at the German Technical Inspection Agency (TUV) and be entered in the vehicle registration papers in accordance with § 19 (2) of the Regulations Authorizing the Use of Vehicles for Road Traffic (StVZO).

Caution

The heater must not be operated (not even with time setting) in closed rooms, such as garages or workshops, without exhaust-gas extraction.

The heater must be switched off at service stations and fuel dispensing areas.

Important

Before disconnecting the battery and after installing the independent heating system, print out the fault memories of the control units.

Lay all hose lines and electric cables in such a way that they do not sag or rub against other objects. Also ensure that cables and lines are freely accessible!

The hose lines must be laid without tension.

Drilling instructions

Burr bore points and coat with inorganic zinc paint.

Treat cavities with cavity preserving agent recommended by vehicle manufacturer.

In order to avoid starting problems at the beginning of a heating period, the heater should be operated every four weeks for ten minutes outside the heating period and when the engine is cold.

Tools and materials required

Regular screwdriver
Phillips screwdriver
1/2″ torque wrench
Ratchet with 1/2″ drive
1/2″ extension
1/2″ drive socket, A/F 10 mm, 12 mm, 13 mm, 17 mm, 19 mm, 22 mm
1/2″ hexagon drive socket, A/F 4 mm, 6 mm, 8 mm
1/2″ Torx drive socket, E10, E14, TX30
Ratchet with 1/4″ drive
1/4″ extension
1/4″ drive socket, A/F 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 13 mm
Ring spanner, A/F 7 mm, 8 mm, 9 mm, 10 mm, 13 mm, 17 mm, 19 mm
Open-jawed spanner, A/F 8 mm, 10 mm, 13 mm, 14 mm, 15 mm, 17 mm, 32 mm
Drill
Twist drill bit, dia. 3.5 mm, 5 mm, 6 mm, 6.5 mm
Pliers
Multigrip pliers
Universal pliers
Universal knife
Hammer
Centre punch
Water-soluble marker pen
Cable lamp
Paint brush Inorganic zinc paint
Cavity sealant
Protective glasses
Gloves
Ser. No.     Illustration     Designation

I               F 32 72 075    Special tool for airbag
II              F 32 64 263    Testing device
III             F 32 64 264    Adapter piece
IV            F 32 64 265    Hose clamp

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 DieselIndependent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 DieselIndependent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Contents

Chapter

  1. Removing Front Passenger Seat
  2. Disconnecting and Removing Battery
  3. Removing Backrest
  4. Removing Luggage-Compartment Panelling
  5. Removing Cover Strips
  6. Removing Cable Covers
  7. Removing Glove Compartment
  8. Removing Right Side Panelling
  9. Removing Right Air Duct
  10. Removing Air Filter
  11. Draining Air Conditioner (only models with air conditioner)
  12. Removing Cover
  13. Removing Pressure Lines (only models with air conditioner)
  14. Installing Supplementary Wiring Harnesses
  15. Removing Stanchion Sensor
  16. Installing Fuel Lines
  17. Installing Supplementary Fuel Pump
  18. Removing Engine-Compartment Cover
  19. Draining Coolant
  20. Installing Heater for Independent Heating
  21. Installing Coolant Hoses
  22. Inserting Relays
  23. Bleeding Cooling System
  24. Installing Outside-Temperature Sensor (only models with air conditioner)
  25. Initial Operation of Independent Heating I Independent Ventilation System

1. Removing Front Passenger Seat

F 32 65 012

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove head restraint in direction of arrow in illustration.

Models with electric seat adjustment

Fully retract head restraint.

All models

Take out first-aid kit from under seat.

F 32 65 010

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Slide seat forward as far as it will go.

Detach bowden wire (1) for belt-height adjustment fixture. Remove Torx screw (2) for seat belt.

F 32 65 011

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove Torx screws (see arrows in illustration).

Models with centre arm rest

F 34 64 115

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Set centre arm rest to vertical position.

All models

Lift up rear of seat (1) carefully in direction of arrow in illustration and lift out front brackets (2).

Models with electrical seat adjustment, seat heating, lumbar support

Disconnect cable plug-in connection under seat.

All models

Remove seat.

2. Disconnecting and Removing Battery

F 34 71 003

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

For models with supplementary battery (e.g. for car tele­ phones), disconnect negative terminal of supplementary battery.

Important

Print out fault memories. Contents of fault memories are deleted when battery is disconnected.

Remove cover (1) at bottom right of rear seat base. Remove hexagon screw (2) and cover (3).

F 34 61 002

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove hexagon nut (1), washer (2) and negative cable (3).

F 34 65 036

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Lift out and remove rear-seat bench (1) from mounting bracket in direction of arrows in illustration.

Models with seat heating

Disconnect cable plug-in connection under rear-seat bench.

F 34 65 210

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with folding rear seats

Slide front seats forward as far as they will go. Use loop (2) to pull seat cushion (1) in direction of arrow in illustration.

F 34 65 211

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Press together locks (1) of seat cushions (2) and remove seat cushions (2).

F 32 64 272

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with anti-theft alarm system

Remove hexagon nut (1). Remove cable connector from microswitch (3). Disconnect battery cover (2).

F 32 64 273

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove battery terminal (1) and put to one side. Remove hexagon screw (2), battery clamp (3), and vent (4). Remove battery.

3. Removing Backrest

F 34 52 009

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with rear head restraints

Remove head restraints in direction of arrow in illustration.

Installation information

Press retaining lugs (1) of panelling (2) into cover (3).

F 34 52 010

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Turn slotted screws (1) through 90″ in counterclockwise direction and remove cover (2).

F 32 65 004

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with centre arm rest

Fold down centre arm rest and remove panelling attached to Velcro-type fastener.

Press together lock in direction of arrows in illustration and remove centre arm rest.

F 34 65 132

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with cooling box

Release locking screw (1). Push in retaining bracket (2) in direction of arrow in illustration. Remove cable connector (3).

F 34 65 133

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Carefully remove cooling box (1) with the assistance of a second person.

Installation information

Retaining lugs (2) must be inserted into recesses (3).

F 32 72 019

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove hexagon nuts (1). Remove hexagon screws (2) of safety belts.

Installation information

Tightening torque of hexagon screws (2) is 48 Nm.

F 34 65 001

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Fold back insulating mat (1) on right and left. Remove hexagon nuts (2) on right and left.

F 32 52 003

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Lift backrest (1) out of brackets and pull forward. Guide safety belts through covers (2) and remove backrest.

F 34 65 212

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with folding rear seats

Remove hexagon nut (1). Take out seat-base panelling (2).

F 34 65 213

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove hexagon screws (1) of safety belts (2) and take off washers (3).

Installation information

Tightening torque of hexagon screws (1) is 48 Nm.

F 34 65 214

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Press lever (1) in direction of arrow in illustration and release. Fold forward backrest (2).

F 34 65 215

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Press lock (1) in direction of arrow in illustration and remove backrest (2).

F 34 65 216

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove hexagon nut (1). Pull out and remove side upholstery (2) on left and right sides of vehicle and in direction of arrow in illustration.

F 34 65 217

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Installation information

Insert retainer (1) into guide (2).

4. Removing Luggage-Compartment Panelling

F 32 72 028

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove luggage-compartment floor mat. Remove plastic nuts (1) and luggage-compartment panelling (2).

F 32 51 184

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with cooling box

Remove plastic screws (4). Remove right and left halves of divided luggage-compartment panelling (1 and 2).

F 32 65 402

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Turn slotted screws (1) of left luggage-compartment panelling (2) through 90′ and remove panelling (2).

F 34 65 162

Turn slotted screws (1) of right luggage-compartment panelling (2) through 90′ in direction of arrow in illustration and remove panelling (2 and 3).

Remove jack and wheel chock.

Note

For models with folding rear seats, remove split-rivet pins at front of luggage-compartment panelling (3).

F 34 71 007

Punch split-rivet pins (1) in direction of arrow in illustration.

Installation information

Pull out split-rivet pins (1) from body cavity underneath cover (2) so that they can be used again.

F 34 71 008

Lift out split rivets (1).

Fold down cover (2) in direction of arrow in illustration. Lift wiring harness (3) out of clips (4) and remove cover (2).

F 34 65 135

Models without supplementary battery

Remove plastic nut (1) and hexagon screw (2) of wiring­ harness sheathing (3). Remove wiring-harness sheathing (3).

F 34 65 134

Remove hexagon screw (1). Remove wiring-harness sheathing (2).

5. Removing Cover Strips

F 34 64 117

Only right side of vehicle

Lever out and remove front and rear cover strips (1). Remove edge guard (2). Pull out B-column panelling (3) in direction of arrow in illustration.

Installation information

Press lugs (4) of B-column panelling (3) into retaining clips.

F 30 52 054

Press together and lever out retaining clips (see arrows in illustration) with pliers.

6. Removing Cable Covers

F 32 64 275

Fold back carpet (1) and remove split rivets (2) in direction of arrow in illustration.

F 34 64 118

Remove split rivets (1).

F 34 64 119

Pull clips (1) in direction of arrow in illustration. Disconnect cable plug-in connection (2).

7. Removing Glove Compartment

F 32 64 279

Open glove compartment. Remove clips (1) from right and left sides of glove compartment. Remove holding strap (2).

F 34 64 056

Pull down lever (1) in direction of arrow in illustration. Remove glove compartment.

F 34 64 057

Remove Phillips screws (1). Pull out glove-compartment panelling (2) in direction of arrow in illustration.

F 34 64 120

Remove cable connector of glove-compartment light (1). Remove cable connector (2).

Installation information

Install retaining lugs (4) of panelling (3).

F 34 64 121

Remove Phillips screws (1). Remove panelling (2).

F 34 64 122

Lever out retaining lugs (1) and remove connector (2) in direction of arrow in illustration.

F 34 64 125

Important

Panelling (1) is fitted in the storage compartment (3) with the lugs (2).

Carefully remove panelling (1) in direction of arrow in illustration.

F 34 64 124

Remove Phillips screws (1).

F 34 64 060

Mark position of hexagon screws (1) on retaining bracket (2). Remove hexagon screws (1).

F 34 64 200

Remove cable connector (1) and vacuum hose (2). Remove bracket (3).

F 34 64 123

Models with air conditioner

Remove Phillips screws (1). Pull out air duct (2) from ventilation line (3) on heater (4). Remove bracket (5).

8. Removing Right Side Panelling

F 34 64 127

Remove edge guard (1) in direction of arrow in illustration. Turn hexagon-socket-head screws (2) through 90′.

Remove side panelling (3).

Models with speaker system

Remove cable connector from speaker .

Installation information

Install retaining lugs of panelling.

9. Removing Right Air Duct

F 34 64 128

Remove hexagon nuts (1). Carefully pull out and remove right air duct (2) from rubber bearing.

Pull out and support carpet (3).

10. Removing Air Filter

F 34 64 568

Remove air hose (1) in direction of arrow in illustration. Untighten screws (2) and take off upper part of air filter.

F 34 64 569

Untighten screws (1), remove air pipe (2) and remove lower part of ail filter . Cover opening of air pipe (2).

11. Draining Air Conditioner

(only models with air conditioner)

F 34 64 135

Remove closing caps of service valves (1) in the pressure lines (2). Connect assembly testing device, evacuating device and filling device to the service valves. Ensure that the pressure pin in the angled end of the filling hoses presses down the pressure pins of the service valves.

Important

Wear gloves and protective glasses . If draining take places too quickly, oil from the system and the refrigerant compressor will be drained along with the refrigerant. Drain refrigerant slowly into a recycling container.

Caution

As soon as the manometer reads O bar or a low positive pressure, or if no more refrigerant is escaping from the connected filling hoses, this means that the system is empty. Remove hose lines and seal service valves with closing caps.

12. Removing Cover

F 32 65 251

Remove slotted screws (see arrows in illustration) . Remove cover.

13. Removing Pressure Lines

(only models with air conditioner)

F 34 64 228

Remove hexagon nut (1). Fold bracket (2) in direction of arrow in illustration.

F 32 64 297

Remove hexagon nut (1) from drying bottle (2). Pull back bracket (3) and turn in direction of arrow in illustration.

F 32 64 295

Remove hexagon-socket-head screw (1) from air-conditioning compressor .

F 32 64 298

Remove hexagon screw (1). Take off pipe clip (2). Remove pressure lines.

Note

The illustrations are shown with the engine removed for clearer presentation .

Important

Fit plugs to all connections of the air conditioner to prevent damage from moisture.

Installation information

Use new 0-rings when installing pressure lines.

14. Installing Supplementary Wiring Harnesses

F 34 64 136

Bend back heat-protection sheet. Cut out pre-marked section (1) from insulating mat (2) on right side of engine compartment.

F 34 64 193

Remove sealing compound and take off cover (1) in passenger compartment .

Models without air conditioner

Install supplementary main wiring harness and 20-pin relay box.

Models with air conditioner

Install supplementary main wiring harness and 12-pin relay box.

Note

If cover (1) is not present, drill bore hole of dia. 35 mm to cable channel.

F 34 64 196

Guide cable connector of supplementary main wiring harness (1) through bore hole (2) into engine compartment. Insert rubber grommet (3) into bore hole (2).

F 34 64 287

Connect tied-back cable plug-in connection (1) at supplementary main wiring harness (2).

F 34 64 137

Models without air conditioner

Position 20-pin relay box (1) to bracket (2). Add hexagon nuts (3) and secure.

Models with air conditioner

Position 12-pin relay box (4) to bracket (5). Add hexagon nuts (6) and secure.

F 34 64 138

All models

Install relay box and bracket (1) in A-column. Insert hexagon screws and washers (2) and secure. Attach cable connector (3) of supplementary main wiring harness (4) to relay box and bracket (1). Insert supplementary main wiring harness (4) into standard-fitted cable strap.

F 34 64 139

Release tied-back cable connector (1) from vehicle wiring harness and connect to cable connector (2) of supplementary main wiring harness (3).

Note

If the cable connector (1) is not present on the vehicle wiring harness, the universal wiring harness must be installed (see parts microfiche).

F 34 64 140

Models without air conditioner

Remove cable connector (1) from heater (2). Connect cable bridge (3) to heater (2).

Connect cable connector (1) to cable bridge (3).

F 32 64 358

Models with air conditioner

Remove cover (1) of rear-window heater switch. Using a small regular screwdriver, press back clip (2) to switch of heating control unit (3) and lift out heating control unit (3) in direction of arrow in illustration .

Important

In order to avoid damage to the heating control unit, cover the storage compartment with a piece of cloth.

F 32 64 359

Connect supplementary main wiring harness (1) to plug-in station (2) of heating control unit. Install heating control unit.

Note

Insert supplementary main wiring harness into standard-fitted cable strap.

F 34 65 335

Models without plug-in station at heating control unit

Disconnect connectors (1 and 2) and connect to cable bridge (3) underneath heater as shown in illustration.

F 34 62 002

Models with clock and outside-temperature/digital display

Remove radio and pull lever (1) as far as it will go in direction of arrow in illustration. Remove clock (2) and

outside-temperature/digital display.

F 34 62 003

Important

Adjust setting of screw (4) on rear of outside-temperature/ digital display for independent heating I independent ventilation system.

Item Temperature display Hour display
1 “Celsius 12 hours
2 °Celsius 24 hours
3 “Fahrenheit 12 hours

F 34 64 143

Position cover (1) on outside-temperature/digital display for independent heating I independent ventilation system (2) and press down until it snaps into place.

F 34 64 144

Insert outside-temperature/digital display for independent heating I independent ventilation system (1) into opening. Press lever (2) as far as it will go in direction of arrow in illustration. Install radio or radio-opening cover. Lay supplementary main wiring harness as far as rear right seat base. Insert supplementary main wiring harness into standard-fitted cable strap or cable covers. Jack up vehicle. Mark and remove front right and rear right wheels.

Important

Pay attention to tightening torque of wheel studs (see operating instructions). After 50 km, tighten wheel studs according to specified tightening torque.

F 34 64 145

Lift out and disconnect cable plug-in connection (1). Pull out rubber grommet (2).

F 34 64 146

Release standard-fitted cable strap. Lift out wiring harness ( 1).

F 34 64 243

Disconnect cable plug-in connection (1) at rear axle.

Important

Pay attention to colour of plug-in connection (1). Install supplementary wiring harnesses in accordance with respective colours.

F 34 64 149

Remove hexagon screw (1) from fuel tank (2). Bend heat-protection sheet (3) to side.

F 34 64 150

Important

Take care not to damage foam seal. Open luggage compartment.

Lift out luggage-compartment floor mat. Remove Phillips screws (1) and take off cover (2).

F 34 64 151

Open bracket (1) in direction of arrow in illustration and remove cable connector (2).

Note

It is necessary to lower the fuel tank in order to remove wiring harness (3). The following work steps are required for this.

F 34 64 152

Support fuel tank (1) from below. Remove hexagon-socket­ head screws (2) and washers (3) from right and left clamp band (4).

F 34 64 216

Lower fuel tank by 100 mm. Open standard-fitted cable straps (1). Remove wiring harness.

Install new wiring harness from installation kit and close cable straps.

Reinstall the following parts in reverse sequence

Fuel tank

Supplementary wiring harness

Heat-protection sheets

F 32 64 407

Release cable loop (2) if necessary. Lay supplementary wiring harness (1) along vehicle wiring harness to rear right of seat base.

F 34 64 570

Connect cable connector (1) of supplementary main wiring harness (2) to supplementary wiring harness (3). Secure cable connector (4) of supplementary main wiring harness (2) at earth terminal.

F 34 65 141

Lay supplementary main wiring harness (1) to rear partition panelling (2) as shown in illustration. Pull out rubber grommet (3) from rear partition panelling (2) and cut out opening (4). Guide supplementary main wiring harness (1) through opening (4) into passenger compartment. Reinstall rubber grommet (3).

F 34 64 571

Insert fuses (I and II) into fuse carrier (1). 25 Amp fuse at position I.

10 Amp fuse at position II.

Connect relay No. 1 390 383 (2) to relay frame K62 (3). Push relay frame (3) and fuse carrier (1) into bracket underneath retaining plate for second battery as shown in illustration.

F 34 65 350

Connect cable connectors (1-4) of supplementary main wiring harness (5) to control unit (6). Fit metal nuts (7) to control unit (6) as illustrated.

Screw Phillips screws (8) into metal nuts (7) by hand.

F 34 65 572

Remove Phillips screws (1).

Carefully remove retaining plate (2) and lay to one side.

F 34 65 351

Lay supplementary main wiring harness (1) and control unit (2) along side-panel plate (3) as shown in illustration.

F 34 64 467

Insert control unit (1) into opening (2) of side-panel plate (3) as shown in illustration.

F 34 65 353

Connect cable connector (1) of supplementary wiring harness to cable connector (2) of auxiliary battery.

F 34 65 354

Thread cable straps (1) into bore holes (2) of retaining plate (3) and side-panel plate (4). Insert supplementary main wiring harness into cable straps (1) and close cable straps (1).

F 34 65 355

Attach wiring-harness sheathing (1 and 2) from installation

kit to right side of luggage compartment (use adhesive tape if necessary) as shown in illustration.

Install luggage-compartment panelling.

15. Removing Stanchion Sensor

F 34 64 573

Release hose clips (1). Unplug return hose (2) and supply hose (3). Disconnect cable connector (4). Remove securing nut (5) in direction of arrow in illustration. Take stanchion sensor out of tank.

Note

Supply hose (3) and return hose (2) must not be interchanged.

F 34 64 574

Take fuel hose (3) and hose clamp (2) out of installation kit. Push fuel hose (3) onto pipe (1) of return line and secure with hose clamp (2). Reinstall stanchion.

Reconnect cable connector , supply hose and return hose. Secure cover .

16. Installing Fuel Lines

F 34 64 153

Important

Remove sealing compound from internal threading of stud bolt (3). Attach guide (1) with small opening (4) in direction of wheel house (5). Attach guides (2) with small opening (4) in direction of outside of vehicle.

Connect all clips (there are 12) as far as rear axle.

Connect guides (1 and 2) to stud bolts (3) on underside of vehicle.

F 34 64 202

Important

Front fuel line (1) must not be fitted close to underside of vehicle (7).

Guide front fuel line (1) through bore hole (2) into engine compartment. Clip front fuel line (1) into small opening (3) of clip bracket (4). Position bracket (5) and tighten Phillips screw (6).

F 34 64 230

Note

Cut off required length of fuel hose (2) from piece goods.

Clip rear fuel line (1) along underside of vehicle into guides . Attach fuel hose (2), length 40 mm, to front fuel line (3) and rear fuel line (1) with clic clips (marked violet) and close clic clips. Position all brackets and tighten Phillips screws .

17. Installing Supplementary Fuel Pump

F 34 64 258

Remove hexagon screw (1). Take off hose clip (2) of supply line (3) and return line (4).

F 34 64 260

Position hose clamp (IV) of return line (1) and disconnect return line. Mark and cut through return line (1) at a distance of 190 mm from standard-fitted return pipe.

F 34 64 261

Attach hose clips (1) to return line (2). Insert T-piece (3) into return line (2). Connect fuel hose (4) to T-piece (3) with clic clip (5) (marked white) and close clic clip.

F 32 64 317

Important

Ensure that T-piece is aligned correctly .

The T-piece must not be tilted by more than 60″. Close clamping collars.

F 34 64 223

Note

For installation kits with pre-assembled supplementary fuel pump, the following two work steps do not apply . Connect fuel hose ( 1) to connector (2) of supplementary fuel pump (3) with clic clip (marked white) and close clic clip.

F 34 64 289

Connect bracket (1) with hose clip (2) and rubber element (3) to supplementary fuel pump (4).

F 34 64 262

Secure supplementary fuel pump (1) with hexagon screw (2) and washer (3) to securing point of hose clip (4). Connect fuel hose (5) to supplementary fuel pump (1) with clic clip (marked white) and close clic clip.

Note

Remove hose clamp from return hose.

F 34 64 263

Connect fuel hose (1) to fuel line (2) with clic clip (marked violet) and close clic clip.

Connect cable connector (3) to supplementary fuel pump (4).

Note

Connect adapter wiring harness (5) if necessary .

18. Removing Engine-Compartment Cover

F 34 64 575

Remove hexagon nuts (1 and 3). Remove engine-compartment cover (2).

F 34 64 576

Remove hexagon screws (1 and 2). Remove covers (3).

F 34 64 226

Models with automatic transmission

Remove hexagon screws (1) and hexagon nuts (2). Remove covers (3).

19. Draining Coolant

F 34 64 189

Remove cover of expansion tank .

Remove hexagon screw (1) on right of engine block. Remove sealing ring (2). Catch coolant.

Note

The hexagon screw (1) and sealing ring (2) are no longer required.

F 34 64 214

Remove self-locking hexagon nut (1) from exhaust manifold (2).

Installation information

Replace self-locking hexagon nut (1 ) .

F 34 64 190

Insert hollow screw (1) and sealing rings (2) into pipe (3).

F 34 64 275

Position pipe (1) on stud bolt (2).

Insert and tighten hollow screw (3) and sealing rings. Attach and secure self-locking hexagon nuts (4).

20. Installing Heater for Independent Heating

F 32 64 319

Important

Follow drilling instructions of second page.

Affix drilling template (1) in front right wheel house as shown in illustration and mark bore holes (2) with centre punch. Drill through marked bore holes with a twist drill bit of dia. 3.5 mm and enlarge to dia. 6.5 mm.

F 34 64 286

Note

The illustrations are shown with the engine removed for clearer presentation.

Push heat-protection hose (1) over fuel hose (2). Connect fuel hose (2) to front fuel line (3) with clic clip (marked violet) and close clic clip.

F 34 64 158

Connect flexible exhaust-gas hose (1) and pipe clip (2) to silencer (3) on heater (4) and t ighten pipe clip (2).

F 34 64 577

Connect coolant hose (1) and hose clip to heater (2) and tighten hose clip.

F 34 64 578

Lift heater (1) in engine compartment. Lay flexible exhaust-gas hose (2) along engine-compartment rear bulk to underside of vehicle .

F 32 64 353

Position omega clip (1) to heat-protection hose and insert into opening at heater bracket.

F 34 64 220

Connect fuel hose ( 1) to heater connector (3) with clic clip (2) (marked white) and close clic clip.

Push heat-protection hose (4) in direction of arrow in illustration over heater connector (3).

F 34 64 159

Remove heater cover (1). Connect cable connectors (2, 3) to heater (1). Attach cover .

Important

Insert rubber gaskets of wiring harnesses into openings at cover.

F 34 64 218

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Insert heater bracket into bore holes. Position and secure hexagon nuts (1).

Important

Check position of heater. The minimum distance between components and bodywork is 5 mm (to avoid friction from rubbing and droning noises).

F 34 64 213

Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with stud bolts

Connect pipe clips (1) to flexible exhaust-gas hose (2) and stud bolt (3). Position and secure metal nuts (4).

F 34 64 210

Models without stud bolts

Mark bore holes (1) with centre punch as shown in illustration . Drill through marked bore holes with a twist drill bit of dia. 3.5 mm and enlarge to dia. 5 mm.

A = 15 mm

B = 130 mm

Important

Follow drilling instructions of second page.

F 34 64 211

Connect pipe clips (1) to flexible exhaust-gas hose (2). Insert and secure hexagon screws (3).

21. Installing Coolant Hoses

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Take off cover (1). Open hose clips and remove coolant hoses (2 and 3).

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Remove cable connector (1) and overflow line (2). Remove hexagon nuts (3) on right and left sides of expansion tank. Remove expansion tank (4).

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Release hose clip (1). Remove coolant hose (2) from return connecting piece (3). Remove hexagon nut from (4) on right and left sides of vehicle and take off cover (5).

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Release hose clip (2) at coolant pipe (1) and remove coolant hose (3). Lift out and remove coolant hose (3) from hose bracket.

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Cut through coolant hose (1) with dimension a = 460 mm. Shorten right coolant hose (2) by distance b = 15 mm.

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Pre-assemble subsequent coolant-hose connection with hose clips.

Important

Pay attention to direction of arrow on non-return valve (2).

Connect coolant hoses (1, 3 and 4) and hose clips to non-return valve.

F 34 64 583

Notes

For models with air conditioner , the coolant hose (1) is connected to the auxiliary water pump. Coolant hose (1) is no longer required.

Release hose clips. Pull off and remove coolant hose (1) at cylinder head and at water valve or auxiliary water pump.

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Secure double pipe (1) at cylinder head using removed valve-cover screws (2) as shown in illustration.

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Pre-assemble subsequent coolant-hose connection and hose clips. Connect coolant hoses (1, 2, 3) and hose clips to thermostat housing (4). Push protective hose (5) onto coolant hose (2) with opening facing downwards .

F 34 64 586

Connect coolant hose (7) of heater and hose clip to connector (6) of double pipe.

Install pre-assembled hose connection (8) and hose clips as shown in illustration. Connect connector (9) and hose clip to heater.

Connect connector (5) and hose clip to connector (4) of double pipe. Fit coolant hose (3) and hose clip to pipe (2). Push protective hose (1) with opening over hose clip of coolant hose (3) as illustrated. Tighten all hose clips.

Note

The illustrations are shown with the engine removed for clearer presentation.

F 34 64 587

Install coolant hose (4) and hose clips. Connect connector (3) and hose clip to connector (2) of double pipe. Connect connector (1) and hose clip to cylinder head.

Connect connector (5) and hose clip to supplementary water pump or water valve. Tighten all hose clips.

F 34 64 588

Install pre-assembled hose connection (3) and hose clips as shown in illustration.

Connect connector (2) and hose clip to coolant pipe (1). Connect connector (4) and hose clip to return line of heating system. Connect connector (5) and hose clip to connector (6) of double pipe. Press coolant hose (3) into clip under suction pipe. Tighten all hose clips.

22. Inserting Relays

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Open clip of fuse box at front left of engine compartment. Remove cover (see arrow in illustration). Reinstall all removed parts in engine compartment in reverse sequence. Install engine-compartment covers.

F 34 64 589

Important

Fuse box I = models with low equipment variants

Fuse box II = models with high equipment variants

Fuse box I

Connect relay to plug-in station x58

Fuse box II

Connect relay to plug-in station x58 Close fuse box. Connect battery.

Order No. Relay K4: AWT 6131 1 388 913

Note

Selection table (AWT) 6131 1 388 913 contains the following relays:

Relay No. Striebel 1 388 911

Relay No. Siemens 1 378 786

23. Bleeding Cooling System

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Set heating control (1) to “warm”.

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Models with air conditioner

Set heating control (see arrows in illustration) at heating control unit to “warm” .

Important

Air conditioner must not be switched on.

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Unscrew bleeder screw (1). Replenish coolant supply.

Important

Use pre-specified strength of coolant recommended by manufacturer. If coolant outlet is free of bubbles, close bleeding screws and fill expansion tank to maximum level. Close expansion tank. Run engine until it reaches operating temperature. Repeat bleeding process until the whole cooling system is completely bled. Switch off engine and allow to cool. Pressure test cooling system using special tools (II and Ill).

24. Installing Outside-Temperature Sensor

(only models with air conditioner)

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Press in lever (1) in direction of arrow in illustration and lift out protecting cap on left (2) from front of bumper.

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Insert outside-temperature sensor (see arrow in illustration).

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Connect cable connector (1) to tied-back cable connector (2). Fit protecting cap.

25. Initial Operation of Independent Heating Independent Ventilation System

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with outside-temperature/digital display

1. Set ignition lock to position (I).

2. Set fan switch to level 1.

3. Set heating to “warm”.

Switching on directly

Press “EIN” button for 3 seconds until LED flashes .

When outside temperature > 16 ·c

Independent ventilation starts and vehicle blower is activated.

When outside temperature < 16 ·c

Independent heating starts.

In order to check the correct functioning of independent heating, it is recommended that with an outside temperature of more than 16 “C, the outside-temperature sensor is allowed to cool to below 16 “C during the complete operational check.

Models without air conditioner

The vehicle blower does not switch itself on until the coolant has reached a temperature of 55 ‘C.

Switching off directly

Press “AUS” button.

All models

For information on programming and activation of the independent heating I independent ventilation system, see BMW Owner’s Handbook.

Models with air conditioner

Fill air conditioner in accordance with BMW Repair Instructions.

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Independent Heating / Independent Ventilation BMW 5 Series E34 (525 tds) M51 Diesel

Models with on-board computer
  1. Set ignition lock to position (I).
  2. Set fan switch to level 1.
  3. Set heating to “warm”.

Switching on directly Press “ZEIT” button. Press “S/R” button.

When outside temperature > 16 ·c

Independent ventilation starts and vehicle blower is activated.

When outside temperature < 16 ·c

Independent heating starts.

In order to check the correct functioning of independent heating, it is recommended that with an outside temperature

of more than 16 ‘C, the outside-temperature sensor is allowed to cool to below 16 ·c during the complete

operational check.

All models

For information on programming and activation of the independent heating I independent ventilation system, see BMW Owner’s Handbook.

Models with air conditioner

Fill air conditioner in accordance with BMW Repair Instructions.

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