Subsidiary Battery BMW 5 Series E34 from 1/89

EBA – 01 29 9 787 203
BMW Installation Instructions

Subsidiary Battery BMW 5 Series E34 from 1/89

Specialised knowledge is required.

Installation time: Approx. 5-6 hours – this may vary, depending on the condition of the vehicle and its fittings.

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.

Installation is possible only in conjunction with appropriate special fittings (see parts microfiche)

Important

The subsidiary battery is dry when precharged and must be filled with the appropriate acid only in accordance with the battery manufacturer’s specifications .

Always observe the relevant safety instructions when handling battery acid.

Drilling Instructions

Burr drilled edges and coat with zinc paint. Remove drillings thoroughly .

Treat cavities with cavity preserving agent that is approved by vehicle manufacturer.

Tools and Materials Required

1/2″ ratchet 1/2″ extension
1/2″ drive socket, 10, 13, 17 mm A/F
1/2″ torque wrench
1/4″ ratchet
1/4″ extension
1/4″ drive socket, 10, 13 mm A/F
Drill
Twist drill bit, 3.5 mm, 4 mm, 6.5 mm dia.
Stepped drill bit, 4 – 30 mm dia.
Open-jawed spanner, 10, 13 mm A/F
Regular screwdriver
Phillips screwdriver
Hammer
Mandrel, 5 mm dia.
All-purpose knife
Marking tool
Flat file
Round file
Tape measure
Electric torch
Zinc paint
Cavity preserving agent
Underseal
Brush Soap
Water-soluble marker pen
Cleaning cloth

Contents

Chapter

  1. Disconnecting Battery
  2. Removing Rear Seat Bench
  3. Removing Centre Arm Rest (only models with centre arm rest)
  4. Removing Cold Box (only models with cold box)
  5. Removing Backrest
  6. Removing Luggage Compartment Panelling
  7. Removing Wheelhouse Panelling, Rear Left
  8. Drilling Fixture Points for Retaining Plate
  9. Laying Battery Degassing Hose
  10. Installing Bracket
  11. Installing Battery Relay
  12. Installing Retaining Plate
  13. Installing Subsidiary Battery
  14. Laying Supplementary Wiring Harness
  15. Connecting Supplementary Wiring Harness
  16. Installing Luggage Compartment Panelling

1. Disconnecting Battery

F 34 71 002

Subsidiary Battery BMW 5 Series E34 from 1/89

Important

Print out fault memory.

When the battery is disconnected, the fault memories are deleted.

BMW 518i, 520i, 525i

Remove negative terminal post and place aside (arrow).

F 34 71 003

Subsidiary Battery BMW 5 Series E34 from 1/89

BMW 530i, 535i, 524d, 525tds

Remove cover (1) from bottom right of rear seat base. Remove hexagon screw (2) and take off covering (3).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon nut (1). Remove washer (2).

Disconnect negative cable (3).

2. Removing Rear Seat Bench

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Subsidiary Battery BMW 5 Series E34 from 1/89

Pull out and remove rear seat bench (1) from its mount in direction of arrow.

Models with rear seat heating

Disconnect cable plug-in connection below rear seat bench.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Models with folding rear seats

Move front seats forward as far as possible.

Pull out seat cushions (1) in direction of arrow by means of loop (2).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Press together locking device (1) of seat cushion (2) and remove seat cushion (2).

3. Removing Centre Arm Rest

(only models with centre arm rest)

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Subsidiary Battery BMW 5 Series E34 from 1/89

Fold down centre arm rest and remove lining on Velcro-type fastener .

Press together locking device as indicated by arrows and remove centre arm rest.

4. Removing Cold Box

(only models with cold box)

F 32 51 184

Subsidiary Battery BMW 5 Series E34 from 1/89

Remove screws (4).

Remove luggage compartment panelling (1, 2) from rear partition panel (3).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Release locking screw (1).

Insert retainer (2) in direction of arrow. Remove cable connector (3).

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Subsidiary Battery BMW 5 Series E34 from 1/89

With the help of another person, carefully remove cold box (1).

Note on installation

Retaining lugs (2) must be inserted in openings (3).

5. Removing Backrest

Models with rear head restraint

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove head restraint (1) in direction of arrow.

Note on installation

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

F 34 52 010

Subsidiary Battery BMW 5 Series E34 from 1/89

Turn slotted screws (1) by 90′ and remove cover (2).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon nuts (1) and screws (2) from seat belts.

Note on installation

Tightening torque for hexagon screws (2): 48 Nm.

F 34 65 001

Subsidiary Battery BMW 5 Series E34 from 1/89

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

F 32 52 003

Subsidiary Battery BMW 5 Series E34 from 1/89

Lift backrest (1) out of mounts and pull forward.

Pass seat belts through slots (2) and remove backrest (1).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Models with folding rear seats

Remove hexagon nuts (1).

Take out seat base panelling (2).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon screws (1) of seat belts (2) and washers (3).

Note on installation

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

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Subsidiary Battery BMW 5 Series E34 from 1/89

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

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Subsidiary Battery BMW 5 Series E34 from 1/89

Press locking device (1) in direction of arrow and remove backrests (2).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon nuts (1).

Pull out and remove side upholstery (2) on right and left vehicle sides in direction of arrow.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Note on installation

Insert retainer (1) in guide (2).

6. Removing Luggage Compartment Panelling

F 32 72 028

Subsidiary Battery BMW 5 Series E34 from 1/89

Take out luggage compartement floor mat.

Remove plastic nuts (1) and take out luggage compartment panelling (2).

F 32 72 034

Subsidiary Battery BMW 5 Series E34 from 1/89

Models with ski bag

Remove plastic screws (4) and take off and remove luggage compartment panelling (1, 2) from rear partition panel (3).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Models with cold box

Remove plastic screws (4).

Take out the right and left halves of the divided luggage compartment panelling (1 and 2).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Note

The left luggage compartment panelling (2) is no longer required.

Turn slotted screws (1) of left luggage compartment panelling (2) by 90° and take out luggage compartment panelling (2).

F 34 65 162

Subsidiary Battery BMW 5 Series E34 from 1/89

Turn slotted screws (1) of right luggage compartment panelling (2) by 90° in direction of arrow and take out luggage compartment panelling (2).

Take out jack and wheel chock.

Remove luggage compartment panelling (3).

Note

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

F 34 71 007

Subsidiary Battery BMW 5 Series E34 from 1/89

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

Note on installation

Take out split-rivet pins (1) from bodywork cavity below cover (2) and reuse.

F 34 71 008

Subsidiary Battery BMW 5 Series E34 from 1/89

Lever out split rivets (1).

Fold open cover (2) in direction of arrow.

Lift wiring harness (3) out of clasps (4) and remove cover (2).

7. Removing Wheelhouse Panelling, Rear Left

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon nuts (1) on left side of vehicle and take out wheelhouse panelling (2).

Note on installation

Install clip (3) on sheet metal (4).

8. Drilling Fixture Points for Retaining Plate

F 34 65 134

Subsidiary Battery BMW 5 Series E34 from 1/89

Remove plastic nuts (1) of wiring harness cover (2). Take off wiring harness cover (2).

F 34 65 135

Subsidiary Battery BMW 5 Series E34 from 1/89

Remove hexagon nut (1) and hexagon screw (2). Take off wiring harness cover (3).

Note

Wiring harness cover (3) is no longer required.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Remove bracket (1) with hexagon screws (2) and washers (3) from retaining plate (4).

F 34 65 136

Subsidiary Battery BMW 5 Series E34 from 1/89

Fit retaining plate (1) in luggage compartment so that surfaces (2-4) are in contact with bodywork sheet metal.

F 34 65 137

Subsidiary Battery BMW 5 Series E34 from 1/89

Mark bore areas (arrows) with water-soluble marker pen. Remove retaining plate (1 ).

Mark bore areas (arrows) with centre punch. Remove bracket from retaining plate.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Lever out left luggage compartment vent (1) from clasps and remove in direction of arrow.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Bore through bore areas (1, 2) with twist drill bit dia. 4 mm. Enlarge bore holes (2) to 6.5 mm dia.

Important

Beneath the bore areas (1), there is a bodywork cavity which must be treated with cavity preserving agent, approved by the vehicle manufacturer, from the vehicle underbody through a bore hole.

Important

Read drilling instructions on first page.

9. Laying Battery Degassing Hose

F 32 65 411

Subsidiary Battery BMW 5 Series E34 from 1/89

Mark bore area (1), dimension A = 25 mm, mark with centre punch, drill with twist drill bit dia. 3.5 mm and enlarge to 11 mm dia.

Important

Read drilling instructions on first page.

F 32 65 413

Subsidiary Battery BMW 5 Series E34 from 1/89

Draw battery degassing hose (1) approx. 30 mm through rubber grommet.

Lay battery degassing hose (1) as shown in illustration. Insert rubber grommet (2) in bore hole.

10. Installing Bracket

F 34 65 138

Subsidiary Battery BMW 5 Series E34 from 1/89

Insert hexagon screws (1) (M6x15) with sealing rings (2) from wheelhouse (3) into luggage compartment (4).

Fit sealing rings (5) to hexagon screws (1) and install bracket (6).

Fit hexagon nuts with washers (7).

Install hexagon nuts (8) and secure bracket (6).

Important

Repair undersea! in wheelhouse .

Install wheelhouse panelling in reverse sequence to removal.

11. Installing Battery Relay

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Subsidiary Battery BMW 5 Series E34 from 1/89

Attach battery cutoff relay (5) to relay frame (2).

Secure positive cable (1) of supplementary wiring harness (6) with Phillips screws (4) to relay frame.

Press covers (3) down into catch on relay frame (2).

F 34 65 611

Subsidiary Battery BMW 5 Series E34 from 1/89

Press relay holder (1) into retaining plate (2) as shown in illustration.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Install battery cutoff relay K 14/X628 ( 1) and fuse holder X10007 (2) on relay holder of retainirig plate (3) as shown in illustration.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Insert 10 A fuse (1) into plug-in station (2) of fuse holder (3) as shown in illustration .

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Subsidiary Battery BMW 5 Series E34 from 1/89

Until 9/92

Lay supplementary wiring harness (1) as shown in illustration to rear partition panel (2).

Remove rubber grommet (3) from rear partition panel (2) and cut out opening (4).

Insert supplementary wiring harness (1) through opening (4) into passenger compartment. Install rubber grommet (3).

Note

In vehicles with folding rear seats, lay supplementary wiring harness behind wiring harness cover from installation kit.

12. Installing Retaining Plate

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Subsidiary Battery BMW 5 Series E34 from 1/89

Install retaining plate (1) in luggage compartment so that supplementary wiring harness (2) and standard wiring harness (3) are laid behind retaining plate.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Insert hexagon screws (1) (M6x15) and Phillips screws with washers (2) (B4, 8×16) in retaining plate (3) and tighten by hand.

Insert hexagon screws (4) (M6x15) in retaining plate (3),

install hexagon nuts and tighten by hand.

Important

Check laying of cable.

Align and secure retaining plate (3).

13. Installing Subsidiary Battery

F 34 65 149

Subsidiary Battery BMW 5 Series E34 from 1/89

The subsidiary battery is dry when precharged and must be filled with the appropriate acid only in accordance with the battery manufacturer’s specifications.

Important

Always observe the relevant safety instructions when handling battery acid.

Place subsidiary battery (1) on retaining plate (2) as shown in illustration.

Fit retaining bracket (3) with Phillips screws (4) and secure Phillips screws (4).

F 32 65 422

Subsidiary Battery BMW 5 Series E34 from 1/89

Secure positive cable of battery relay (1) with hexagon screw (2), washer (3) and hexagon nut (4) to positive terminal of subsidiary battery.

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Subsidiary Battery BMW 5 Series E34 from 1/89

Fold down cover (5).

Secure connection (1) of negative cable (2) with hexagon screw (3), washer (4) and hexagon nut (5) to negative terminal of subsidiary battery (6).

Attach connection (7) of negative cable (2) to pin (8). Install and secure washer (9) and hexagon nut (10).

F 32 65 421

Subsidiary Battery BMW 5 Series E34 from 1/89

Attach battery degassing hose (1) to tube (2) of degassing tank (3).

Insert tube (4) of battery degassing tank (3) in bore (5) of subsidiary battery (6).

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Subsidiary Battery BMW 5 Series E34 from 1/89

Fit omega clip (1) to supplementary wiring harness (2) and degassing hose (3).

Fit omega clip (1) in bore (4) of retaining plate (5).

14. Laying Supplementary Wiring Harness

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Subsidiary Battery BMW 5 Series E34 from 1/89

Lay supplementary wiring harness (1) as shown in illustration along retaining plate (2).

Attach cable connector (3) of supplementary wiring harness to cable connector (4) of standard wiring harness.

F 34 65 169

Subsidiary Battery BMW 5 Series E34 from 1/89

Pull cable straps (1) into bores (2) of retaining plate (3). Insert supplementary wiring harness (4) and standard wiring harness (5) in cable straps and seal cable straps (1).

F 34 65 355

Subsidiary Battery BMW 5 Series E34 from 1/89

Install wiring harness covers (1, 2) from installation kit as shown in illustration on right side of luggage compartment, and secure with adhesive tape if necessary.

15. Connecting Supplementary Wiring Harness

F 32 65 431

Subsidiary Battery BMW 5 Series E34 from 1/89

BMW 520i, 525i until 9/88

Carefully cut open shrink-fit hose (1) and remove. Disconnect cable connection (2).

Fit new shrink-fit hose (3).

Attach cable connection (2) to supplementary wiring harness (4).

Fit shrink-fit hose (3) over cable connection (2) and heat.

F 34 65 158

Subsidiary Battery BMW 5 Series E34 from 1/89

BMW 520i, 525i from 9/88

Open cover (1) of cable support on right under rear seat bench in direction of arrow.

Secure supplementary wiring harness (2) to position (3) as shown in illustration.

Close cover (1).

F 34 65 159

Subsidiary Battery BMW 5 Series E34 from 1/89

BMW 530i, 535i, 524td, 525tds

Secure positive cable (1) of supplementary wiring harness as shown in illustration to positive terminal (2) (as shown in illustration).

F 34 65 160

Subsidiary Battery BMW 5 Series E34 from 1/89

Models with anti-theft alarm system

Remove hexagon nuts (1) and hexagon screw (2). Raise cover (3) and disconnect cable connector of microswitch (4).

Remove cover (3).

F 34 65 159

Subsidiary Battery BMW 5 Series E34 from 1/89

Secure positive cable (1) of supplementary wiring harness to negative terminal post (2).

Reinstall all parts which have been removed in reverse sequence.

16. Installing Luggage Compartment Panelling

F 34 65 161

Subsidiary Battery BMW 5 Series E34 from 1/89

Install luggage compartment panelling in sequence (1, 2, 3) on left side of luggage compartment and lock in place.

Reinstall all parts which have been removed in reverse sequence.

F 34 65 356

Subsidiary Battery BMW 5 Series E34 from 1/89

Cut out luggage compartment mat as shown in illustration.

Dimension A = 160 mm Dimension B = 240 mm

Note

Reinstall all parts which have been removed in reverse sequence.

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