Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

EBA – 01 29 9 787 287
BMW Installation Instructions

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Technical knowledge of the system is required. Installation time: approx. 8-10 hours depending on the condition and level of equipment of the car.

General Instructions

All illustrations show the installation steps on a left- hand drive car. In right-hand drive cars, some of the steps must becarried out as if for a mirror image.

Remove all swarf, deburr all the edges around holes you drill and coat them with zink-based paint.

Tools and other equipment required

Regular flat-head screwdriver
Cross-recessed screwdriver
Open-end spanner, 10 mm A/F
1/2” reversible ratchet
1/2” extension piece
1/2” socket wrenches, 17 mm, 22 mm A/F
1/2” torque wrench
1/4” reversible ratchet
1/4” extension piece
1/4” socket wrenches, 8 mm, 10 mm A/F
Ring spanners, 8 mm, 10 mm, 13 mm 17 mm, 19 mm A/F
Hammer
Tape measure
Drift punches, 3 mm, 4 mm dia.
Power drill
Angular drill
Twist drill, 3.5 mm dia.
Stepped drill, 4-30 mm dia.
Hose clip pliers
Water-soluble pen
Prick punch
Cable lamp
File
Glycerine
Serial No. Illustration    Name

I                F 32 72 075  Special tool

II               F 32 61 013  Washer jet adjuster

III              F 34 65 208  Pusher BMW No. 61 1 132

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Table of Contents

Section

  1. Preparations on the Car/Removal
  2. Auxiliary Wiring Harness/Overview
  3. Running the Front and Rear Auxiliary Wiring Harnesses
  4. Installing the Wiper Switch
  5. Removing the Front Bumper
  6. Installing the Headlight Washer Jets
  7. Running the Headlight Cleaning System Hose Lines
  8. Installing the Headlight Cleaning System Washer Fluid Reservoir
  9. Installing the Windscreen Washer Jets
  10. Running the Intensive Cleaning System Hose Lines
  11. Installing the Intensive Cleaning System Washer Fluid Reservoir
  12. Checking Operation

1. Preparations on the Car/Removal

  1. Print out fault memory
  2. Remove rear seat bench
  3. Disconnect battery
  4. Remove front and rear scuff mouldings on left-hand side
  5. Remove driver’s seat

2. Auxiliary Wiring Harness/Overview

F 34 63 094

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Pos. Description Connection location in vehicle Colour of wire Graphic

symbol

Slot
A Jack contact Windscreen washer pump Bk/Br Bk/Gr X107 1
B Jack Headlight cleaner pump Br/Vi Vi/Bk X123
C Jack Intensive cleaner pump Vi/Bk Bk/Gr/Ye X110
D Cable eye Earthing point, front right side panel Br X166
E Housing In glove compartment
E1 Jack contact In housing E Bk/Br X13B 1
E2 Jack contact In housing E Bk/Gn X13B 2
F Housing In glove compartment
F1 Pin contact In housing F Bk/Br X13S 1
F2 Pin contact In housing F Bk/Gn X13S 2
G Pin contact On wiper plug below steering column Bk/Gn/Ye X295 7
H Pin contact On wiper plug beneath steering column Br X492 6
I Jack contact In yellow plug in front left footwell Bk/Gn X14B 25
J Jack contact In ZV module beneath rear seat bench X285S
K Housing In ZV module beneath rear seat bench X285B
L Jack contact In white plug, left next to steering column Gr/Bk X15B 8
Pos. Description Connection location in vehicle Colour of wire Graphic

symbol

Slot
M Cable eye Earthing point beneath rear seat bench Br/Or X492
N blank On B+ beneath rear seat bench Rd X448
O 26-pin jack Beneatch rear seat bench X1242
P Relay socket K53 Beneath rear seat bench on Ctrl housing X99
Q Relay socket K11 Beneath rear seat bench on Ctrl housing X1082
R Relay socket N6 Beneath rear seat bench on Ctrl housing X61
S Relay socket N21 Beneath rear seat bench on Ctrl housing X10031

3. Running the Front and Rear Auxiliary Wiring Harnesses

Front auxiliary wiring harness

F 34 63 095

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

The installation positions of the auxiliary wiring harness are:

to windscreen washer pump (1),

to headlight cleaner pump (2),

to intensive cleaner pump (3),

to earthing terminal on front right side panel (4), to wiper plug (5), to plug X15S (6), to plug X14S (7), to control-unit board (8), to earthing terminal on transmission tunnel at rear (9).

F 34 64 230

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove cross-recessed screws from electronics box (arrows) and take off lid.

F 34 63 057

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove cross-recessed screws (1).

F 34 63 058

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove hexagon nut (1) and remove mounting (2) from electronics box.

F 34 63 059

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Pull up lever (1) and pull off plug (2) in direction of arrow. Push spring (3) in direction of arrow and pull off plug (4). Release plug (5).

F 34 63 060

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Loosen hexagon nuts (1), pull out jack (2), lift out seal (3) and take out relay strip (4) and it turn round.

F 34 63 061

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove protective cap (1) and loosen hexagon nut (2). Remove cable (3). Tilt relay strip (4) away from you towards rear.

F 34 63 062

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Lift out electronics box (1) in direction of arrow. Do not remove it.

F 34 63 063

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove screw (1) and lift washer fluid reservoir (2) sidewards (arrow).

F 34 63 064

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Turn plastic screws (1) through 90° and remove headlight cover (2).

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Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove cross-recessed screws (1) and push glove compartment cover (2) downwards in direction of arrow. Do not remove it.

F 34 65 002

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove cross-recessed screw (1) and remove trim panel (2) in direction of arrow.

F 34 65 003

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Turn plastic screws (1) through 90° and remove. Remove the four cross-recessed screws (2) and pull off trim panel (3) downwards.

F 34 61 027

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Models fitted with air conditioning

Carefully pull vent (1) out of air duct (2) of heater (3). Pull plug (4) off gong (5). Remove trim panel (6).

F 34 65 004

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Prise out the three blanking caps (1) using screwdriver and remove cross-recessed screws (2).

Remove trim panel (3).

F 34 65 006

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove blanking cap (1) and remove screw (2). Turn plastic screws (4) through 90° and remove footwell trim panel.

F 34 63 096

Run jacks (B and C) and jack contact (A) into right- hand side panel and run auxiliary wiring harness towards electronics box.

F 34 63 097

Pull jack (1) of vehicle wiring harness off pump of windscreen cleaning system and open it. Pull out violet/black jack contact (2) and strip insulation.

F 34 63 098

Plug jack contact (A) of auxiliary wiring harness into jack (1) and close jack lid (2).

F 34 63 099

Run auxiliary wiring harness through existing cable clips (1) along right-hand, front side panel up to electronics box, as shown in drawing. Secure earthing point (D) to earthing terminal (3) with nut (2).

F 34 63 070

Cut open rubber plug (1) and pull auxiliary wiring harness (2) in through grommet (3).

F 34 63 071

Run auxiliary wiring harness through housing towards passenger compartment.

Note about installation

After refitting the electronics box, take up the slack in the auxiliary wiring harness.

F 34 63 100

Run auxiliary wiring harness (1) into glove compartment and plug connectors (E1, E2) into housing (E).

Rear auxiliary wiring harness

F 32 65 592

Fold back carpet and release cable covers (arrows) by removing expanding rivet (1) on left-hand side of car.

F 34 63 101

Run connectors (J, M, N, O, P, Q, R and S) of auxiliary wiring harness (1) into rear compartment of rear seat.

F 34 63 107

Press clip (1) apart (arrow) and pull out module (2).

F 34 63 108

Disconnect jack (1) and remove module (2).

F 34 63 109

Pull all wires out of jack (1). Use special tool III.

Note about installation

Please mark the two brown/violet wires of slots 10 and 11, so that they cannot be mixed up.

F 34 63 110

Plug wires just pulled into 12-pin jack housing (K) supplied, as follows:

Br/Gr/Ye wire Slot 1
Bk/Wh/Ye wire Slot 2
Bk/Rd/Ye wire Slot 3
Br/Or wire Slot 4
Bk/Wh wire Slot 5
Rd/BI/Ye wire Slot 6
Bk/BI wire Slot 7
Vi/Bk wire Slot 8
Bk/Br wire Slot 9
Br/Vi wire Slot 10
Br/Vi wire Slot 11
Bk/Gr wire Slot 12

Nip off and insulate brown wire (1) left over.

F 34 63 139

Plug jack (K) and plug (J) of auxiliary wiring harness together.

F 34 63 111

Cut clip (1) off new module (2).

F 34 61 144

Plug 26-pin jack (O) onto module (1). Crimp red wire (N) to B+ (3) and insert a fuse into fuse holder (2). Fasten relay sockets (P, Q, R and S). Plug on relay (4). Screw earthing cable (M) to earthing terminal.

F 34 63 102

Run connectors (L, I, G, F1 and F2) of auxiliary wiring harness into left-hand footwell.

F 34 61 145

Plug wire (I) into yellow jack (1) located in footwell.

Note about installation

If a plug is fully equipped, crimp the pin or jack contacts to the same-coloured cables using 1-pin plugs.

F 34 63 104

Run wire (L) to white plug (1) (X15S) and plug it in.

F 34 63 105

Run wire (G) to black plug (1) beneath steering column and connect it to plug. Tie back excessive lengths of wire.

Run auxiliary wiring harness (2) with connectors (F1 and F2) via steering column to transmission tunnel and towards glove compartment.

F 34 63 106

Run auxiliary wiring harness into glove compartment and plug connectors (F1 and F2) into plug (F).

Connect plugs (E) and (F) together.

4. Installing the Wiper Switch

F 34 61 023

Pull locking lever (1) of steering-wheel height adjustment in direction of arrow.

Pull steering column (2) out as far as it will go and push steering-wheel adjustment locking lever (1) back to locked position.

F 34 61 024

Models without airbag

Carefully prise out BMW emblem (1).

Unscrew self-locking hexagon nut (2).

Remove washer (3). Mark alignment of steering wheel to steering shaft and pull off steering wheel.

Caution

Replace self-locking hexagon nut (2).

Tightening torque: 80 Nm.

F 32 64 216

Remove screws (1) and (2).

Remove lower steering-column shroud (3).

F 34 61 025

Remove upper steering-column shroud (1) in direction of arrow.

Note about installation

Insert collar (2) into cut-out (3) as shown in drawing.

Models with airbag

F 34 71 043

Caution

For safety reasons, steering wheels equipped with an airbag may only be removed by a franchised BMW workshop.

Remove cross-recessed screws (1).

Remove steering-column shroud (2).

F 34 71 044

Pull plug-in connection (1) out of clip (2) and pull apart.

F 34 71 045

Unscrew steering-wheel hub cap retaining screws (4 in total) using special tool (I).

Note about installation

Tightening torque of hub cap retaining screws: 5 Nm.

F 34 71 046

Pull off plug (1) in direction of arrow and remove airbag unit.

Caution

When you put the airbag unit down, e.g. on the passenger seat, always put it down so that the plug side is pointing up (as shown in the drawing).

F 34 71 047

Unscrew self-locking hexagon nut (1). Remove washer (2). Mark alignment of steering wheel to steering shaft (e.g. prick-punch) and pull off steering wheel.

Caution

Replace self-locking hexagon nut (1).

Tightening torque: 80 Nm.

F 34 71 048

Note about installation

Locking pin (1) must lock into hole (2).

F 34 71 049

Note

Unscrewing the nut leads to the locking spring (1) which fixes the contact ring in its centre position becoming effective.

F 34 71 050

If necessary, adjust so centred.

Push down spring, turn contact ring (1) to left or right as far as it will go and turn ring back approx. 3 rotations until centring arrows align with each other. Let go of spring.

F 34 61 026

Drive out bolts (1) in direction of arrows.

Remove upper steering-column shroud (2) in direction of arrow.

Note about installation

Insert collar (3) into cut-out (4) as shown in drawing.

F 34 61 028

Open cable straps (1). Pull out cables (2) in direction of arrow.

F 34 61 029

Push back retaining lugs (1).

Pull out wiper switch (2).

Pull apart cable connector beneath dashboard.

Fit new wiper switch.

5. Removing the Front Bumper

F 34 51 126

Remove registration plate.

Prise out left- and right-hand bumper strips (1).

F 34 64 011

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Unclip left- and right-hand bumper strips (1) and remove them.

F 34 64 012

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Unscrew hexagon nuts (1) on left- and right-hand sides of bumper (2).

Note about installation

Tightening torque of hexagon nuts: 48 Nm.

F 34 51 102

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Pull wheel arch trim (1) on left- and right-hand sides of car in direction of arrow.

F 32 64 151

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Models fitted with fog lamps or outside temperature gauge

Rotate plug-in connection (arrows) and pull apart.

All models

Remove bumper with the aid of an assistant.

F 34 64 016

Models fitted with air conditioning

Carefully pull off air guides (1 and 2) on left- and right- hand sides of bumper.

Dismantling the front bumper

F 34 51 107

Pull off edge protector (1).

F 34 51 108

Models fitted with fog lamps

Pull off cable connector (1).

Unscrew hexagon screws (2) and remove left and right fog lamps (3).

Note about installation

The fog lamps are marked left or right.

F 34 51 121

Remove centre bumper strip (1) from bumper (2).

F 34 51 115

Mark centre point (1) of recesses (2) in bumper carrier bar (3) on left- and right-hand sides of bumper and punch-mark. Drill out punch-marked positions with 3.5 mm twist drill.

Carry out this step only on cars fitted with fog lamps.

F 34 51 110

Drive through expansion rivet pins (1) and lift out expansion rivets (2).

Note

Remove all expansion rivets from the front side of the bumper.

Note about installation

Re-use the expansion rivet pins (1) and expansion rivets (2).

F 34 51 111

Remove expansion rivet pins (1) and expansion rivets (2) on inside of bumper lifting them upwards.

Note about installation

Re-use the expansion rivet pins (1) and expansion rivets (2).

All models

F 34 51 112

Carefully lift out bumper carrier bar (1).

6. Installing the Headlight Washer Jets

Note

The illustrations in this section show the steps for installing the headlight washer jets on one side of the bumper only. Install the washer jets on the other side following the steps in the same way and in the same order.

F 34 51 116

Drill out 3.5-mm hole (1) on underside of bumper (2) to a diameter of 28 mm.

Deburr edges around hole.

Carry out this step only on cars fitted with fog lamps.

F 34 51 117

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Mark position on top side of bumper (2) for drilling hole (1) (as shown in drawing) and punch-mark.

A = 25 mm

B = 15 mm

C = 80 mm

Drill punch-marked position (1) with 3.5 mm twist drill and then drill out to 16 mm dia.. Deburr edges around hole.

Note

In the case of more recent bumpers, mark the halfmoon-shaped cut-out on the topside of the bumper carrier bar from the inside and punch-mark the centre point on the top side of the bumper.

F 34 51 118

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Make cut-out (1) as shown in drawing.

A = 5 mm

B = 3 mm

F 34 61 003

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Insert headlight washer jet (1). Slip on spacer (2) and hexagon nut (3) and tighten.

Models fitted with fog lamps

Do not yet fit fogs lamps.

F 34 61 004

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Insert fog-lamp washer jet (1) so that lug (4) fits into cut-out (5). Slip on washer (2) and hexagon nut (3) and tighten.

Carry out this step only on cars fitted with fog lamps.

7. Running the Headlight Cleaning System Hose Lines

Cars without fog lamps

F 34 63 114

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push in valve (1) as far as it will go.

Note

Before fitting the valve, coat it with glycerine.

F 34 63 115

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Fit hose holder (1) into cut-outs (2) of bumper carrier bar (3).

Note

Choose lengths of hose which prevent the hose lines from becoming kinked.

To make them easier to push onto the jets, coat the inside of the hose ends with glycerine.

F 34 63 117

Push hose (1) and hose clip onto headlight washer jet (2) and close hose clip. Fit C-shaped anti-kink protector (3) onto hose (1).

Close hose holder (4).

F 34 63 118

Push hoses (2) and hose clips onto headlight washer jet (3) and T-piece (1). Close hose clips (4).

Cars fitted with fog lamps

F 34 63 144

Push in valves (1) as far as they will go.

Note

Before fitting the valves, coat them with glycerine.

F 34 63 116

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Fit hose holder (1) into cut-outs (2) of bumper carrier bar (3).

Note

Choose lengths of hose which prevent the hose lines from becoming kinked.

To make them easier to push on to the jets, coat the inside of the hose ends with glycerine.

F 34 63 119

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push distributor (1) with hoses (2), T-piece (4) and hose clips onto fog-lamp washer jet (3).

Close hose clips.

F 34 63 120

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hose (1) and hose clip onto distributor connection (2) and close hose clip.

Run hose (1) through hose holder (3) as shown in drawing.

F 34 61 012

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hose (1) and hose clip onto fog-lamp washer jet (2) and close hose clip.

F 34 63 121

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push distributor (1) with hoses (2) and hose clips onto headlight washer jet (3) and T-piece (4).

Close hose clips.

F 34 63 122

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hose (1) and hose clip onto distributor connection (2) and close hose clip. Run hose (1) through hose holder (3) as shown in drawing.

F 34 61 015

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Run hose (1) to headlight washer jet (2). Fit C-shaped anti-kink protector (3) onto hose (1) as shown in drawing. Push hose (1) and hose clip onto headlight washer jet (2) and close hose clip.

Close hose holder (4).

F 34 63 123

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hose (2) and hose clip (3) onto pump (1).

Close hose clip (3).

Note

Length of hose (2): 500 mm.

F 34 61 067

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Cut prestamped cut-out (1) out of air guide (2) and fit into bumper. Affix air guides (2 and 3) onto left- and right-hand sides of bumper.

Note

Fit fog lamps where appropriate.

F 34 63 124

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hose (2) and hose clip onto T-piece (1). Close hose clip. Feed pump into engine compartment and fit bumper.

8. Installing the Headlight Cleaning System Washer Fluid Reservoir

F 36 63 125

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove seal (1) from standard washer fluid reservoir. Insert seals (1 and 2) into washer fluid reservoir (3). Fit filter (4) and lid (5). Affix backing support (6) to fluid reservoir (3).

F 36 63 126

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Secure fluid reservoir (3) with slotted screw. Insert wind-screen washer pump (2) into washer fluid reservoir (3) and connect jack (A).

Insert headlight washer pump (1) into fluid reservoir (3) and connect jack (B).

Note about installation

Connect level regulator if fitted.

9. Installing the Windscreen Washer Jets

F 34 63 056

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove expansion rivet (1) from bonnet and remove insulating mat (2).

F 34 61 093

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Remove left and right windscreen washer jets. Open hose clip (1). Disconnect hose (2) and non-return valve (3). Push lug (4) towards windscreen washer jet (5) and remove jet (5).

F 34 61 092

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Open hose clips (1) and pull hoses (2) off T-piece (3). Run new hose lines without non-return valve to installation position of windscreen washer jets (4) using hose clips of T-piece (3).

Note about installation

If non-return valves are not fitted, do not replace existing hoses.

F 34 61 043

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Install new twin windscreen washer jets.

Push hoses (1) and hose clips onto connectors (2) of

twin washer jets and close hose clips.

10. Running the Intensive Cleaning System Hose Lines

F 34 61 044

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hoses (1) and hose clips onto connectors (2) of twin washer jets (3) and close hose clips.

Note about installation

Run hoses (1) through standard hose holders.

F 34 61 045

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Push hoses (1) and hose clips onto T-piece (2). Close hose clips.

Push hose (3) and hose clip onto T-piece connector (4) and close hose clip. Run hose (3) along standard hose (5) in engine compartment to installation position of intensive cleaning system washer fluid reservoir. Refit insulating mat in reverse order of removal operations.

F 34 61 146

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Run hose (1) of intensive cleaning system through enginecompartment as shown in drawing.

11. Installing the Intensive Cleaning System Washer Fluid Reservoir

F 36 63 127

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Insert seal (4) into washer fluid reservoir (1). Fit lid (2) with marker tag (3).

F 36 63 128

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Fix fluid reservoir (1) to fluid reservoir (2). Insert pump (3) into fluid reservoir (1) and connect jack (C). Push hose (4) and hose clip (5) onto pump (3).

Close hose clip (5).

12. Checking Operation

Fill the washer fluid reservoirs and intensive cleaning system fluid reservoir with an appropriate cleaning fluid in accordance with vehicle manufacturer specifications.

F 34 61 072

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

Turn on ignition.

Turn on dipped beam and fog lamps (if fitted).

Push wiper switch (1) in direction of arrow.

Check whether intensive cleaning system, headlight washer jets and fog-lamp washer jets work properly.

F 34 51 125

Headlight Cleaning System with Intensive Cleaning System for Cars Fitted with Central-locking System (ZV) Module BMW 5 Series E34

If necessary, adjust direction of headlight washer jets using special tool II.

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