Independent Heating / Independent Ventilation BMW 7 Series E32 – M60

EBA – 01 29 9 787 518
BMW Installation Instructions

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Specialised knowledge is required.

Installation time: approx. 6 – 8 hours – this may vary, depending on the condition of the vehicle and its fittings.

Retrofitting of the independent heating/independent ventilation is possible only in conjunction with the installation kit for the second battery (see instructions for BMW accessories microfiche and BMW parts microfiche) .

All instructions and illustrations are given for left-hand drive models.

In the case of retrofitted parts, in Germany an acceptance test in accordance with § 19 (2) StVZO (German Motor Vehicle Safety Standards) at the TUV (German Technical Inspection Agency) and an entry in the vehicle’s documents is required.

Caution

The heating unit must not – even with preset time – be operated in closed areas, such as garages or workshops , without exhaust-extraction .

The heating unit must be switched off at petrol stations and fuel dispensing systems .

Important

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

All hose lines and electric cables must be laid so that they do not sag or scuff. Make sure they are not obstructed.

The hose lines must be laid tension-free .

Drilling Instructions

Burr all bore edges and coat with inorganic zinc.

Treat cavities with cavity preserving agent approved by vehicle manufacturer.

Outside the heating period, the heating unit must be put into operation for 10 minutes every four weeks with the engine cold in order to prevent starting difficulties at the beginning of the heating period (see BMW Owner’s Handbook).

Tools and materials required

Regular screwdriver
Phillips screwdriver
1/2″ torque wrench
Ratchet with 1/2″ drive
1/2″ extension
1/2″ drive socket, 10 mm, 12 mm, 13 mm, 17 mm, 19 mm, 22 mm A/ F
1/2″ hexagon drive socket, 4 mm, 6 mm, 8 mm NF
1/2″ Torx drive socket, E10, E14, TX30
Ratchet with 1/4″ drive
1/4″ extension
1/4″ drive socket, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 13 mm
Ring spanner , 7 mm, 8 mm, 9 mm, 10 mm, 13 mm, 17 mm, 19 mm NF
Open-jawed spanner, 8 mm, 10 mm, 13 mm, 14 mm, 15 mm,
17 mm, 32 mm NF
Drill
Flexible shaft
Twist drill bit, dia. 3.5 mm, 5 mm, 6 mm, 6.5 mm
Stepped drill bit, dia. 4 – 38 mm
Pliers
Multigrip pliers
Universal pliers
All-purpose knife
Hammer
Centre punch
Tape measure
Water-soluble marker pen
Cable lamp
Brush Inorganic zinc
Cavity sealant
Protective glasses
Gloves

Serial No Illustration Designation

I       F 32 72 075 Special tool for airbag

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

II      F 32 64 263 Test device

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

III    F 32 64 264 Adapter

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

IV     F 32 64 265 Hose clamp

Contents

Chapter

  1. Necessary Preliminary Work
  2. Removing Engine Cover
  3. Removing Expansion Tank
  4. Removing Cable Cover
  5. Removing Jumper Start Support
  6. Cutting Heat-Protection Sheet
  7. Laying Supplementary Wiring Harness to Independent Heating Unit
  8. Installing Relay Box
  9. Laying Connecting Line between Heating Control and Relay Box
  10. Laying Independent Heating Supplementary Wiring Harness to Rear
  11. Laying Exhaust Line
  12. Laying Intake Air Line
  13. Laying Coolant Hoses
  14. Installing Independent Heating Unit
  15. Venting Cooling System
  16. Installing Outside-Temperature Sensor
  17. Initial Operation of Independent Heating/Independent Ventilation

1. Necessary Preliminary Work

  1. Remove front seat on passenger’s side
  2. Read out fault memory
  3. Disconnect battery
  4. Remove rear seat bench
  5. Remove rear backrest
  6. Remove glove compartment
  7. Models without subsidiary battery – install subsidiary battery. (For procedure, see installation instructions for subsidiary battery, E32 M60)

Note

Leave luggage compartment panelling and rear seat bench removed. Install cable cover, rear right, only after independent heating supplementary wiring harness has been installed

  1. Remove Washer Reservoir
  2. Remove Air Filter Box with Ai r-Flow Sensor
  3. Drain Coolant

2. Removing Engine Cover

F 32 65 811

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Use screwdriver to lever out plastic plugs (1), remove hexagon nuts and remove cover .

F 32 65 829

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Remove soundproofing (1).

3. Removing Expansion Tank

F 32 64 322

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Remove cover.

Open hose clips and withdraw coolant hoses (2, 3).

F 32 64 323

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

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

Remove expansion tank (4).

4. Removing Cable Cover

F 32 64 324

Cut open cable straps (1).

Unscrew hexagon nuts (2) and remove cable cover (3).

5. Removing Jumper Start Support

F 32 64 330

Remove covers (1) and (2) in direction of arrow. Cut open cable straps (3) and move cable strand (4) to the side.

F 32 64 615

Remove hexagon nuts (1) and move lines (2) to the side. Remove hexagon nuts (3) and move cables (4) to the side. Remove hexagon screw (5), take out housing (6) with holder.

6. Cutting Heat-Protection Sheet

F 32 64 616

Withdraw brake line (1) from guide (2).

Withdraw brake line (1) from guides on left and right of guide (2). Unscrew guide (2).

F 32 64 617

Remove B+- cable (1) from holder (2) and move to the side. Unscrew holder (2).

F 32 64 618

Remove sheet-metal nut (1).

F 34 64 136

Bend heat-protection sheet forward.

Cut pre-marked area (1) out of insulating mat (2) in engine compartment on right.

F 32 64 619

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

Bend back heat-protection sheet.

Pierce heat-protection sheet and use a knife to cut an area out of heat-protection sheet corresponding to opening (2) in partition.

F 32 64 620

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Overview of Independent Heating Supplementary Wiring Harness

Item Designation Installation location in vehicle
a 2-pin connector Water valve in engine compartment, left
b 3-pin connector Independent heating unit at right suspension strut dome
c 12-pin connector Relay box behind glove compartment, right
d 8-pin connector On 8-pin connector X512 of vehicle wiring harness. Installed on relay box holder behind glove compartment, right
e 3-pin connector Connecting line to heating control unit. Installed on relay box holder under glove compartment , right
f Cable socket Earth cable On B- terminal of subsidiary battery in luggage compartment, right
g Fuse carrier On carrier sheet-metal , subsidiary battery in luggage compartment, right
h Cable socket B+ cable On B+ terminal of subsidiary battery in luggage compartment, right
i Relay holder Overvoltage relay On carrier sheet-metal of subsidiary battery at top in luggage compartment, right
j Relay holder On carrier sheet-metal of subsidiary battery at bottom in luggage compartment , right
k 3-pin connector Connecting line On branch “e” of independent heating supplementary wiring harness
I 3-pin connector
On heating control unit in centre console

7. Laying Supplementary Wiring Harness to Independent Heating Unit

F 34 64 196

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Pass branches (a) and (b) of independent heating supplementary wiring harness ( 1) through bore (2) into engine compartment.

Insert rubber grommet (3) in bore (2).

F 32 64 350

Lay branch (a) of solenoid valve (1) along main wiring harness (2) to water valves and secure with cable straps.

Models with clock, outside-temperature digital display

F 34 62 002

Remove radio or cover for radio cutout. Pull lever ( 1) up to stop in direction of arrow. Remove clock (2) or

outside-temperature digital display .

F 34 62 003

Important

Set screw (4) on rear of outside-temperature digital display for independent heating/independent ventilation .

Item Temperature display Hours 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/independent ventilation (2) and press into place.

F 34 64 144

Insert outside-temperature digital display for independent heating/independent ventilation (1) in recess. Press lever (2) in direction of arrow up to stop.

Install radio or cover for radio cutout.

8. Installing Relay Box

F 32 64 401

Place relay box (1) on holder (2). Install hexagon nut (3) with washers (4) and tighten.

Insert holder (5) in recess (6) and turn by 45 ‘.

F 32 64 402

Position relay box with holder (1) as shown in illustration above glove compartment.

Install and tighten hexagon screws (2) with washers (3). Install cable connector (4) branch (c) of independent heating supplementary wiring harness on relay box with holder (1).

9. Laying Connecting Line between Heating Control and Relay Box

F 32 64 358

Remove cover (1) from rear window switch. Press retaining clip (2) with a small screwdriver back through heating control unit switch (3) and lift out heating control unit (3) in direction of arrow.

Important

In order to avoid damaging the heating control unit, cover the parcel shelf with a cloth.

F 32 64 621

Install cable connector (1), (branch I) on heating control unit (2) as shown.

Lay connecting line (3) along heating wiring harness (4) to relay box and secure with cable straps (5).

F 32 64 405

Attach 8-pin cable connector X512 of vehicle wiring harness

(1) to cable connector (2) (branch d) of independent heating supplementary wiring harness and install on holder (3).

F 32 64 622

Connect 3-pin cable connector (1) (branch k) of connecting line (2) with 3-pin cable connector (3) (branch e) of independent heating supplementary wiring harness.

Install this connection on cable connection (4).

10. Laying Independent Heating Supplementary Wiring Harness to Rear

F 32 64 623

Lay independent heating supplementary wiring harness (1) along vehicle wiring harness to second battery (2) in luggage compartment (3).

F 32 64 624

Press rubber grommet (1) out of rear partition panel (2). Pass independent heating supplementary wiring harness (3) through opening (4) and insert in slit rubber grommet (1).

Press rubber grommet into place.

Lay independent heating supplementary wiring harness (3) along wiring harness (4) to second battery (5).

F 32 64 625

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

Drill through body panel (3) through holes (2) with a 3.5 dia. drill.

Remove wiring harness cover (1), burr bore holes, remove drillings and coat with inorganic zinc to protect against corrosion. Secure wiring harness cover with 4.2 mm sheet-metal screws.

F 32 64 626

Insert holder (1) in holder metal (2) of subsidiary battery and turn by 45°.

Secure earth cable (3) (branch f) and positive cable (4) (branch h) of independent heating supplementary wiring harness on appropriate terminals of subsidiary battery (5).

F 32 64 627

Insert relays (1) and (2) in relay holders (3) (branch i) and (4) (branch j) .

Install relay holders (3) and (4) on holder on holder metal (5) as shown in illustration.

Provide fuse carrier (6) (branch g) with a 15-amp fuse (7) and install on holder as shown.

F 32 64 664

Reinstall luggage compartment panelling. Complete right-hand luggage compartment panel (1) with flat parcel shelf (2) from installation kit.

Note on installation

Reinstall all removed parts in passenger compartment in reverse sequence.

11. Laying Exhaust Line

F 32 64 628

Fahrtrichtung = Direction of travel

Drill two holes, 3.5 mm dia., from above in frame rail (1) as shown. Burr drill holes, remove drillings and coat with inorganic zinc.

F 32 64 629

Fahrtrichtung = Direction of travel

Drill a hole, 3.5 mm dia., in side at distance of approx .

50 mm from heat-protection sheet (1) in frame rail (2).

Note

Access to this area is difficult. Use flexible shaft with short drill.

Pay attention to drilling instructions on Page 1.

F 32 64 630

Position heating unit (1) on carrier (2) as shown in illustration. Fit retainers (3) to carrier (2).

Insert damper element (4) from above and secure retainer (3) with hexagon nut (5).

F 32 64 631

Insert pins (1) in independent heating carrier (2) on suspension strut dome (3) and secure from below with hexagon nuts (4).

F 32 64 632

Drill one end of perforated strip (1) to 8 mm dia. and bend as shown in illustration.

F 32 64 633

Place heating unit (1) on pins (2). Place perforated strip (3) on threaded bolts (4) of damper element.

Place other end on front threaded bolt of suspension strut dome (5).

Fit retaining clamps (7) to exhaust line (6). Secure exhaust line to front connection of heating unit.

F 32 64 634

Lay exhaust line (1) along right-hand frame rail (2) to rear at bottom. Secure clamps (3) with sheet-metal screws (4.2 mm) (4).

Note

Do not yet tighten the sheet-metal screws . The exhaust line must still be centred.

Only vehicles with automatic transmission

F 32 64 635

Remove securing screws (1) and engine cover (2).

F 32 64 636

Fahrtrichtung = Direction of travel

Lay exhaust line (1) along right-hand frame rail (2) as shown in illustration over exhaust manifold (3) to rear.

F 32 64 637

Insert blind-rivet nut (1) in hexagon hole (2).

F 32 64 638

Place silencer (1) with clamp (2) on exhaust line (3). Secure clamp (2). Insert spacer sleeve (4) between silencer (1) and floor panel (5).

Secure silencer (1) with hexagon screw (6) and blind-rivet nut (7) to floor panel.

Note

If necessary, push exhaust line through from engine compartment.

F 32 64 639

Bend clamp (1) open and install on exhaust line (2). Align clamp (1) as shown in illustration.

Drill a hole, 3.5 mm dia., in floor panel through clamp bore.

Secure clamp with sheet-metal screw (4.2 mm).

Also tighten securing screws of 3 clamps on frame rail. Remove heating unit.

Note

Only vehicles with automatic transmission

Reinstall engine cover.

12. Laying Intake Air Line

F 32 64 301

Jack up vehicle.Remove right front wheel. Unscrew hexagon nuts (1) and remove bulkhead metal sheet (2).

Installation information

Tighten wheel studs to required tightening torque and retighten after 50 km (see Owner’s Handbook).

F 32 64 640

Release hose clip (1) from fuel hose (2). Withdraw fuel hose (2) from fuel return line (3).

Release hose clip from injection tube, right cylinder group, and completely remove fuel line (2).

Important

Catch any discharged fuel.

F 32 64 641

Lever out rubber grommet (1) and withdraw from fuel return line (2).

F 32 64 642

Fahrtrichtung = Direction of travel

Install new rubber grommet (1) from installation kit on fuel return line (2) as shown in illustration.

Press rubber grommet into recess in wheel house.

F 32 64 643

Insert intake air line ( 1) from wheel house (2) into rubber grommet (3) until end of line is flush with wheel house.

Lay intake air line in engine compartment along wheel house to independent heating unit.

13. Laying Coolant Hoses

F 32 64 644

Coolant hose overview

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

F 32 64 326

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Open hose clips and remove standard coolant hose (1).

Note

Coolant hose (1) is no longer required.

F 32 64 645

Cut open cable strap (1).

Remove hexagon screw (2) and take out holder (3)

Note

Holder (3) is no longer required.

F 32 64 646

Fahrtrichtung = Direction of travel

Install pipe (1) as shown in illustration and secure with hexagon screws (2).

Secure line (3) with a cable strap to right-hand holder (4) of pipe (1).

F 32 64 647

Release hose clips from coolant hoses (1 ) and remove both coolant hoses (1 ).

The coolant hoses (1) are no longer required.

F 32 64 648

Provide coolant hose (1) with hose clips as shown in illustration. Fit connection (2) to heating unit connections and tighten hose clip.

Fit connection (3) to right-hand cylinder head and secure with hose clip (4).

Lay end of hose (5} along engine compartment rear baulk (6)

to independent heating unit.

Note

Connection (7) is fitted to expansion tank and secured with a hose clip.

F 32 64 649

Fit hose clip (3) to connection (5) of coolant hose (1). Install non-return valve (2) as shown in illustration and secure with hose clip (3).

Important

When installed, the arrow mark on the non-return valve must point towards the independent heating unit.

F 32 64 650

Preassemble auxiliary water valve ( 1) as shown in illustration. Secure coolant hose (2) with hose clip (4} to auxiliary water valve (1).

Secure coolant hose (3) with hose clip (4} to auxiliary water valve from below.

F 32 64 651

Fahrtrichtung = Direction of travel

Secure preassembled auxiliary water valve (1) with hose retainer to front coolant hose.

Secure coolant hose (5) with a hose clip to connection of left-hand cylinder head.

F 32 64 652

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Install coolant hose (1) as shown in illustration.

Secure end of hose (2) with hose clip (3) to rear upper connection.

Fit end of hose (4) with hose clip (5) on free connection of water valves (6) and close hose clip.

Secure end of hose (7) with a hose clip to pipe.

Important

Tighten all hose clips.

After assembly, some hose clips are no longer accessible.

14. Installing Independent Heating Unit

F 32 64 653

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Overview of independent heating unit

  1. Independent heating unit
  2. Exhaust line
  3. Intake line
  4. Fuel line to tank
  5. Fuel line to independent heating unit
  6. Silencer

F 32 64 654

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Note

Remove independent heating unit carrier (if not yet removed) .

Secure fuel lines (1) with hose clips 13.1-15.3 to inlet and outlet connections of independent heating unit (3).

Use white felt marker to transfer arrow marks from independent heating unit to fuel hoses.

F 32 64 655

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Secure coolant hose (1) with hose clip (2} to water outlet connection (3) of independent heating unit (4).

Secure coolant hose (5) with hose clip (6) to lower water inlet connection (7).

F 32 64 656

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Assemble carrier (1) as shown in illustration.

F 32 64 657

Place independent heating unit (1) in engine compartment. Lay coolant hose (2) along wheel house to pipe.

Lay fuel lines (3) and (4) along wheel house.

Fit coolant hose (5) with a hose clip to non-return valve (6). Tighten hose clip.

Install independent heating unit on holder. Secure coolant hose (2) with a clip to pipe.

F 32 64 658

Lay fuel line (3) (arrow marking pointing away from independent heating unit) to coolant return line (2) at right-hand wheel house and secure with a hose clip.

Lay fuel line (4) (arrow marking pointing toward independent heating unit) to end of injection line of right cylinder bank.

Secure fuel line (4) with a hose clip on connection below pressure reducer (5).

Important

Avoid nicks and scuffing.

Fix fuel hoses with cable straps.

F 32 64 659

Secure exhaust line (1) with pipe clamp to independent heating unit exhaust connection.

Secure intake line (2) with pipe clamp to independent heating unit intake connection.

Secure independent heating unit to suspension strut dome (4) with mount (3).

Insert connector holder (5) as shown in illustration and turn by 45°.

Attach connector (6) to branch (b) of independent heating supplementary wiring harness and install on holder (5).

Attach branch (a) of supplementary wiring harness to auxiliary water valve.

F 32 64 660

Secure coolant hose (1) with cable straps (3) to cover (2).

Note on installation

Reassemble in reverse sequence to removal.

15. Venting Cooling System

F 34 64 206

Set heat control (1) to “warm”.

F 32 64 233

Models with air conditioner

Set heat control (arrows) on heating control unit to “warm”.

Important

Air conditioner must not be switched on.

F 32 64 661

Open vent screw (1).

F 32 64 662

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Open vent screw (1) on coolant return hose. Tighten coolant drain plug on cooler. Top up coolant.

Important

Use only coolant approved by BMW in specified mixture ratio.

When bubble-free coolant emerges, close vent screws and fill expansion tank to maximum mark.

Seal expansion tank.

Run engine to operating temperature.

Pressure-test cooling system with special tools (II, III).

16. Installing Outside-Temperature Sensor

(Only models without outside-temperature sensor)

F 32 64 663

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Attach outside-temperature sensor (1) and connect tied-back 2-pin connector X1063 (2).

17. Initial Operation of Independent Heating/ Independent Ventilation

F 34 64 114

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

Models with outside-temperature/digital display

1. Turn ignition lock to position (I).

2. Fan switch to position 1.

3. Heating to position “warm”.

Direct switching on

Press ON button for 3 seconds, LED flashes.

With outside temperature > 16°C

Independent ventilation starts, vehicle fan is switched on.

With outside temperature < 16°C

Independent heating starts. To check that independent heating is functioning properly, it is recommended that, with outside temperature > 16’C, the outside-temperature sensor be cooled to below 16″C during the entire function test.

The vehicle fan switches on only when the coolant is heated to 55’C.

Direct switching off

Press OFF button.

Models with on-board computer

F 32 64 368

Independent Heating / Independent Ventilation BMW 7 Series E32 - M60

1. Turn ignition lock to position (I).

2 . Fan switch to position 1.

3. Heating to position “warm”.

Direct switching on Press TIMER button. Press S/R button.

With outside temperature > 16°C

Independent ventilation starts, vehicle fan is switched on.

With outside temperature < 16°C

Independent heating starts. To check that independent heating is functioning properly, it is recommended that, with outside temperature > 16″C, the outside-temperature sensor be cooled to below 16″C during the entire function test.

All models

For programming and activating the independent heating/independent ventilation, see BMW Owner’s Handbook.

Important

Print out fault memory.

banner