64 11 206 Removing and installing or replacing heater

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

Necessary Preliminary Tasks:

Draw off refrigerant from A/C system. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A) .
Remove fresh air duct. Refer to 64 31 053 REMOVING AND INSTALLING OR REPLACING FRESH AIR DUCT .
Remove trim for instrument panel. Refer to 51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM .
Remove temperature sensor for cold-air distributor. Refer to 64 11 916 REPLACING TEMPERATURE SENSOR FOR COLD-AIR DISTRIBUTOR .

WARNING: Follow instructions for working on cooling system. Refer to 17 00 ... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

WARNING: To avoid injury, cover holder (1) on support tube (2).

Fig 1: Identifying Holder And Support Tube

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Unscrew nuts (1).

Installation:

Tightening torque, refer to 64 53 8AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUE - E60 .

Detach refrigerant line (2) in direction of arrow.

Unclip refrigerant line (3).

Fig 2: Locating Refrigerant Line

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WARNING:

When installing heater, make sure left and right air ducts are correctly seated.
Check left and right air ducts for leaks.
If necessary, reseal left and right air ducts with butylene tape.
If left and right air ducts are resealed, make sure flaps can move freely.

Feed out rubber grommet (1).

Installation:

Make sure rubber grommet (1) is correctly seated.

Release nut (2) and detach refrigerant lines (3) and (4) in direction of arrow.

Installation:

Tightening torque, refer to 64 53 7AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUE - E60 .

Replace sealing rings.

Release nuts (5) on right air duct.

Installation:

Tightening torque, refer to 64 11 4AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUE - E60 .

Fig 3: View Of Rubber Grommet

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Feed out rubber grommet (1).

Installation:

Make sure rubber grommet (1) is correctly seated.

Release spring clamps (2) and detach coolant hoses (3).

IMPORTANT: Carefully blow through aluminum triple pipe to remove remaining coolant from heat exchanger for heating system.

Installation:

Vent cooling system and check for leaks.

Release nuts (4) on left air duct.

Installation:

Tightening torque, refer to 64 11 4AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUE - E60 .

Fig 4: Locating Rubber Grommet

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Disconnect rear compartment air duct (1) in direction of arrow.

Installation:

Make sure rear compartment air duct (1) is correctly seated.

Fig 5: View Of Rear Compartment Air Duct

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Release screws (1).

Remove left air duct (2) in direction of arrow.

Fig 6: Identifying Left Air Duct Retaining Screws

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Release screws (1).

Remove right air duct (2) in direction of arrow.

Fig 7: Locating Right Air Duct Retaining Screws

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Carefully lever out locks (1) and (2).

Detach air distributor (3) in direction of arrow.

Installation:

Make sure air distributor (3) is correctly seated.

Fig 8: View Of Air Distributor

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IMPORTANT: Follow instructions for handling optical fibers. Refer to 61 00 ... NOTES ON HANDLING OPTICAL FIBERS .

Necessary Preliminary Tasks:

Disconnect all necessary cable ties on support tube.
Release wiring harnesses/cable ducts and lay to one side.
If necessary, remove control units/disconnect plug connections.

Installation:

Make sure wiring harnesses/cable ducts are correctly routed and secured.

If necessary, remove CD changer (1). Refer to 65 11 072 REMOVING AND INSTALLING/REPLACING CD CHANGER .

Loosen screws (2).

Set fuse-carrier (3) down in footwell.

Fig 9: Identifying Fuse-Carrier

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Release screws (1).

Installation:

Tightening torque, (21.4 N.m.).

Fig 10: Locating Support Tube Retaining Screws

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Release screws (1).

Installation:

Tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING TORQUES - E60 .

Fig 11: View Of Support Tube Retaining Screws

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Release screws (1).

Installation:

Tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING TORQUES - E60 .

Fig 12: Identifying Support Tube Retaining Screws

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Unscrew nuts (1).

Installation:

Tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING TORQUES - E60 .

Fig 13: View Of Support Tube Retaining Nuts

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Unscrew nuts (1).

Detach support tube (2) and remove from vehicle with assistance of a second person.

Installation:

Tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING TORQUES - E60 .

Fig 14: Locating Support Tube Retaining Nuts

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If necessary, unlock and disconnect plug connections on heater.

Remove heater (1) in direction of arrow.

Installation:

Make sure heater (1) is correctly seated.

Fig 15: Removing Heater

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Installation:

Make sure condensate drain (1) is correctly seated in grommet (2).

Fig 16: View Of Condensate Drain In Grommet

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