64 11 208 Replacing heater core (automatic A/C)

WARNING: This page is about a different car, the 2003 BMW 525i, 2002 BMW 525i, and 2001 BMW 525i. However, it is still accessible from the selected car via links, so may be relevant.

Unfasten clip from left air duct, twist air duct and pry out.

Fig 1: Loosening Clip From Left Air Duct

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Installation:

Fit air duct to end wall, twist and insert at bottom of microfilter.

Fig 2: Fitting Air Duct To End Wall & Inserting In Microfilter Bottom

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WARNING: Danger of scalding!
Only perform this work after engine has cooled down.

Unfasten water hoses (1 to 3) on the end wall. Carefully blow through lines to remove remaining coolant from heating element.

Installation:

Filling and bleeding the cooling system.

Fig 3: Removing Water Hoses

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Remove center console. 51 16 220 REPLACING WOODEN FINISHERS FOR ODDMENTS TRAY (CENTER CONSOLE)

Remove trim for instrument panel (lower section). See 51 45 030 REMOVING AND INSTALLING TRIM FOR INSTRUMENT PANEL (LOWER SECTION)

Remove lower section of steering column casing with footwell trim. See 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY

Remove left footwell air duct.

Release screws and pull out left footwell air outlet in direction of arrow.

Fig 4: Removing Left Footwell Air Outlet

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Unfasten screws and remove pipes.

Installation:

Replace sealing rings.

Fig 5: Releasing Screws & Removing Pipes

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Unfasten screw and remove bracket.

Fig 6: Releasing Screws & Removing Bracket

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Unhook servodrive for footwell ventilation and place to one side.

Fig 7: Releasing Footwell Ventilation Servodrive

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Up to 03/99:

Release screws and pull out right footwell air outlet in direction of arrow.

Fig 8: Removing Right Footwell Air Outlet

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Unfasten screws and clips and remove cover from heater core.

Fig 9: Removing Cover From Heater Core

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Release retainers and lift out air duct for rear compartment footwell.

Fig 10: Removing Rear Compartment Footwell Air Duct

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Pull out heater element in direction of arrow.

Fig 11: Removing Heater Element

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CAUTION: Do not bend cooling fins.
If necessary, clean or align cooling fins with fin comb.

From 03/99:

Unhook retaining lugs (1) and pull out right footwell air outlet in direction of arrow.

Fig 12: Removing Right Footwell Air Outlet

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NOTE: For purposes of clarity, the following shows the heater/air conditioner removed.

Unclip retainer (1).

Release screws (2) and pull heater core cover (3) in direction of arrow out of guide.

Fig 13: Removing Heater Core Cover

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Installation:

Make sure guide is correctly seated.

Fig 14: Identifying Proper Guide Seating

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Pull out evaporator temperature sensor (1) in direction of arrow and set to one side.

If necessary, close footwell flap (2) in direction of arrow.

Pull out heater element (3) in direction of arrow.

Fig 15: Removing Evaporator Temperature Sensor

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CAUTION: Do not bend cooling fins.
If necessary, clean or align cooling fins with fin comb.