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64 11 219 Replacing heater core (air conditioner control)

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 Left Air Duct Clip
G03129113Courtesy of BMW OF NORTH AMERICA, INC.

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
G03129114Courtesy of BMW OF NORTH AMERICA, INC.
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
G03129115Courtesy of BMW OF NORTH AMERICA, INC.

Remove center console. See 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 steering column. See STEERING COLUMN

Unclip air duct (1) on both sides and pull out in direction of arrow.

Fig 4: Removing Air Duct
G03129116Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: For purposes of clarity, the following shows the heater/air conditioner removed.

Release screws (1).

Unclip retainers (2) and remove cover for heater element (3) in direction of arrow.

Fig 5: Removing Heater Element Cover
G03129117Courtesy of BMW OF NORTH AMERICA, INC.

Detach air flap (1) in direction of arrow from shaft.

Unclip retainer (2).

Release screws (4) and pull housing section (3) in direction of arrow out of guide.

Fig 6: Removing Housing Section
G03129118Courtesy of BMW OF NORTH AMERICA, INC.

Screw on hose clamps (1) and detach pipes in direction of arrow.

Installation: 

Replace sealing rings.

Ensure sealing rings and hose clamps (1) are correctly seated.

Pull out housing section (2) in direction of arrow.

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

Fig 7: Removing Housing Section & Heater Element
G03129119Courtesy of BMW OF NORTH AMERICA, INC.
CAUTION: Do not bend cooling fins.
If necessary, clean or align cooling fins with fin comb.