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

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. 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: Removing Air Ducts (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

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

Fig 2: Installing Air Ducts (Automatic A/C)

Courtesy 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. See 17 00 039 BLEEDING COOLING SYSTEM AND CHECKING FOR LEAKS .

Fig 3: Removing Water Hoses (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Remove center console. See 51 16 200 REMOVING AND INSTALLING ODDMENTS TRAY .

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.

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 (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and remove pipes.

Installation:

Replace sealing rings.

Fig 5: Releasing Screws And Removing Pipes (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screw and remove bracket.

Fig 6: Releasing Screws And Removing Bracket (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Unhook servodrive for footwell ventilation and place to one side.

Fig 7: Releasing Servodrive (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Up to 03/99:

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

Fig 8: Releasing Screws And Removing Right Footwell Air Outlet (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and clips and remove cover from heater core.

Fig 9: Removing Heater Core Cover (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 10: Removing Rear Compartment Footwell Air Duct (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Pull out heater element in direction of arrow.

Fig 11: Removing Heater Element (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

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 (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

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 (Automatic A/C)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Make sure guide is correctly seated.

Fig 14: Identifying Proper Guide Seating

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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