AC mounting BMW 328i 1997 E36 Workshop Manual

611-
8



WIPERS
AND
WASHERS

Windshieldwiper
motor,
removing
and
in-

stalling

1
.
Disconnect
negative
(-)
cable
from
battery
.



8
.
Install
wiper
arm
crank
in
straight
line
with
linkage
.
See

Fig
.
20
.

CA
UTION-

"
Prior
to
disconnectiog
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

"
Use
tendercover
to
protect
windshield
.

2
.
Remove
wiper
assembly
as
described
earlier
.

3
.
Remove
nut
on
wiper
motor
linkage
crank
and
remove

linkage
crank
from
motor
.
See
Fig
.
19
.

0012539

Fig
.
19
.
Wiper
linkage
crank
nut
(arrow)
and
wiper
motor
mounting
bolts
(A)
.

4
.
Unscrew
three
motor
to
assembly
mounting
bolts
and
remove
motor
.
Refer
to
Fig
.
19
.

5
.
Insta¡¡
new
motor
to
wiper
assembly
.
Do
not
insta¡¡

crank
.

6
.
Connect
motor
to
electrical
harness
.
If
necessary,
re-

connect
battery
temporarily
.

WINDSHIELD
WIPER
ASSEMBLY

7
.
Operate
motor,
then
turn
off
switch
.
Motor
will
stop
in

"park"
position
.

NOTE
-

When
installing
wiper
crank
onto
wiper
motor,
bracecrank
with
a
drift
pin
through
the
hole
on
crank
into
hole
onwiper
assembly
.

Fig
.
20
.
Align
wipercrank
with
linkage,
as
illustrated
.

9
.
Remainder
of
installation
is
reverse
of
removal
.

0012538

Tightening
Torques

"
Wiper
motor
to
wiper
assembly
(use
new
bolts)
.
..
..
10
Nm
(89
in-lb)

"
Wiper
motor
crank
to

wipermotor
(M8
nut)
......
..
.
...
.
27
Nm
(20
ft-Ib)

Headlight
switch,
replacing

1
.
Remove
left
side
dash
insert
and
disconnect
harness
connector
to
headlight
switch
.
See
Fig
.
10
.

3
.
Remove
nut
mounting
switch
to
dash
insert
.
See
Fig
.
11
.

Fig
.
11
.
Headlight
switch
mounting
nut
(arrow)
.

4
.
Pull
switch
out
from
housing
.

SWITCHES
AND
ELECTRICAL
ACCESSORIES



612-5

0012558

5
.
Installation
is
reverse
of
removal
.
Align
new
switch
to
dash
insert
.
See
Fig
.
12
.

Tightening
Torque

"
Headlight
switch
retaining
nut
.
......
2
Nm
(18
in-lb)

Foglight
switch,
replacing
0012559
Fig
.
10
.
Removing
headlightswitch
electrical
harness
connector



1
.
Remove
left
side
dash
insert,
as
described
earlier,
and
(arrow)
.



remove
foglight
switch
harness
connector
.

2
.
PA
off
headlight
switch
knob
.
Wrapping
adhesive
tape
aroundknob
facilitates
removal
.



spring
tabs
together
.

0012560
Fig
.
12
.
Fit
groove
on
headlightswitch
into
switch
bezel
ondash
insert
(arrows)
.

2
.
Slide
foglight
switch
out
of
dash
insert
by
sqúeezing

3
.
Installation
is
reverse
of
removal
.

Hazard
warning
switch,
replacing

1
.
Unclip
shift
boot
and
lift
up
from
shift
lever
console
.
Carefully
remove
insulation
pad
.
See
250
Gearshift
Linkage
.

2
.
Working
underneath
center
console,
push
hazard
warning
switch
up
and
out
of
console
with
your
fingers
.

3
.
Disconnect
harness
connector
from
switch
.

4
.
Installation
is
reverse
of
removal
.

Power
window
switch,
replacing

1
.
Unclip
shift
boot
and
lift
up
from
shift
lever
console
.
Carefully
remove
insulation
pad
.
See250
Gearshift
Linkage
.

2
.
Working
underneath
center
console,
push
window
switch
up
out
of
console
with
your
fingers
.
See
Fig
.
13
.

3
.
Disconnect
harness
connector
from
switch
.

4
.
Installation
is
reverse
of
removal
.

INTERIOR
SWITCHES

3
.
Break
open
plastic
retainer
in
back
of
instrument
clus-
ter
andremove
coding
plug
.
See
Fig
.
5
.

5
.
Reset
vehicle
mileage
.

1
ILO

NOTE-

Consultan
authorized
BMW
dealer
service
department
about
resetting
vehicle
mileage
using
the
special
BMW
Service
tester
.

Vehicle
speed
sender,
replacing

0

0013029

Fig
.
5
.



Remove
coding
plug
retainer
with
a
screwdriver
(arrow)
.

4
.
Install
coding
plug
and
new
retainer
.
Reinstall
instru-
ment
cluster
.

The
vehicle
speed
sender
supplies
an
electronic
pulsed

speed
signal
to
the
speedometer
.
The
sender
is
mounted
be-

neath
the
rear
of
the
car,
on
the
differential
cover
plate
.

1
.
Locate
vehicle
speed
sender
electrical
connector
at

back
of
differential
.
Depress
retaininglevers
on
con-
nector
and
remove
.
See
Fig
.
6
.

INSTRUMENTS
620-
3

0013180
Fig
.
6
.



Vehicle
speed
sender
harnessconnector
(A)
and
sender
(B)
.

2
.
Remove
vehicle
speed
sender
retaining
screws
and
re-

move
sender
from
differential
cover
.

3
.
On
installation,
replace
O-ring
and
coat
with
oil
(90W)
.
See
Fig
.
7
.

0011755
NOTE-



'

If
the
speedometer
is
malfunctioning,
check
the
vehicle



Fig
.
7,



O-ring
correctly
installed
on
vehicle
speed
sender,
speed
sensor
hamess
connectoron
the
rear
differen-
tial
.
Water
damage,
frayed
wires
and
corrosion
of
the
connectorcontactsareoftenthecause
ofspeedometer



4
.
Insta¡¡
sender
into
differential
and
tighten
mounting
malfunction
.



bolts
evenly
in
stages
until
the
sender
is
firmly
seated
.

Tightening
Torque

"
Vehicle
speed
sender

to
differential
cover
...
.
.....
6
.6-8
.4
Nm
(53-74
in-lb)

INSTRUMENT
CLUSTER

Taillight
assembly,

removing
and
installing

1
.
Open
trunk
lid
.
Remove
cover
from
rear
of
taillight
.
Re-

fer
to
Fig
.
11
.

2
.
Depress
locking
tabs
on
electrical
harness
convector

and
disconnect
from
rear
of
taillight
lens
assembly
.
Re-

move
four
taillight
assembly
retaining
nuts
.
See
Fig
.
13
.

0012574

Fig
.
13
.
Taillight
mounting
nuts
(arrows)
and
harness
connector
(A)
.

3
.
Installation
is
reverse
of
removal
.

Center
Brake
Light

On
convertible
models,
it
is
necessary
to
open
trunk
lid
and

remove
inner
tailgatetrim
adjacent
to
license
plate
light
as-

sembly
.
Then
remove
the
electrical
connectors
and
four
cen-

ter
brake
light
retaining
nuts
.
Push
center
brake
light
out
.

Replace
bulbs
if
necessary
.

On
4-door
and
coupe
models,
open
trunk
lid
.
Working
di-

rectly
under
center
brake
light,
turn
bulb
socket
counterclock-

wise
1
/4turn
andremove
from
center
brake
light
assembly
.

Replace
bulb
if
necessary
.
See
Fig
.
14
.

EXTERIOR
LIGHTING



630-
5

0012575

Fig
.
14
.
Turncenter
brake
light
socket
counterclockwise
and
remove
bulb
.

Center
brake
light
housing,
replacing

(4-door
andcoupe
models)

1
.
Remove
rear
window
parcel
shelf
.
See513
Interior
Trim
.

2
.
Depress
tabs
on
center
brake
light
electrical
connector

and
disconnect
.

3
.
Remove
retaining
screws
and
remove
socket
.

4
.
Replace
bulb
.

REAR
LIGHTING

9
.
Release
blower
motor
retaining
strap
andremove
blow-
er
motor
and
fans
fromcowl
opening
.

NOTE-

Twist
and
rotate
blowermotor
assembly
to
facilítate
re-
moval
from
opening
.
If
the
blower
motor
is
to
be
rein-stafled,
use
care
not
to
damage
fan
wheels
during
removal
.
ff
the
blower
motor
fs
to
be
replaced,
cut
offfan
wheels
at
center
to
aid
in
removal
.

10
.
Installation
is
reverse
of
removal
.
When
installing
a
re-
placement
blower
motor,
instan
motor
into
cowlarea
before
installing
fan
wheels
.
Blower
motor
test
specifi-

cations
are
listed
in
Table
a
.

NOTE
-

On
replacementblowermotors
from
BMW,
thefan
wheels
come
unattached
to
aid
in
installation
.
Locatearrow
on
blower
motor
and
instan
fan
wheels
atthis
po-
sition
.
Be
sure
color
coolng
matches
.
Retain
fan
wheels
using
the
new
clips
.
See
an
authorized
BMW
parts
de-
partment
for
the
latest
parts
information
.

Table
a
.
Blower
Motor
Test
Values

Testingvoltage



13
VDC

Operating
voltage



9-15
VDC

Max
.
current
consumption
(approx
.)



12
amps

Maximum
speed



3,600-4,000rpm

Axialplay
(max
.
allowable)



1
.0
mm
(0
.04
in
.)

Blower
motor
resistor
pack,
replacing

The
blower
resistor
pack
is
clipped
into
the
upper
left
side
of
theheater
box
.

1
.
Remove
lower
left
dash
trim
panel
.
See513
Interior

Trim
.

2
.
Working
under
left
(driver's)
side
of
dash,
unclip
and

pulí
out
resistor
pack
from
sideof
heater
box
.
Remove

harness
connector
from
resistor
pack
.
See
Fig
.
7
.

3
.
Installation
is
reverse
of
removal
.

Heater
valve,
replacing

The
two-way
heater
valve
is
located
in
the
rear
of
the
engine

compartment
on
the
driver
side
.
The
solenoid
operated
valves

control
the
coolant
flow
through
the
dual-chamber
heater

core
.

1
.
Drain
engine
coolant
.
See
170
Radiator
and
Cooling

System
.

HEATING
AND
AIR
CONDITIONING



640-
3

uuiGO4I

Fig
.
7
.



Blower
fan
resistor
pack
(black
arrow)
and
resistor
pack
re-
ceptacle
(white
arrow)
below
left
sideof
dash
.

WARNING
-

Allow
the
cooling
system
to
cool
before
opening
ordraining
the
cooling
system
.

2
.
Disconnect
hoses
and
harness
connector
at
heater
valve
.
See
Fig
.
8
.

001[ó38b

Fig
.
S
.



Hoses
(A)
and
harnessconnector
(B)
at
heatervalve
.

3
.
Carefully
pull
heater
valve
out
of
rubber
mounting
and

pull
up
and
out
of
engine
compartment
.

4
.
Installation
is
reverse
of
removal
.
Use
new
hose

clamps
.
Inspect
hoses
and
replace
asnecessary
.

HEATER
AND
CONTROLS

640-4



HEATING
AND
AIR
CONDITIONING

Heater
box,
removing
and
installing

The
heater
box,
located
underneath
thecenter
of
the
dash-

board,
houses
theheater
core,
the
A/C
evaporator,
and
asso-

ciated
sensors
and
actuators
.
Removal
of
theheater
box

requires
that
the
A/C
refrigerant
be
discharged
.

CAUTION-

"
Removing
the
heater
box
requires
evacuating
the
AIC
system
.
DO
NOT
attempt
this
procedure
without
proper
tools
and
training
.

"
Any
person
who
services
a
motor
vehicle
air
con-

ditioner
must,
by
law,
be
properly
trained
and
cer-
tified,
and
use
approved
refrigerant
recycling
equipment
.
Technicians
must
complete
an
EPA-
approved
recycling
course
to
be
certified
UU12639

Fig
.
10
.
Heater
core
mounting
nuts
at
left
sideof
bulkhead
(arrow)
.

1
.
Drain
engine
coolant
.
See
170
Radiator
and
Cooling



wiper
assembly
shown
removed
for
clarity
.

System
.

2
.
Remove
complete
dashboard
.
See513
Interior
Trim
.

3
.
Remove
blower
motoras
described
earlier
.

4
.
Remove
nut
retaining
water
hose
flange
to
rear
bulk-
head
.
I'ush
flange
to
one
side
.
See
Fig
.
9
.

Fig
.
9
.



Nut
retaining
coolant
hose
flangeat
bulkhead
(arrow)
.

NOTE-

Clear
any
remaining
coolant
from
the
heater
core
by
blowing
compressed
air
finto
the
coolant
feed
hose
.

HEATER
AND
CONTROLS

0012638b

6
.
Cut
wire
tie
holding
wire
harness
to
heater
box
and
dis-

connect
cable
harness
connector
from
heater
box
.
See

Fig
.
11
.

0012647

Fig
.
11
.
Harness
connectors
(A)
and
cable
tie
(B)
at
heaterbox,
under
driver
side
dash
.

7
.
Followingmanufacturer's
instructions,
connect
ap-

proved
refrigerant
recovery/recycling/recharging
unitto

A/C
system
and
discharge
system
.

8
.
Unbolt
A/C
refrigerantlines
flange
from
engine
bay
bulkhead
.
See
Fig
.
12
.

9
.
On
models
with
rotary-knob
A/C
control
head
:
Discon-
5
.
Remove
nuts
from
heater
box
retaining
bracket
on
en-



nect
wiring
harness
connectors
to
A/C
control
module
gine
bulkhead
left
side
.
See
Fig
.
10
.
Repeat
procedure



in
center
console
and
remove
module
.
See
Fig
.
13
.
for
right
side
nuts
.

Fig
.
12
.
Mounting
bolt
for
A/C
refrigerant
line
flange
(arrow)
.

001Suu7

Fig
.
13
.
A/
C
control
module
(A)
behind
center
console
.
Arrows
pointto
electrical
harness
connectors
to
be
disconnected
.

CAUTION
-

Replace
heater
and
AIC
flange
O-rings
and
tight-

en
fasteners
to
specified
torques
.

0012644

HEATING
AND
AIR
CONDITIONING



640-5

Fig
.
14
.
Heating
and
ventilation
ducts
on
left
side
of
heater
box
(arrows)
.
Right
side
ducts
are
similar
.

Fig
.
15
.
Heater
box
retaining
bracket
in
center
console
(arrow)
.

0012645

10
.
Unclip
andremove
heating
and
ventilation
ducts
on



Tightening
Torques

sides
of
heater
box
.
See
Fig
.
14
.



"
A/C
refrigerant
lines
flange

to
bulkhead
..............
.
..
..
.
3
.5
Nm
(31
in-lb)

11
.
Remove
heater
box
retaining
bracket
on
center
tunnel



"
Water
hose
flange
to
bulkhead

and
remove
heater
box
.
See
Fig
.
15
.



(M6
nut)
................
.
...
..
3
.5
Nm
(31
in-lb)

"
Heater
box
retaining
bracket

12
.
Installation
is
reverse
of
removal
.
Evacuate
and
re-



to
tunnel
................
.
..
..
.
4
.5
Nm
(40
in-lb)

charge
A/C
system
using
specialized
equipment
.
Fill

and
bleed
cooling
system
.
See
170
Radiator
and

Cooling
System
.

HEATER
AND
CONTROLS

10
.
Pul¡
heater
core
up
and
backward,
away
from
heater
box
.
If
necessary,
remove
left
and
right
reinforcing
bracket
bolts
.
See
Fig
.
20
.

CAUTION-

Replace
coolant
flange
O-rings
and
tighten
fas-
teners
to
specified
torques
.

Tightening
Torques

1
.
Remove
center
console
.
See
513
Interior
trim
.

0012660

Fig
.
20
.
PA
heater
core
upand
towardback
of
car
.
Lower
mounting
bolts
for
steering
column
brace
and
glove
compartment
sup-
port
frame
may
have
to
be
removed
(arrows)
.

11
.
Installation
is
reverse
of
removal
.
Fill
and
bleed
cooling

system
.
See
170
Radiator
and
Cooling
System
.

"
Coolant
flange
to
heater
core
.
..
....
3
Nm
(27
in-lb)



Heater
andA/C
Control
Head

Heatercore
temperature
sensor,
replacing

The
automatic
heating
and
air
conditioning
systemuses

severa¡
sensors
to
control
interior
air
temperature
.
Use
the
fol-

lowing
procedure
and
the
data
in
Table
b
to
pinpoint
problems

with
theheater
core
sensors
.

2
.
Remove
Multi-Information
Display
(MID)
module
.
See

6201nstruments
.

HEATING
AND
AIR
CONDITIONING



640-7

0012648

Fig
.
21
.
Remove
heatercore
temperaturesensors
in
direction
shown
(arrow)
.

Table
b
.
Heater
CoreTemperatureSensor
Test

Values

Test
temperature



Resistance

4°F
(-20°C)



84
.39
-
109
.61
k
ohms

14
°
F
(-10°C)



48
.58
-
62
.09
k
ohms

32°F
(0°C)



28
.89
-
36
.40
k
ohms

68°F
(20°C)



11
.13
-
13
.83
k
ohms

140°F
(60°C)



2
.19
-
2
.78
k
ohms

212°F
(100°C)



0
.58
-
0
.77
k
ohms

Two
types
of
heater
and
aír
conditioning
control
heads
viere
installed
in
E36
cars
.
Early
models
have
control
heads
with
four
rotary
knobs
and
a
separate
control
module
.
A
flexible

shaft,
clipped
to
the
right
sideof
the
control
head,
controls
the
heater
flaps
.

Later
model
E36
cars,
starting
in
approximately
mid-1995,

have
digital
display
control
heads
with
buttons
.
The
A/C
con-
trol
module
is
integrated
with
the
digital
control
head
.

Heater
and
A/C
control
head,

removing
and
installing
(rotary-knob)

3
.
Pul¡
temperature
sensors
from
heater
box
and
discon-



1
.
Remove
Multi-Information
Display
(MID)
module
from

nect
harness
connectors
.
See
Fig
.
21
.



center
of
dash
.
See
620
Instruments
.

4
.
Installation
is
reverse
of
removal
.



2
.
Pul¡
off
outer
rotary
knobs
from
A/C
control
head
.
Re-

move
two
screwsonknob
bezels
.
Remove
control
pan-

el
face
plate
by
prying
it
off
control
head
gently
.
See
Fig
.

22
.

3
.
Carefully
push
control
head
back
into
dash
and
down-

ward
through
MID
opening
.
See
Fig
.
23
.

HEATER
AND
CONTROLS

640-10



HEATING
AND
AIR
CONDITIONING

i

El
Radio

Antenna

Rear



.
,



si,-
Left
side



I
d

1
.
Rear
vents
2
.
Fresh
air
3
.
Face-level
vents
4
.
Recirculation
5
.
Footwell
vents
0013017

Fig
.
28
.
Location
oflate
production
air
distribution
motors
in
heater
box(shown
in
rear,
side
and
top
views)
.

Heater
andA/C
air
distribution
motor,

replacing
(rotary-knob)

1
.
Toaccess
left
side
motors
(dash
vent
mixing
or
recircu-

lation
flap),
remove
lower
dash
panel
and
knee
bolster

on
driver
side
.
See
513
Interior
Trim
.

2
.
To
access
right
side
motor
(fresh
air
flap),
remove
glove

compartment
.
See513
Interior
Trim
.

3
.
Each
motor
can
be
removed
after
its
electrical
wiring

harness
connector
has
been
removed
.
Squeeze
plastic

clip
to
release
motor
.
See
Fig
.
29
.

Fig
.
29
.
A/
C
air
distribution
motor
plastic
retaíning
clip
(arrow)
.
Re-
lease
clip
and
tilt
motor
out
of
housing
.

Rear
Window
Defogger

0011877

The
rear
window
defogger
switch
is
integrated
with
the
heating
andA/C
control
head
.

HEATER
AND
CONTROLS

Fig
.
30
.
Wiring
diagram
of
rear
window
defogger
and
radio
antenna
.

Rear
Window
Blower
(Convertible
Models)

A
blower
fan,
fitted
into
the
rear
seatback,
defogs
therear

window
.
It
will
only
operate
with
the
engine
nunning
and
the

top
raised
.
A
microswitch
behindthe
rear
seats
provides
the

signal
that
thetop
is
raised
.

To
access
the
blower
fan
motor,
it
is
necessary
to
remove

four
screwsfrom
the
center
seat
back
.
Remove
the
wiring
har-

ness
connector
and
motor
mounting
boits,
then
remove
motor

by
pulling
it
down
and
forward
.
See
Fig
.
31
.

ri

Suppressor
filter

1
0013005

Fig
.
31
.
Rear
window
blower
in
center
of
rear
seat
back
(arrow)
.

The
electric
rear
window
defogger
is
integrated
with
the
ra-

dio
antenna
.
See
Fig
.
30
.



y



/f



0013014

Fig
.
36
.
6-cylinder
engine
belt
diagram
:
To
remove
A/C
belt,
lever
ten-
sioner
(A)
in
clockwise
direction
using
long-handled
wrench
or
breaker-bar
.

6
.
Disconnect
electrical
harness
connector
from
com-
pressor
.

7
.
Remove
A/C
pressure
hose
and
suction
hose
flange



10
.
Before
recharging,
evacuate
system
for
at
least
30
min
.
bolts
from
compressor
.
Plug
hoses
immediately
See



Recharge
system
following
equipment
manufacturer's

Fig
.
37
.



instructions
.
See
Table
d
.
A/C
System
Refrigerant

Capacities
.

0011879

Fig
.
37
.
A/
C
compressor
pressure
hose
(A)
and
suction
hose
(B)
.
(6-
cylinder
engine
shown
.
4-cylinder
engine
is
similar
.)

HEATING
AND
AIR
CONDITIONING



640-
1
3

Fig
.
38
.
A/
C
compressor
mounting
boits
(arrows)
.

9
.
Installation
is
reverseof
removal
.

CAUTION
-

"
Always
replaceO-rings
when
reconnecting
re-
frigerantfines
.

"
When
installlng
a
new
compressor
always
re-
place
receiverldrier
unit
.

Tightening
Torques

"
A/C
compressor
to
engine
block
....
22
Nm
(17
ft-Ib)
"
A/C
line
flange
to
A/C
compressor
5/8
in
.
fine
.
......
.....
....
.
.....
20
Nm
(15
ft-Ib)

3/4
in
.
fine
.......
.....
..........
39
Nm
(29
ft-Ib)

7/8
in
.
fine
...
....
.....
..........
42
Nm
(31
ft-Ib)

11/16
in
.
fine
.....
..
..
..
...
.
.....
48
Nm
(35
ft-Ib)

A/C
Compressor
Clutch

The
compressor
clutch
can
be
replaced
without
disturbing

thesealed
refrigerant
system,
although
clearances
in
the
six-

cylinder
cars
may
be
very
tight
.
Detach
the
compressor
from

the
compressor
bracket
togain
extra
clearance
.

8
.
Remove
compressor
mounting
boits
.
See
Fig
.
38
.
Re-



Typical
A/C
compressor
and
clutch
is
shown
in
Fig
.
39
.
move
compressor
by
pulling
downward
from
under-

neath
car
.



Remove
driveplate
and
pulley
to
access
clutch
magnetic

winding
.
See
Fig
.
40
.

AIR
CONDITIONING