BMW - 5 Series M5 - Workshop Manual - 2001 - 2001

BMW Parts and Accessories Installation Instructions F 46 0651 2W Conversion from IHKR (integrated heater and air conditioner control) to IHKA (automatic heating and air conditioning) BMW 3 Series (E46) Technical knowledge is required. Only for use within the BMW trading organisation. Installation time approx. 6 hours, which can vary according to the condition and fittings of the vehicle. Conversion/Installation Kit no. 64 50 0 029 507 Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 Contents Chapter Page Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1. Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2. Connection overview IHKA and AUC (automatic recirculating air control) wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . 5 3. Convert heater/air-conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4. Install and connect IHKA wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5. Install and connect AUC sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6. Finalising operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7. Circuit diagram IHKA wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 8. Circuit diagram AUC wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/2 Important notes Safety instructions ! The current accident prevention regulations should be observed. When dealing with component parts of the airbag system safety instructions should be complied with. For more detailed information please refer to the TIS under RA no. 32 34 ... . Non-observance of the safety instructions can lead to erroneous activation and injury from the airbag system." Assembly instructions When installing cables, do not kink or damage them otherwise faults may occur which can only be localised and remedied later by extensive reworking. Costs arising in this way will not be reimbursed by BMW. The procedures, Convert heater/air-conditioner and Install IHKA wiring harness, are best shown on a dismantled heater/air-conditioner. Should specified pins be assigned, bridges, double crimping or parallel connections will have to be made. All operations are shown on a left-hand drive vehicle. Target Group Target group for these installation instructions is technical personnel who have been trained on BMW vehicles and who have specialised knowledge of vehicle electrical systems. Tasks: Carry out all maintenance, repair and installation work on BMW vehicles on own account. All operations should be carried out with the aid of the current BMW - repair instructions - circuit diagrams in a rational sequence with the prescribed tools (special tools) whilst observing the current safety regulations. Required tools and auxiliary materials MoDiC or DIS Set of flat-tip screwdrivers Set of Phillips screwdrivers Set of Torx screwdrivers Set of 1/2 inch socket wrenches Set of fork wrenches/ring wrenches Side-cutting pliers 1/2 inch torque spanner Hand lamp Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/3 1. Preliminary work 0 TIS AW no. Carry out short test Disconnect negative terminal of the battery The following components should be disassembled first: Trim panel for instrument panel Cross-bracing Battery (only vehicles with 4-cylinder petrol engine) Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 12 00 ... 51 45 030 EN/4 2. Connection overview IHKA and AUC wiring harness 0 A12 A4 A1 A6 A2 A10 A3 A8 A9 A7 A11 A A5 B B2 B3 B4 B5 B1 F 38 0657 2W 0 0 Item Designation Signal Cable colour/ cross-section Anschlussort im Fahrzeug Code desig. plug-in place --- --- A IHKA wiring harness A1 Connector, 6-pole, black At IHKA operating unit X18341 A2 Connector, 3-pole, black At IHKA operating unit X18348 A3 Connector, 2-pole, black At heater/air-conditioner X18722 A4 Connector, 2-pole, black With butt-joint connector at blower cable X816 A5 Connector, 5-pole, black At the blower output stage X671 A6 Connector, 2-pole, black At temperature sensor of evaporator X771 A7 Connector, 2-pole, black At temperature sensor of heat exchanger X772 A8 Connector, 3-pole, black At actuator, footwell X18788 A9 Connector, 3-pole, black At actuator, defrosting X664 A10 Connector, 3-pole, black At actuator, air distribution X18347 A11 Connector, 3-pole, black At actuator, fresh/recirculating air left X18346 A12 Connector, 3-pole, black B AUC wiring harness At actuator, fresh/recirculating air right --- X18345 --- B1 Connector, 4-pole, black B2 Socket contact BL At AUC sensor X3211 At IHKA operating unit X610, Pin 18 At IHKA operating unit X610, Pin 11 At IHKA operating unit X610, Pin 16 At IHKA operating unit X610, Pin 15 Ø 0,5 mm2 B3 Socket contact BR/BL Ø 0,5 B4 Socket contact GE Ø 0,5 B5 Socket contact mm2 mm2 BR/GE Ø 0,5 mm2 Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/5 3. Convert heater/air-conditioner Der The procedure, Convert heater/air-conditioner, is best shown on a dismantled heater/ air-conditioner. The connection to the blower motor, connector X816, remains connected for the time being." Disconnect the existing IHKR wiring harness from the individual components and lay it aside. 0 0 Unclip deflection lever (1) from mechanical flap actuator (2). 2 1 F 46 0647 2W 0 0 1 Screw out Torx screw (1) and remove cover plate (2). 2 F 46 0648 2W 0 0 1 3 2 Screw out Torx screws (1) and remove complete flap mechanism (2) from the heater/air-conditioner (3). 1 F 46 0650 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/6 3. Convert heater/air-conditioner 0 0 Insert supplied new flap spindle (1) in the heater/ air-conditioner (2) until it engages. 2 1 F 46 0649 2W 0 0 Make sure the teeth are in synchronisation." Insert supplied gear shafts (1) in the heater/airconditioner (2) until they engage. 1 2 F 46 0636 2W 0 0 Screw base plate (1) with supplied Torx screws to the heater/air-conditioner (2). 1 2 F 46 0637 2W 0 0 1 Clip actuator (1) into base plate (2). 2 F 46 0638 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/7 3. Convert heater/air-conditioner 0 0 1 Clip actuators (1 and 2) as shown into base plate (3). Die The electrical connections of the actuators (1 and 2) must point towards each other as shown." 3 2 F 46 0639 2W 0 0 Clip deflection lever (1) into actuator (2). 2 F46 0 641 2W 1 F 46 0641 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/8 4. Install and connect IHKA wiring harness The procedure, Install IHKA wiring harness, is best shown on a disassembled heater/air-conditioner." 0 A8 A10 A3 A9 A7 A12 A5 F 46 0660 2W Connect IHKR wiring harness as follows: 0 Item A3 A5 A7 A8 A9 A10 A12 Code designation X18722 X671 X722 X18788 X664 X18347 X18345 Connection point Clip into heater/air-conditioner At the blower output stage At the temperature sensor, heat exchanger At the actuator, footwell At the actuator, defrosting At the actuator, air distribution At the actuator, fresh/recirculating air, right Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/9 4. Install and connect IHKA wiring harness 0 0 3 A11 2 Install branch cables A6 and A11 along the IHKR wiring harness to the left side of the heater/airconditioner and connect as follows: - A6, connector X711, to temperature sensor, evaporator (1). - A11, connector X18346, to actuator, fresh/recirculating air left (2). Take care to see that the branch cables A6 and A11 are not lying against the adjustment lever (3)." 1 A6 F 46 0644 2W 0 0 X816 2 At a suitable place, cut the two cables to connector X816 (cable colours BR and GR/BR) coming from the IHKA wiring harness (1) and the IHKR wiring harness (2) and insulate the cable ends. 1 F 46 0658 2W 0 0 3 2 Connect the open cable ends (cable colours BR and GR/BR) from the IHKA wiring harness (1) and the IHKR wiring harness (2) with the supplied butt-joint connectors (3) and shrinkage tubing. See TIS RA no. 61 13 ..." 1 F 46 0659 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/10 5. Install and connect AUC sensor 0 0 X3211 1 3 Only vehicles with 4 or 6-cylinder petrol engine Clip AUC sensor (1) into the radiator casing (2) and connect connector X3211. Install AUC wiring harness (3) in the engine compartment, right, to the end panel. 2 F 46 0655 2W 0 0 Only vehicles with 4 or 6-cylinder diesel engine Clip AUC sensor (1) into the radiator casing (2) and connect connector X3211. Install AUC wiring harness (3) in the engine compartment, right, to the end panel. 3 2 X3211 1 F 46 0653 2W 0 0 All vehicles Install AUC wiring harness (1) through the rubber grommet (2) into the interior. 2 1 F 46 0654 2W 0 0 BL BR/BL GE BR/GE 1 X610 Install branch cables B2 - B5 along the heater/airconditioner (1) to the 18-pole white connector X610 and pin in as follows: PIN PIN PIN PIN 18 11 16 15 B2-B5 F 46 0656 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/11 6. Finalising operations - Reassemble vehicle in the reverse order of disassembly using the supplied IHKA operating unit. - Connect battery. - Code the conversion via the path "Retrofit IHKA". - Carry out short test. - Carry out function test of the IHKA. Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/12 Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/13 VEDF 1 GR 0.5 3 VEDF B14 X771 2 GN 0.5 4 FUE- FUE- X772 B11 2 GN 0.5 3 FUE- FUE- 1 GNGR 0.5 4 WTL WTL U-GEBL 3 5 HOT+ 5 31L<4 1 1 15HZE 4.0 GNBR BR 4.0 1 31L<4 15HZE 2 X18722 A11 HOT- GNBR BR 4.0 4.0 2 1 BLRT X816 M30 X18341 0.5 2 HOT+ U-GEBL N2 X671 HOT- 0.35 WS 1 M38 X18788 SM-FT 0.35 GE SM1 0.35 SW MI-BUS 1 X664 M35 0.35 WS SM-FT 1 0.35 GE SM1 0.35 SW MI-BUS 1 0.35 WS VB 2 X5992 0.35 GE VB 3 1 VB 4 1 X5994 0.35 SW MI-BUS 1 X18348 M18347 X5993 0.35 SW 3 0.35 GE SM2 0.35 WS SM-FT 1 X18347 SM-FT SMMI-BUS X18346 M18346 0.35 WS SM-FT 1 0.35 GE SM1 0.35 SW MI-BUS 1 X18345 1 0.35 GE 1 0.35 SW 1 F 46 0652 2W M18345 0.35 WS SM-FT SMMI-BUS 7. Circuit diagram IHKA wiring harness 7. Circuit diagram IHKA wiring harness Key A11 IHKA operating unit B11 B14 Temperature sensor, heat exchanger Temperature sensor, evaporator M30 M35 M38 M18345 M18346 M18347 Blower motor Actuator, defrosting Actuator, footwell Actuator, fresh/recirculating air left Actuator, fresh/recirculating air right Actuator, air distribution N2 Blower output stage X664 X671 X771 X772 X816 X5992 X5993 X5994 X18341 X18345 X18346 X18347 X18348 X18722 X18788 Actuator, defrosting Blower output stage Temperature sensor, evaporator Temperature sensor, heat exchanger Blower motor Soldered connector 2 Soldered connector 3 Soldered connector 4 IHKA operating unit Actuator, fresh/recirculating air left Actuator, fresh/recirculating air right Actuator, air distribution IHKS operating unit Blower Actuator, footwell Cable colours RT SW GE BL GN BR GR WS red black yellow blue green brown grey white Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/14 8. Circuit diagram AUC wiring harness 0 B414 4 1 3 2 X3211 0,50 BL 0,50 BR/BL 0,50 BR/GE 0,50 GE X610 18 11 15 16 A11 F 46 0645 2W Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/15 8. Circuit diagram AUC wiring harness Key A11 IHKR operating unit B414 AUC sensor X610 X3211 IHKR operating unit AUC sensor Cable colours BR GE BL brown yellow blue Conversion/Installation Kit no.: 64 50 0 029 507 Installation Instructions no.: 01 29 0 029 506 Date: 01.2001 EN/16