Parts and Accessories Installation Instructions

Parts and Accessories Installation Instructions

065 0047 Z

Retrofit auxiliary heating system BMW 7 Series (E 65 and E 66) with M54, N62 and N73 engines The installation time for cars with M54 or N62 engines is approx. 9 – 10 hours, for cars with N73 engines it is approx. 11 – 12 hours, although this may vary depending on the condition of the car and the equipment in it. Retrofit kit No.

64 50 0 139 926

Before installing the retrofit kit, use the latest CIP application to ascertain the car's status and if necessary update the software in accordance with the action plan. The actual duration of the software update can vary for technical reasons.

Retrofit kit No. 64 50 0 139 926 Installation Instructions No. 01 29 0 139 927

Issue date: 07.2002

Contents Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page Important information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1.

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

2.

Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3.

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4.

Installation and cabling diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

5.

To install the triple pipe and changeover valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

6.

To convert the coolant system in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

7.

To install the auxiliary heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

8.

To connect the fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

9.

To install the silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

10. To install and connect the wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

11. Concluding work and coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

12. To operate the auxiliary heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

13. Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24


Issue date: 07.2002

EN/2

Important information The retrofit kit is for use within the BMW dealership organisation only. Subject to technical modifications. Target group The target group for these installation instructions is specialist personnel trained on BMW cars with the appropriate specialist knowledge. All work must be completed using the latest BMW repair manuals, circuit diagrams, servicing manuals and work instructions in a rational order using the prescribed tools (special tools) and observing current health and safety regulations. Installation information Observe the tightening torque values for screw connections. The required tightening torque values are set out in the part information system (TIS). Ensure that the cables/lines are not kinked or damaged as you install them in the car. The installed cables/lines are to be secured with cable ties. If the specified PIN chambers are occupied, bridges, double crimps or twin-lead terminals must be used. After the installation work the auxiliary heating system retrofit must be coded using DISPlus, MoDiC III or GT1 via the Retrofit path. Ordering instructions The hoses from the heater to the engine return AI and the Telestart transmitter AJ are not included in the installation kit and must be ordered separately (see EPC for part number). Notes on commissioning and operation If the equipment is retrofitted in the Federal Republic of Germany (FRG) it must undergo an acceptance test pursuant to § 19 (2) of the Road Traffic Act and then also be entered in the vehicle documents. To do this, print out these installation instructions and give them to the customer. If the car is or is to be registered outside the Federal Republic of Germany, the appropriate national regulations apply. Operating the auxiliary heating system places a strain on the car’s battery. If the car is equipped with a 90 Ah battery, this must be replaced with a more powerful 110 Ah battery (see EPC for part number and documentation). To avoid starting problems and to stabilise the car’s electrical system we recommend that you drive the car adequately in the period when you use the auxiliary heating system so that the battery remains well charged. Recommendation: 30 minutes auxiliary heating system use = 30 minutes driving time.

!

Danger of poisoning Do not use the auxiliary heating system in enclosed spaces such as garages or workshops. Danger of explosion The auxiliary heating system must be switched off at filling stations and/or filling points.

Required special tools Tester for pressure testing the cooling water circuit (17 0 000)


Issue date: 07.2002

EN/3

1.

Preparations

0

TIS instruction No. Conduct a brief test Disconnect the negative pole of the battery

12 00 ...

The following components must be removed first of all: Rear seat bench

52 24 005

Rear right door sill strip

51 47 030

Front right door sill strip

51 47 000

A pillar trim at the bottom right

51 43 075

B pillar trim on the right

51 43 148 / 51 43 150

Glove compartment

51 16 360 ---

Release the front fuse holder

---

Engine noise control covers Microfilter housings, left and right

64 31 010

Air duct, microfilter on the right

64 31 ...

Closing panel in centre of power unit compartment

51 71 085

Wheel arch trim on the front left

51 71 040

Rear left underbody shield

51 47 ...

Underbody shield on the left

51 47 ...

Drain the cooling water

17 00 005 / 17 00 039 ---

Undo the water valve


Issue date: 07.2002

EN/4

2.

Parts list

0

A

I

E F G H

J

K L M N O P W

V

U

C

B

AC

AD

AE

X

AF

Q R Z

Y

D

AG

S

T

AA

AB

AH AI

AJ ON OFF

B

MODE

MW

065 0207 Z 0

Legend A

Wiring harness

S

Clic hose clip (3x)

B

Auxiliary heater

T

Fuel line

C

Changeover valve

U

Triple hose holder

D

Fuel metering pump

V

Silencer

E

Hexagonal screw M6 x 30 mm (2x)

W

Counter-holder

F

Washer (2x)

X

Cable tie (20x)

G

Spacer bush (2x)

Y

Hose from changeover valve to auxiliary heater

H

Blue grommet (2x)

Z

Hose from triple pipe to changeover valve

I

Black grommet (2x)

AA Hose from triple pipe to changeover valve

J

Hexagonal screw M6 x 16 mm (2x)

AB Hose

K

Plastic nut (4x)

AC Triple pipe

L

Rubber grommet (4x)

AD Hose from triple pipe to additional water pump

M

Hexagonal screw M6 x 20

AE Hose from heating element to triple pipe

N

Blind rivet nut (rubber-lined)

AF Duplicate factory label

O

Hexagonal screw M6 x 18 mm

AG Insulation-piercing connector

P

Blind rivet nut

H

Fusible link 20 A

Q

Hose clip (12x)

AI

Hose from heater to engine return (not supplied in the retrofit kit)

R

Cable tie with holder (4x)

AJ Telestart transmitter (not supplied with retrofit kit)


Issue date: 07.2002

EN/5

3.

Connection diagram

0

X785 C1

C2

B4 B3 X764 B2 B1

D2

D1

E1

A

A1 X642 A2

E2

G

F

X997

065 0208 Z

0

Item

Description

Signal

Cable colour / Cross-section

Connection location in the car

Abbreviation / Slot

---

---

---

---

A

Wiring harness

X642

2-pin socket casing

Auxiliary heater

X642

A1

Socket contact

Terminal 30

RT/BL/GE 2.5 mm2

Auxiliary heater

X642 PIN 1

A2

Socket contact

Terminal 31

BR 2.5 mm2

Auxiliary heater

X642 PIN 2

X764

6-pin socket casing

Auxiliary heater

X764

B1

Socket contact

CAN-high

GN/OR 0.35 mm2

Auxiliary heater

X764 PIN 2

B2

Socket contact

CAN-low

GN 0.35 mm2

Auxiliary heater

X764 PIN 3

B3

Socket contact

SHMV

GR/SW 0.5 mm2

Auxiliary heater

X764 PIN 4

B4

Socket contact

DOSP

SW/RT 0.75 mm2

Auxiliary heater

X764 PIN 6

X785

2-pin socket casing

Changeover valve

X785

C1

Socket contact

Terminal 31

BR 0.5 mm2

Changeover valve

X785 PIN 1

C2

Socket contact

SHMV

GR/SW 0.5 mm2

Changeover valve

X785 PIN 2


---

---

---

---

---

---

Issue date: 07.2002

EN/6

3.

Connection diagram

0

X785 C1

C2

B4 B3 X764 B2 B1

D2

D1

E1

A

A1 X642 A2

E2

G

F

X997

065 0208 Z

0

Item

Description

Signal

Cable colour / Cross-section

Connection location in the car

Abbreviation / Slot

D1

Ribbon cable

CAN-high

GN/OR 0.35 mm2

CAN high post A pillar on the right

X10582 Chamber 2

D2

Ribbon cable

CAN-low

GN 0.35 mm2

CAN low post A pillar on the right

X10582 Chamber 1

X997

2-pin socket casing

Fuel metering pump

X997

E1

Socket contact

DOSP

SW/RT 1.5 mm2

Fuel metering pump

X997 PIN 1

E2

Socket contact

Terminal 31

BR 1.5 mm2

Fuel metering pump

X997 PIN 2

F

Socket contact

Terminal 30

RT/BL/GE 2.5 mm2

Front fuse holder A 48 GR 8-pin socket casing

X10454 PIN 8

G

Cable lug M6

Terminal 31

BR 2.5 mm2

Earth post connection behind the left headlight

X165


---

---

Issue date: 07.2002

EN/7

4.

Installation and cabling diagram

0

1

2

A

3 E65

4

D

C B

065 0209 Z

Legend 0

1

Electrics box

2

Fuse holder

3

CAN high/low post X10582

4

Earth post X165

A

Wiring harness

B

Auxiliary heater

C

Changeover valve

D

Fuel metering pump


Issue date: 07.2002

EN/8

5.

To install the triple pipe and changeover valve

0 0

C

L

0

Insert the rubber grommets L into the lugs on the changeover valve C.

065 0210 Z 0

Screw the changeover valve C to the existing coarse thread bolt using plastic nuts K.

C

K

0

065 0211 Z 0

Insert the rubber grommets L into the lugs on the triple pipe AC.

AC

L

065 0212 Z

0 0

Thread the triple pipe AC into the engine compartment. Screw the triple pipe AC to the existing coarse thread bolt using plastic nuts K.

AC K 065 0213 Z Retrofit kit No. 64 50 0 139 926 Installation Instructions No. 01 29 0 139 927

Issue date: 07.2002

EN/9

5.

To install the triple pipe and changeover valve

0 0

C

AC AA Z

Install the hoses Y, Z and AA on the changeover valve C and on the triple pipe AC. Secure the hoses with hose clips.

Y 065 0214 Z


Issue date: 07.2002

EN/10

6.

To convert the coolant system in the engine compartment

1

2

3

1**

4

1*

5

6

7

065 0236 Z

0

Remove components 1 (1*/1**), 4 and 6 (no longer required).


Issue date: 07.2002

EN/11

6.


0

Legend to figure 065 0236 Z 0

1

Hose from heating element to engine return on the N62 engine

1*

Hose from heating element to engine return on the M54 engine

1** Hose from heating element to engine return on the N73 engine 2

Hose from water valve to heating element on left

3

Hose from water valve to heating element on right

4

Double hose holder

5

Water valve

6

Hose from additional water pump to water valve

7

Additional water pump


Issue date: 07.2002

EN/12

6.


AI*

Z

Y

AI

AE 1

2

AI**

U

C

AE

B

AA

AB

AC

3

4

AD

065 0215 Z

0

Install components AB, AD, AE, AI (AI*/AI**) and U as shown.


Issue date: 07.2002

EN/13

6.


Legend to figure 065 0215 Z 0

1

Hose from water valve to heating element on left

2

Hose from water valve to heating element on right

3

Water valve

4

Additional water pump

B

Auxiliary heater

C

Changeover valve

U

Triple hose holder

Y

Hose from changeover valve to auxiliary heater

Z


AA


AB

Hose

AC

Triple pipe

AD

Hose from triple pipe to additional water pump

AE

Hose from heating element to triple pipe

AI

Hose from heating element to engine return on the N62 engine

AI*

Hose from heating element to engine return on the M54 engine

AI** Hose from heating element to engine return on the N73 engine

Reinstall the closing panel in the centre of the power unit compartment after modifying the coolant system.


Issue date: 07.2002

EN/14

7.

To install the auxiliary heater

0 0

Secure the counter holder W using hexagonal screws J.

W J 065 0216 Z 0 0

1

Insert the blue H and black I rubber grommets into the retaining lugs of the auxiliary heater (1). Push spacer bushes G into the black rubber grommets I.

H

I

G

0

065 0217 Z 0

Push the auxiliary heater B on to the counter holder. Secure the auxiliary heater B using hexagonal screws E and washers F.

B

E/F

065 0218 Z 0 0

Q

Push on the hoses (1) and Y and secure them with hose clips Q.

1 Y 065 0219 Z Retrofit kit No. 64 50 0 139 926 Installation Instructions No. 01 29 0 139 927

Issue date: 07.2002

EN/15

8.

To connect the fuel supply

0 0

Open the holder (2) on the left underbody. Connect the fuel line T to the fuel hose (1) and secure it with a Clic hose clip S.

1

Run the fuel line T along the holder (2) to the fuel tank.

S

Close the line holders (2) again.

2 T 065 0220 Z 0 0

The rivet nut collar points towards the fuel metering pump.

O P

Secure the fuel metering pump D loosely using a blind rivet nut P and hexagonal screw O.

D 065 0221 Z 0 0

1 S

T

2

Push the fuel metering pump holder D into the openings provided. Push the fuel metering pump D into place and tighten the screw O until the rivet nut has been fully riveted into place. Cut off the end cap of the fuel outlet port (1) and connect to the fuel hose (2).

O D

Connect the fuel hose (3) to the fuel line T. Secure the hoses using Clic hose clips S.

3 065 0222 Z


Issue date: 07.2002

EN/16

9.

To install the silencer

0 0

Secure the silencer V loosely using a blind rivet nut Nand hexagonal screw M.

N

V M 065 0223 Z 0 0

1

Push the silencer V on to the exhaust pipe (2). Press the silencer V with the blind rivet nut into the retaining lug (1) and tighten using hexagonal screw M.

V M 2 065 0224 Z

0 0 0

Using a saw, cut out the underbody shield (2) along the existing marking (1).

2

1 065 0225 Z


Issue date: 07.2002

EN/17

10. To install and connect the wiring harness 0 0

X165 A

Insert branches A – C of the wiring harness A-C through the grommet (1) into the wheel arch. Screw branch G onto the earth post connection X165.

G

A-C 1 065 0228 Z 0 0

Lay branches A – C in the wheel arch as shown.

A1-A2 C1-C2 B1-B4 065 0017 Z 0 0

Connect branches A1 and A2 to the 2-pin plug X642 as follows: - A1 RT/BL/GE cable to PIN 1 - A2 BR cable to PIN 2 Connect branches B1 – B4 to the 6-pin plug X764 as follows:

X785 X764

X642 065 0019 Z

- B1 GN/OR cable to PIN 2 - B2 GN cable to PIN 3 - B3 GR/SW cable to PIN 4 - B4 SW/RT cable to PIN 6 Use the single strand seals provided to close the free PIN chambers. Connect branches C1 and C2 to the 2-pin plug X785 as follows: - C1 BR cable to PIN 1 - C2 GR/SW cable to PIN 2 Connect plugs X642, X764 and X785.


Issue date: 07.2002

EN/18

10. To install and connect the wiring harness 0

1

0

Insert the wiring harness A through the grommet (3). Drill 6 mm holes in area (2). Clip the cable tie and holder R into the holes.

R

2

Fasten the wiring harness A with cable ties and lay it to the electrics box (1).

A 3 065 0226 Z 0 0

2

Drill a 10 mm hole (2) in the area of the air inlet grille (1) of the electrics box.

1

065 0022 Z 0 0

Lay the wiring harness A through the grommet (2) and the hole (1) into the passenger footwell.

1

A

2 065 0227 Z

0 0

F

Lay branch F to the front fuse holder (1). Connect branch F to PIN 8 of the grey 8-pin plug X10454. Insert 20 A fusible insert AH into slot F1.

X10454

1 AH 065 0235 Z


Issue date: 07.2002

EN/19

10. To install and connect the wiring harness 0 0

D2

Connect branches D1 and D2 to the cables of the same colours on the CAN high/low post X10582 using an insulation-piercing connector AG.

AG D1

X10582 065 0229 Z

0 0

Lay branches E1 and E2 along the standard wiring harness to the rear seat bench.

E1-E2

065 0230 Z 0 0

E1-E2

Lay branches E1 and E2 in the cable duct (1) to the lefthand fuel tank outlet port (2).

1

2 065 0231 Z 0 0

1

E1-E2

Thread branches E1 and E2 through the grommet (1) and lay them towards the fuel metering pump.

065 0232 Z Retrofit kit No. 64 50 0 139 926 Installation Instructions No. 01 29 0 139 927

Issue date: 07.2002

EN/20

10. To install the wiring harness 0 0

X997

Connect branches E1 and E2 to the 2-pin plug X997 as follows: - E1 SW/RT cable to PIN 1 - E2 BR cable to PIN 2

E1-E2 065 0010 Z


Issue date: 07.2002

EN/21

11. Concluding work and coding 0 0

Affix the duplicate factory label AF to the left MacPherson strut tower (1).

1 The date of installation must remain legible. Only remove the year figures which are not relevant.

AF

Mark the date of installation. Fill and bleed the cooling system as per the instructions. Check the cooling system for leaks.

065 0233 Z

Code the car using DISPlus, MoDiC III or GT-1 via the “Retrofit” path. Conduct a brief test. To initialise the Telestart hand-held transmitter (see section 12) Conduct a function test. Re-assemble the car.


Issue date: 07.2002

EN/22

12. To operate the auxiliary heating system

Operation of the auxiliary heating system using the Control Display and the Telestart hand-held transmitter is described in the owner’s manual of the car.

To initialise the Telestart hand-held transmitter 0 0

5 4

ON

1

OFF

2

MODE

B

Insert the ignition key into the ignition lock and remove it within 1 – 5 seconds. The CAS hand-held control unit is now ready to initialise a Telestart hand-held transmitter for 30 seconds.

2.

Press the OFF key (2) on the Telestart hand-held transmitter and hold it for max. 15 seconds. During this time, press the ON key (1) briefly three times within 10 seconds.

3.

Release both keys. The LED (5) flashes for max. 10 seconds.

4.

The car is briefly locked and unlocked again as a response to show that the initialisation of the Telestart hand-held transmitter has been successful.

5.

Initialisation must be repeated if there is no response.

3

W

M

1.

065 0057 Z

It is possible to initialise up to two Telestart hand-held transmitters. If a second Telestart hand-held transmitter is initialised subsequently, the Telestart hand-held transmitter already in use must be re-initialised. Follow the instructions from point two when initialising the second hand-held transmitter.


Issue date: 07.2002

EN/23

13. Circuit diagram 0

F1

20A

A48

30