BMW Parts and Accessories Installation Instructions 6 Z Automatic air conditioning system BMW Series Compact (E 6/5) LHD and RHD with N engine Specialist knowledge required. Only for use in the BMW dealer organisation. Installation time: approx. hours The installation time may vary depending on condition of the car and the equipment in it. Conversion / Installation kit No. 6 5 7 56 6 5 8 Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5.
Contents Section Page Important information................................................. Preparations........................................................ Installation and cabling diagram........................................ 5. Connection diagram................................................. 6. To install the compressor (cars with manual transmission only)................. 8 5. To install the compressor (cars with automatic transmission only)............... 6. To install the drier................................................... 7. To install the condenser.............................................. 8. To convert the water cooler (cars with manual transmission only)............... 9. To replace the water valve............................................. 5. To install and connect the automatic air conditioning wiring harness............ 6. To install the condensation drain........................................ To install the heater/air conditioning unit................................... To install the refrigerant lines........................................... To install the temperature sensor....................................... 5 5. Concluding work................................................... 6 6. Coding........................................................... 7 7. Circuit diagram / Legend IHKA N engine................................ 8 Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
Important information Installing the air conditioning system reduces the payload of the car by approx. 6 kg. Installation information All work is shown on a LHD car. On RHD cars some work must be completed the opposite way round. Wet all seals and O rings with refrigerator oil before installing them. Do not remove the sealing stoppers from all parts of the refrigerant system until shortly before installation since otherwise the ingress of moisture may damage the system. The microfilter originally installed in the car is to be replaced by the microfilter with activated charcoal supplied in the installation kit. On cars with automatic transmission it is not necessary to replace the water cooler and intake blower since these cars are already fitted with the high water cooler and the 9 W intake blower. The air conditioning system must be coded (see section headed Coding). Do not kink or damage the cables during the installation work since otherwise they may cause faults that can later only be identified and rectified by extensive additional work. The costs incurred as a result of this will not be reimbursed by BMW. If the specified PIN s are occupied, bridges, double crimps or twin-lead terminals must be used. All work is shown on a LHD car. Target group The target group for these installation instructions is specialist personnel trained on BMW cars with specialist knowledge of vehicle electrical systems. Work: All servicing, repair and installation work on BMW cars is completed at your own risk. All work is to be carried out using current BMW - Repair manuals - Circuit diagrams in a rational order using the prescribed tools (special tools) and observing current health and safety regulations. Required tools and equipment MoDiC or DIS Set of flat screwdrivers Set of Philips screwdrivers Set of Torx screwdrivers / inch torque wrench Set of / inch sockets Set of / inch Torx sockets Set of / sockets Set of open-ended/ring spanners Set of Allen keys Torch Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. Preparations TIS instruction No. Conduct a brief test Disconnect the negative pole of the battery... Remove the battery and battery plate The following components must be removed first of all: Trim for the instrument panel 5 5 Microfilter 6 Heating closing panel 5 7 8 Bottom engine trim Front bumper 5 Right headlight 6 Drain the cooling water 7 5 Intake blower 7 Water cooler 7 Heater 6 Electrical box cover, left Ribbed V-belt (no longer required) 8 To prevent cooling water getting into the passenger compartment as you remove the heater, carefully blow out the return port with compressed air (max. bar pressure). Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. Installation and cabling diagram 8 9 5 6 8 7 6 Z Legend IHKA control Heater/Air conditioning unit Air conditioning compressor Condenser 5 Intake blower 6 AUC sensor 7 Drier bottle 8 Air conditioning system wiring harness 9 External temperature sensor Instrument cluster Water valve DME branch Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/5
. Connection diagram A C. - C. A. - A. A A. - A. A C C C. C C. - C. D B E E 9 6 D 6 5 9 8 7 B B B B5 B6 B7 6 5 Z A Item Description Signal DME branch A. Water valve branch A. Water valve branch A External temperature sensor branch A. External temperature sensor branch A. External temperature sensor branch Cable colour / Crosssection SW/BL Ø.5 mm GE/BR Ø.5 mm RT/GR Ø.75 mm BL/BR Ø.5 mm BL/RT Ø.5 mm B Relay socket X5 Air conditioning compressor B Joint connector Terminal BR Ø.75 mm B Joint connector TD signal SW Ø.5 mm B Joint connector K bus WS/RT/GE Ø.5 mm B5 Compressor fuse connector branch B6 Water valve fuse connector branch B7 Branch Terminal 5 RT/GE/VI Ø.75 mm RT/GR Ø.75 mm Connection location in the car To the DME control module A6 To water valve Y To water valve Y To external temperature sensor B To external temperature sensor B To external temperature sensor B Behind the glove compartment on the relay holder Behind the glove compartment on the joint connector Behind the glove compartment on the joint connector Behind the glove compartment on the joint connector Behind the glove compartment on the power distributor A6 fuse slot F6 Behind the glove compartment on the power distributor A6 fuse slot F6 Abbreviation / Slot X6 PIN 9 X8 PIN X8 PIN X77 X77 PIN X77 PIN X9 X X6 GN/GE To the output GN/GE fuse cable F8 Ø.5 mm with a mini-connector C Plug X6 To air conditioning compressor Y X6 C. Compressor branch SW/GR Ø.75 mm To air conditioning compressor Y X6 PIN Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/6
. Connection diagram A C. - C. A. - A. A A. - A. A C C C. C C. - C. D B E E 9 6 D 6 5 9 8 7 B B B B5 B6 B7 6 5 Z Item Description Signal Cable colour / Crosssection Connection location in the car Abbreviation / Slot C Plug X6 C. Pressure sensor branch C. Pressure sensor branch C. Pressure sensor branch C C.* Plug X AUC sensor branch C. AUC sensor branch C.* AUC sensor branch * The connectors C. and C. have the same colour. Therefore, before the installation a continuity measurement is to be taken between plugs X6 and X to ensure that the correct branch has been connected to plug X. See circuit diagram for PIN assignment. Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. To the pressure sensor B8 on the drier bottle SW/GE To pressure sensor B8 X6 Ø.5 mm PIN SW/GR To pressure sensor B8 X6 Ø.5 mm PIN SW/GN To pressure sensor B8 X6 Ø.5 mm PIN To AUC sensor B on the water cooler, right BR On AUC sensor B X Ø.5 mm PIN GE Ø.5 mm On AUC sensor B X PIN BR On AUC sensor B X Ø.5 mm PIN C. AUC sensor branch BL On AUC sensor B X Ø.5 mm PIN D Plug X6 To heater/air conditioning control A D Water valve branch GE/BR To heater/air conditioning control A X68 Ø.5 mm PIN E External temperature gauge BL/RT To air instrument cluster A X76 connector Ø.5 mm PIN E! External temperature gauge connector BL/BR Ø.5 mm To air instrument cluster A X76 PIN EN/7
. To install the compressor (cars with manual transmission only) 6 Z ändern Compressor, pedestal bearing and screws 6 Z! It is essential that the specified screw lengths are used. Pedestal bearing Hexagonal screw M8 x 5 with washer (x) Air conditioning compressor Torx bolt M8 x 55 and washer (x) Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/8
. To install the compressor (cars with manual transmission only) Screw the pedestal bearing () to the engine block () beneath the generator () using the hexagonal screws M8 x 5 (). 6 Z Tightening torque for the hexagonal screws Nm. 6 Z Screw the air conditioning compressor () to the pedestal bearing () using the Torx bolts M8 x 55 (). 6 5 Z Tightening torque for the Torx bolts Nm. 6 5 Z Screw the return roller () to the generator () using the hexagonal screw M x (). Tightening torque for the hexagonal screw 5 Nm. 5 6 6 Z Change 6 6 Z Screw the combination holder with return roller () to the engine block using the hexagonal screws M8 x 6 (5). Tightening torque for the hexagonal screws Nm. Install the supplied ribbed V-belt () as shown. 6 7 Z 6 7 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/9
5. To install the compressor (cars with automatic transmission only) 6 Z Change compressor, screws and adjusting sleeves 6 9 Z! It is essential that the specified screw lengths are used. Air conditioning compressor Torx bolt M8 x 55 and washer (x) Adjusting sleeves (x) Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
5. To install the compressor (cars with automatic transmission only) 6 Z Change Ensure that the two adjusting sleeves () are correctly inserted in the compressor pedestal bearing (), replace the adjusting sleeves if necessary. 6 7 Z Screw the air conditioning compressor () to the pedestal bearing () using the Torx bolts M8 x 55 (). 6 5 Z Tightening torque for the Torx bolts Nm. 6 5 Z Screw the return roller () to the generator () using the hexagonal screw M x (). Tightening torque for the hexagonal screw 5 Nm. 5 6 6 Z Change 6 6 Z Remove the existing holder and replace it by screwing the combination holder with return roller () to the engine block using the hexagonal screws M8 x 6 (5). Tightening torque for the hexagonal screws Nm. Install the supplied ribbed V-belt () as shown. 6 7 Z 6 7 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
6. To install the drier Attach the drier () with holder to the body fold and secure it with a hexagonal self-tapping screw () 6. x 6. Tightening torque for the hexagonal selftapping screw Nm. F 6 6 5 R Secure the holder for the driver to the bottom side member using a hexagonal self-tapping screw () 6. x 6. Tightening torque for the hexagonal selftapping screw Nm. F 6 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
7. To install the condenser Attach the condenser () to the guide () on the water cooler mounting on both sides. F 6 6 7 R Secure the condenser () at the top right to the water cooler mounting using the self-tapping Torx bolt () from the installation kit. F 6 6 8 R Secure the condenser () to the water cooler mounting at the top left with an expanding rivet (). Cars with automatic transmission only: Install the water cooler again following the above instructions in reverse. F 6 6 9 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
8. To convert the water cooler (cars with manual transmission only) Remove the Torx bolts (), take off the mounting plate () and secure it to the new water cooler. F 6 6 7 R Unclip the seal () and secure it to the new water cooler. Install the water cooler and new intake blower following the instructions for their removal in revise (if necessary modify the hose holder for the secondary air intake). F 6 6 8 R Remove the covers () on the air guide. F 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
9. To replace the water valve Disconnect plug X () from the water valve (). Disconnect the water hose () from the water valve (). Remove the water hose () between the water valve () and heater. Pull the water valve () out of its mountings (). 6 9 Z Change 5 6 9 Z 5 6 6 Z 6 6 Z Place the supplied water valve () into the holder provided () on the left MacPherson strut tower. Connect the water hose () from the engine to the front connector on the water valve (). Connect the supplied water hose () to the heater/ air conditioning unit on the rear connection of the water valve 8) and to the heater/air conditioning unit. Reconnect plug X (5) to the water valve (). It is essential that the flow direction shown in the figure is maintained. Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/5
. To install and connect the automatic air conditioning wiring harness A-A C E-E Install the automatic air conditioning cable set along the standard wiring harness in the car. Lay branches A, A, A and C to the left-hand side into the electrics box. Lay branches B-B7 and C-C to the power distributor. Cars without an external temperature gauge only B-B C-C F 6 6 R Connect branch E external temperature gauge to the instrument cluster, blue/red cable, in plug X76 (natural colour) in PIN. Connect branch E external temperature gauge to the instrument cluster, blue/brown cable, in plug X76 (natural colour) in PIN. On cars without an external temperature gauge, branches E and E must be insulated and tied back. Connect branch A DME, black/blue cable, to plug () X6 on the DME control module A6 () PIN 9. 5 Lay branch A water valve Y, through the rubber grommet () in the electrics box to the water valve. Lay branch A external temperature sensor, through the rubber grommet () in the electrics box, along the standard wiring harness to the installation site of the external temperature sensor. F 6 6 R Lay branch C air conditioning compressor, through the rubber grommet () in the electrics box, along the standard wiring harness to the installation site of the air conditioning compressor. Connect branch A. water valve, yellow/brown cable, to plug X85 () PIN. Connect branch A. water valve, red/grey cable, to plug X85 () PIN. 6 Z Connect plug X85 () to the water valve (). 6 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/6
. To install and connect the automatic air conditioning wiring harness Lay branches C and C () through the rubber grommet () to the right-hand side of the engine compartment. F 6 6 5 R Lay branch C. () to the air conditioning compressor Y. Connect branch C. () compressor Y, black/ grey cable, to plug X6 () PIN. Connect plug X6 () to compressor Y (). Secure branch C. () to the body side member using a cable clip (). Ensure that the white contact fuse is secured correctly. F 6 6 6 R Lay branches C.-C. () to the drier bottle. Connect branch C. black/yellow cable, to plug X6 () PIN. Connect branch C. black/grey cable, to plug X6 () PIN. Connect branch C. black/green cable, to plug X6 () PIN. F 6 6 7 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/7
. To install and connect the automatic air conditioning wiring harness Lay branches C.-C. () to the blower frame of the intake blower. Connect branch C. brown cable (twisted with blue cable), to plug X () PIN. Connect branch C. yellow cable, to plug X () PIN. Connect branch C. brown cable (twisted with yellow cable), to plug X () PIN. Connect branch C. blue cable, to plug X () PIN. 5 F 6 6 6 R! The connectors C. and C. have the same colour.therefore, before the installation a continuity measurement is to be taken to ensure that the correct branches on plug X have been connected (see circuit diagram or connection diagram. Branch C. must be connected to plug X6, PIN,. Branch C. must be connected to plug X6, PIN 5,. Clip the AUC sensor () to the blower frame () and connect plug () X. Connect the connectors for the intake blower and attach them to the blower frame (). Vehicles with an additional relay holder only Connect relay K9 to branch B, connect the relay socket X5 () and secure it to the relay holder () as shown. X6 X6 XXX X9 X6 X5 XXX XXX XXX X56 X58 X X56 F 6 6 9 R Vehicles without an additional relay holder only X56 X5 X58 X X56 X5 X Connect relay K9 to branch B, connect the relay socket X5 () and secure it to the relay holder () as shown. X6 X XBD X5 X F 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/8
. To install and connect the automatic air conditioning wiring harness Connect branch B () terminal, brown cable, to joint connector () X9, brown/black cable. Connect branch B () TD signal, black cable, to joint connector () X, black cable. Connect branch B () K bus, white/red/yellow cable, to joint connector () X6, white/red/ yellow cable. F 6 6 R Connect branch B5, compressor, red/violet/yellow cable to the power distributor () slot F6. Connect branch B6, water valve, red/grey cable to the power distributor () slot F6. Connect branch B7, terminal 5, green/yellow cable, to the green/yellow cable coming from fuse F8 using a miniature connector. Fit 7.5 A fuses in slots No. F6 () and F6 () on the power distributor. F 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/9
. To install the condensation drain Remove the marked carpet cut-out and rubber stopper on the gearbox tunnel (). F 6 6 R Insert the condensation drain hose () into the opening. Watch the installation arrow on the condensation drain. The installation arrow must point to the front of the car. F 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. To install the heater/air conditioning unit Carefully insert the heater/air conditioning unit (), align it and secure it with the hexagonal nuts () you removed earlier. Ensure that branch D, plug X6, is not jammed as you install the heater/air conditioning unit connector. Tightening torque for the hexagonal nuts Nm. F 6 6 R Attach the Bowden cable () to the adjustment lever () on the heater/air conditioning unit. Secure and install the coolant hoses and instrument panel following the instructions for their removal in reverse order. F 6 6 R Attach the Bowden cable () to the adjustment lever of the fresh air grille () from the installation kit. Push the fresh air grille into the instrument panel and engage it. I I F 6 6 5 R Connect branch D, plug X6 (), to the heater/air conditioning control connector (). Connect branch D water valve, yellow/brown cable, to plug X68 (natural colour) () in PIN. Connect the plugs () you removed as you removed the instrument panel to the connectors on the heater/air conditioning control (). Push the heater/air conditioning control () into the instrument panel and engage it. F 6 6 55 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. To install the refrigerant lines 6 Z Screw the cable holder () to the engine block () beneath the servo pump () using the hexagonal screw M x 6 (). Tightening torque for the hexagonal screw Nm. 6 Z Remove the marked section of insulation mat () at the front right of the engine compartment and remove the screw ().Break off the marking () for the intake line. F 6 6 7 R Remove the plastic cover ().Secure the rubber buffer 8) with the hexagonal nut M6. Tightening torque for the hexagonal nut 6 Nm. F 6 6 8 R Insert the double tube () and secure it with a locking tooth nut () M6. Tightening torque for the hexagonal nut 8 Nm. Ensure that the rubber grommet () is positioned correctly. F 6 6 9 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. To install the refrigerant lines Insert the outfeed line () from the drier to the evaporator on the double tube using an Allen bolt M8 x () and bolt it into place. Tightening torque for the Allen bolt Nm. F 6 6 R Screw the outfeed line () from the drier to the evaporator to the drier using an Allen bolt M8 x (). 5 Tightening torque for the Allen bolt Nm. Connect plug X6 () to the pressure sensor B8 (5). F 6 6 R 5 Insert the intake line () from the evaporator to the compressor on the double tube () using an Allen bolt M8 x () and screw it into place on the rubber buffer (5) using a hexagonal nut (). Tightening torque for the Allen bolt Nm, for the hexagonal nut Nm. F 6 6 R Screw the intake line () and outfeed line () to the compressor () using the existing Allen bolt M8 x (). 6 Z Tightening torque for the Allen bolt Nm. 6 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. To install the refrigerant lines Screw the outfeed line () to the condenser () using an Allen bolt M8 x (). 6 Z Tightening torque for the Allen bolt Nm. Clip the outfeed line () and intake line () into the line holder (5). 5 6 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/
. To install the temperature sensor Cars without an external temperature gauge only On cars without an external temperature gauge, branches A. and A. must be insulated and tied back. Insert the temperature sensor () in the recess provided in the left bottom trim (). F 6 6 R Connect branch A. blue/brown cable, to plug X77 () PIN. Connect branch A. () blue/red cable, to plug X77 () PIN. Connect plug X77 () to the external temperature sensor (). F 6 6 R Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/5
5. Concluding work - Assemble the car by following the instructions for its dismantling in reverse order - Fill and bleed the cooling system as directed, check for leaks - Check the headlight adjustment and correct if necessary - Affix the filling volume label () - Evacuate the air conditioning system and fill it (ensure that you insert the correct fill volume (7 g)) F 6 6 5 R - Check the air conditioning system for leaks Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/6
6. Coding Coding is essential and must be completed using the latest coding software. Procedure - Connect DIS or MoDIC III to the car - Ignition ON - Select Coding ZCS - Select Series E6 - Select Retrofit - Select IHKA - Automatic air circulation control Yes/No - Start automatic coding (confirm with Y ) - After the coding procedure disconnect the car s battery for at least seconds, then reconnect it and conduct a function test - After completing the coding procedure print the coding label and affix it in the electrics box cover. Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/7
7. Circuit diagram / Legend IHKA N engine A B F6 7,5A F6 7,5A 5 A6 A7 5 F8 5A B M8 M M M5 M6 M M M M M 5,75 RT/GR 6 X5 56 X6 X,75 RT/VI/GE,5 SW X6,5 SW,5 BL,5 BR,5 BR X,5 GE,5 BL/RT X76 X85,75 RT/VI/GE A6 9,5 SW/BL X6 X6 9 6 8 8 5 6 7 X6 X8,5 RT,5 BR,5 GE 6 5 X66 X66 X667 X66 X66 A X77 5 8 X5,5 SW/GR,5 SW/GE,5 SW/GN,75 BR,75 BR,5 GE/SW,5 BR/SW,5 BR/SW,5 GE/RT Y K9 M M X87 X77,5 BL/BR X85,75 GE/BR 6,75 SW/GR X5,5 GN/GE,5 BL/RT,5 RT/GN X86,5 SW/GN, BR, GE/GN X6 X6 X77 X77 X67 5 P Y B8 B B N X68 X55 X9 6 Z Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/8
7. Circuit diagram / Legend IHKA N engine Legend A Instrument cluster X9 Earth A IHKA control module X TD connector A6 Fuse holder I X68 Heater/Air conditioning unit A7 Fuse holder II X6 IHKA A6 DME control module X66 Ventilation left X66 Air circulation B8 Low/High pressure Pressostat X66 Fresh air servo motor B Heat exchanger L X66 Defrost B Evaporator temperature sensor X667 Footwell left B External temperature sensor X67 Output stage B AUC sensor X77 External temperature sensor X77 Evaporator sensor K9 Air conditioning relay X77 Exchanger sensor L X86 Blower M Blower X AUC sensor M Footwell left X5 Fuse holder A6 M5 Defrost X6 Fuse holder A7 M6 Fresh air servo motor X6 K bus connector M8 Ventilation left X76 Instrument cluster X8 IHKA N Output stage X87 Blower X6 DME control module connector X5 Air conditioning relay X85 Water valve Y Magnetic coupling X6 Pressure sensor Y Water valve with additional water pump X6 Magnetic coupling The components in boxes are already mounted on the heater/air conditioning unit. Cable colours RT SW GE BL GN BR GR WS red black yellow blue green brown grey white Retrofit / Installation kit No. 6 5 7 56 / 6 5 8 Installation Instructions No. 9 7 5 Issue date: 5. EN/9