parts and accessories installation instructionsbmw 7 series (e 65 and e 66) with m54, n62 and n73...

065 0047 Z

Parts and Accessories Installation Instructions

Retrofit auxiliary heating systemBMW 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 926Installation 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

EN/2Retrofit kit No. 64 50 0 139 926Installation Instructions No. 01 29 0 139 927 Issue date: 07.2002

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 GT-1 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)

!


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 ---


2. Parts list

0

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)

065 0207 Z

B

M W

ON

OFF

MODE

A B C D

TE F G H I J K L NM O P Q R S

V W X Y Z ABAA

AC AD AIAE AJAF AG AH

U


3. Connection diagram

0

0

Item Description SignalCable 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/GE2.5 mm2

Auxiliary heater X642PIN 1

A2 Socket contact Terminal 31 BR2.5 mm2


X764 6-pin socket casing --- --- Auxiliary heater X764

B1 Socket contact CAN-high GN/OR0.35 mm2


B2 Socket contact CAN-low GN0.35 mm2


B3 Socket contact SHMV GR/SW0.5 mm2


B4 Socket contact DOSP SW/RT0.75 mm2


X785 2-pin socket casing --- --- Changeover valve X785

C1 Socket contact Terminal 31 BR0.5 mm2

Changeover valve X785PIN 1

C2 Socket contact SHMV GR/SW0.5 mm2

Changeover valve X785PIN 2

X785

D1 D2

X997

FG

A

B4

B3

B2

B1

A1

A2

C1 C2

E1

E2

X764

X642

065 0208 Z


3. Connection diagram

0

0

Item Description SignalCable colour / Cross-section

Connection location in the car Abbreviation / Slot

D1 Ribbon cable CAN-high GN/OR0.35 mm2

CAN high post A pillar on the right X10582Chamber 2

D2 Ribbon cable CAN-low GN0.35 mm2

CAN low post A pillar on the right X10582Chamber 1

X997 2-pin socket casing --- --- Fuel metering pump X997

E1 Socket contact DOSP SW/RT1.5 mm2

Fuel metering pump X997PIN 1

E2 Socket contact Terminal 31 BR1.5 mm2

Fuel metering pump X997PIN 2

F Socket contact Terminal 30 RT/BL/GE2.5 mm2

Front fuse holder A 48GR 8-pin socket casing

X10454PIN 8

G Cable lug M6 Terminal 31 BR2.5 mm2

Earth post connection behind the left headlight

X165

X785

D1 D2

X997

FG

A

B4

B3

B2

B1

A1

A2

C1 C2

E1

E2

X764

X642

065 0208 Z


4. Installation and cabling diagram

0

Legend0

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

065 0209 Z

E65

1 2 3

4 C B D

A


5. To install the triple pipe and changeover valve

0

0

0

0

0

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

0

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

0

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

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.

L

C

065 0210 Z

C

K 065 0211 Z

L

AC

065 0212 Z

AC

K

065 0213 Z


5. To install the triple pipe and changeover valve

0

0

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

Secure the hoses with hose clips.

Z

AA

C

Y

065 0214 Z

AC


6. To convert the coolant system in the engine compartment

0

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

0650236Z

1

1**

1*

23

45

6 7



0

Legend to figure 065 0236 Z0

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



0

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

0650215Z

AE

12

U3

AB

4

AD

AI

AI**

AE

AC

AA

YC

B

Z

AI*



Legend to figure 065 0215 Z0

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

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 Hose from triple pipe to changeover valve

AA Hose from triple pipe to changeover valve

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


7. To install the auxiliary heater

0

0

0

0

0

Secure the counter holder W using hexagonal screws J.

0

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.

0

Push the auxiliary heater B on to the counter holder.

Secure the auxiliary heater B using hexagonal screws E and washers F.

0

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

W

J

065 0216 Z

I

G

H1

065 0217 Z

B

E/F

065 0218 Z

Y

1

Q

065 0219 Z


8. To connect the fuel supply

0

0

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.

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

Close the line holders (2) again.

0

The rivet nut collar points towards the fuel metering pump.�

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

0

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).

Connect the fuel hose (3) to the fuel line T.

Secure the hoses using Clic hose clips S.

T

S

1

2

065 0220 Z

P

D

O

065 0221 Z

O

S

1

065 0222 Z

T

2

D

3


9. To install the silencer

0

0

0

0

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

0

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.

00 Using a saw, cut out the underbody shield (2) along the

existing marking (1).

N

M

V

065 0223 Z

V

2

1

M

065 0224 Z

065 0225 Z

1

2


10. To install and connect the wiring harness

0

0

0

0

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.

0

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

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:

- 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.

X165

065 0228 Z

A-C

1

GA

065 0017 Z

C1-C2

A1-A2

B1-B4

X642X764X785

065 0019 Z



0

0

0

0

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.

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

0

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

0

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

0

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.

3

A

1

R

065 0226 Z

2

1

2

065 0022 Z

2

1

A

065 0227 Z

X10454

065 0235 Z

F

1

AH



0

0

0

0

0

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.

0

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

0

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

0

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

065 0229 Z

D1

D2

X10582

AG

E1-E2

065 0230 Z

2

1E1-E2

065 0231 Z

1 E1-E2

065 0232 Z


10. To install the wiring harness

0

0

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

X997

065 0010 Z


11. Concluding work and coding

0

0

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

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

Mark the date of installation.

Fill and bleed the cooling system as per the instructions. Check the cooling system for leaks.

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.

065 0233 Z

AF

1


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 transmitter0

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.�

0

1. 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.

065 0057 Z

B

M W

ON

OFF

MODE

1

2

3

5

4


13. Circuit diagram

0

A48

065 0234 Z

X10582X10454

X642 X764

X764X642

Y7

A14

20A

A8

2.5

RT

BL

GE

0.35

GN

OR

0.35

GN

0.35

GN

OR

0.75

SW

RT

DOSP

DOSP

31L<3

31L<3

30<1 5_CAN_H 5_CAN_L

2.5

BR

1.5

SW

RT

1.5

BR

0.5

BR

0.35

GN

0.5

GR

SW

8

1 2 3

2 6

1

2

4

30<1

F1

X10582

X13885

X918

X997

X997

X165

M Y12

SHMV

SHMV

31L<1

2

1

X785

X785

X13886


13. Circuit diagram

Legend

Cable colours

A14 Auxiliary heater

A48 Fuse holder

Y7 Fuel metering pump

Y12 Changeover valve

X165 Earth terminal 31

X642 Black 2-pin socket casing



X918 Connector


X10454 GR 8-pin socket casing

X10582 CAN high/low ribbon cable on the A pillar post

X13885 Ribbon cable connector

X13886 Ribbon cable connector

BL blue

BR brown

GE yellow

GN green

GR grey

RT red

SW black

OR orange


parts and accessories installation instructionsbmw 7 series (e 65 and e 66) with m54, n62 and n73...

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