I have an 1984 528e that's been gettin' my floor wet with coolant for
all too long now, so I've made the leap and finally found some time to
disassemble the dash and replace the little sucker. I've removed the
entire dash and center console, the AC evap. unit, etc, etc. Removed
about all there is to remove. I finally came to a black box with an
inverted "V" shaped bottom labeled "BEHR" (which I'm assuming enshrouds
the heater core). The box is held together by pressure clips that are
mostly inaccessable but I've popped off the 5 or 6 I can see with a
screwdriver...still, the 'ol BEHR box shows no indication of opening
up. What am I missing? I'm assuming there are lots more clips that I
can't see. Is this the case? Is there a shortcut around this misery?
Does anyone at all have an exploded view of the heater core area? Any
manuals that I've been able to find do not cover the heater core--I'm
assuming because they don't want people evacuating their A/C while
doing this procedure (my A/C is long since empty of refrigerant 'cause
I need a compressor too). Does anyone know of a manual easily
accessable that covers this? Or any inkling of where I can find one?
Lastly, is there any "trick" or special BMW tool for getting these
steel clips (they look like this:> /_____\ )off intact without busting
any plastic? ANY help would be so appreciated, as I'm driving my
beloved 528 with a driver's seat, miles of wires, and not much else!
Not even a tachometer or a lowly "Check Engine" light! If pix would
help let me know 'cause I've taken them. Thank you all so very much;
any help at all or experience with this problem would be welcome and
Here's a link to the exploded view of your heator on the RealOem website.
I have a Chilton's Manual that covers your car. Here's what it says to
remove the heater assembly and core.
1) Disconnect the battery ground. Remove the instrument panel trim at the
bottom left. Remove the package tray.
2) Have the air conditioning system discharged.
3) Remove the two bolts securing the trim panel underneath the evaporator
4) Remove the tape type insulation.
5) Using a backup wrench, disconnect the low and high pressure A/C lines
and cap the open ends.
6) Unfasten the electrical connector for the evaporator. Disconnect he
temperature sensor plug accessible from the outside of the evaporator
7) Remove the two bolts and then remove the bracket that braces the
evaporator houing at the firewall. Remove the mounting bolt from either
side of the houding.
8) Unclip both fasteners and remove the housing.
9) Now move into the engine compartment and remove the rubber insulator
from the cowl. (I think this is really a seal at the top of the firewall)
10) Remove the mounting bolts for the cover which is located under the
11) Remove the mounting nuts for the heater housing located on either side
of the blower.
12) Drain the cooling system then disconnect the 2 hoses at the core.
13) Working inside the vehicle, remove the 3 electrical connectors for the
heater housing. Pull off the 2 air ducts.
14) Remove the 2 mounting nuts and remove the heater unit.
15) Remove the air duct connections from the housing. Push the retaining
bar back and thensplit and remove the 2 blower shells.
16) Remove the retaining clips from the housing halves and split the
housing. Then remove the core.
17) Reverse the removal procedure, noting the following points:
a) Cement a new rubber seal onto the core.
b) Make sure that when reassembling the halves of the housing, all the
distributor flap shafts pass through the holes in the housing.
c) Before reconnecting the refrigerant lines, coat the threads with
clean refrigerant oil.
d) Refill the cooling system with clean coolant and bleed it.
e) Have the air conditioning system evacuated and recharged using an
approved recovery/recycling machine.
They have another routine for just removing the core.
1) Remove the center console and the glove compartment.
2) Disconnect the coolant hoses from the heater. Blow air into the upper
connection to purge the coolant from the core.
3) Remove the screws from the holder. Remove the screws from the right
holder and remove the holder.
4) Remove the motor for the front vents and disconnect the inside
5) Disconnec the screws, straps, and clips holding the heater cover.
Remove the cover to expose the internal coolant pipes.
6) Remove the mounting screws from the coolant pipes and lift out. The
heater core removes from the right.
These don't make much sense to me but hopefully will be more helpful to
someone looking at the hardware.
The trick to removing the clips without breaking the housing lip is to use a
small pin (like a #40 drill) inserted into the hole in the side of the clip
to use as a prybar to open the clip while lifting it off.
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