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BMW E39 Blower Motor Repair
 
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Pelican Technical Article:

BMW E39 Blower Motor Repair

Kerry Jonsson

Time:

4 hours4 hrs

Tab:

$60

Talent:

****

Tools:

Phillips screwdriver, flathead screw driver, T25 Torx socket

Applicable Models:

BMW E39 5-Series (1997-03)

Parts Required:

blower motor

Hot Tip:

You also gain access to the HVAC box to look for leaks in heater core and evaporator

Performance Gain:

Get the blower motor to work at multiple speeds, eliminate noisy motor

Complementary Modification:

You can now replace damaged upper and lower dash pads.

The blower motor increases or decreases the airflow of either outside or recirculated air. It is mounted in the middle of the dashboard under the upper cover. In order to service this motor you need to remove this upper dash panel. It uses two fans (aka squirrel cages) on each side of the motor. The fan blades circulate the air in the HVAC unit and force it past the heater core for heat or the evaporator for colder air. When operating your HVAC you may feel a vibration in the dashboard. This could be the result of some debris getting in the HVAC housing and hitting the fan blades. Also the blower motor itself may be noisy. This might be the result of a faulty motor that needs to be replaced. If you are experiencing these symptoms then you should remove your blower motor and inspect the area.

In order to remove the upper dash panel to access the blower motor you need to remove the driver side lower panel and the passenger side glove box. Go to Glove Box Removal tech article and complete that procedure first. The next tech article that needs to be completed is Driver Side Lower Dash Panel followed by Center Dash Panel. After these three jobs are done you can now start to remove your upper dash panel. Disconnecting the Battery and Steering Wheel Removal are two tech articles that need to be followed after the previous three steps.

There is a foam sound insulating pad that needs to be removed.
Figure 1

There is a foam sound insulating pad that needs to be removed. It is wrapped around the center defroster duct so you have to stretch it to get it out of your way.

On the left of the duct there is a shaft that has to be moved over.
Figure 2

On the left of the duct there is a shaft that has to be moved over. You need to position a flat head screwdriver on the left side of this plastic shaft as shown.

Lever the shaft towards the left side of the car.
Figure 3

Lever the shaft towards the left side of the car. You probably going to have to repeat this process since it is a long shaft and you have to slide it all the way over to get the duct out of the way.

You should start to see the metal tang (red arrow) of the duct flap with the shaft moved all the way to the left side.
Figure 4

You should start to see the metal tang (red arrow) of the duct flap with the shaft moved all the way to the left side. This is the correct position of the plastic shaft to be able to remove the center duct.

There are two clips (green arrows) hidden in between the duct work and the metal dashboard support frame.
Figure 5

There are two clips (green arrows) hidden in between the duct work and the metal dashboard support frame. Use a long flathead screw driver to lever these clips off.

Now tilt the duct straight up from the front in the direction of the blue arrows.
Figure 6

Now tilt the duct straight up from the front in the direction of the blue arrows. It will still be attached with two clips in the back but they are plastic and at this point you can unclip them by pulling the entire duct straight up.

There is a bar (yellow arrows) that connects flaps in the two outer ducts.
Figure 7

There is a bar (yellow arrows) that connects flaps in the two outer ducts. If you just want to access the blower motor for testing then you donÂÂÂ't need to remove the bar. To remove the blower motor cover, there are three clips (green arrows) that hold it on. Use a flat head screwdriver to lever off the clips.

Pull the top of the blower motor cover towards you then pull straight up in the direction of the blue arrow.
Figure 8

Pull the top of the blower motor cover towards you then pull straight up in the direction of the blue arrow. Installation note: There are clips that hold the bottom of the cover in so remember to seat these clips first when reinstalling the cover during reassembly.

If you are removing the blower motor from its housing you will need to remove the bar that is in your way.
Figure 9

If you are removing the blower motor from its housing you will need to remove the bar that is in your way. There is a plastic piece (red arrow) that joins the two metal bars together. This has to be removed from at least one bar.

Put your finger on the plastic tab and push it in the direction of the blue arrow.
Figure 10

Put your finger on the plastic tab and push it in the direction of the blue arrow. Continue to force the entire plastic clip over to the left side. Be careful not to bend the metal bar so during reassembly they line up for reinstallation.

You will have moved the plastic joiner over enough when you see a gap between the two metal bars (red arrow).
Figure 11

You will have moved the plastic joiner over enough when you see a gap between the two metal bars (red arrow).

Now lift the metal bar slightly to get it out of the way of the second bar and pull the piece out by moving it to the right in the direction of the blue arrow.
Figure 12

Now lift the metal bar slightly to get it out of the way of the second bar and pull the piece out by moving it to the right in the direction of the blue arrow. Installation note: The metal bar will slide all the way out of its holder so remember what slot the metal pin goes in for reassembly.

Pull the metal bar on the right to the left in the direction of the blue arrow and pull is all the way out of the duct work.
Figure 13

Pull the metal bar on the right to the left in the direction of the blue arrow and pull is all the way out of the duct work.

Unplug the motor by squeezing the two tabs of the electrical connector and pulling it straight up.
Figure 14

Unplug the motor by squeezing the two tabs of the electrical connector and pulling it straight up. This connector is tight so you may have to work it off.

Remove the three T25 screws that hold down the blower motor to its mount.
Figure 15

Remove the three T25 screws that hold down the blower motor to its mount. The screws pass through rubber grommets that insulate the dash from the vibration of the blower motor. Without these rubber grommets you will experience a loud droning noise under the dash when the blower motor runs at high speed.

Pull the electrical connector wiring (red arrow) out of the way so you have room to remove the motor.
Figure 16

Pull the electrical connector wiring (red arrow) out of the way so you have room to remove the motor. Remember the position of the rubber seal so you can make sure it is in the right position for installation.

Pull the blower motor assembly towards you and lift it out of its enclosure.
Figure 17

Pull the blower motor assembly towards you and lift it out of its enclosure. Make sure nothing falls inside the duct work before installation and you may take this opportunity to vacuum out any debris that may have made it into the HVAC unit. Installing is the reverse of the removal procedure. Be careful to route wiring as you found them so they to do not come in contact with metal panels or screws during installation. This will create a short circuit and start blowing fuses. You may have to position the panel several times to align the screw holes with the brackets they thread into. Do not tighten any screw until you have all of the screws at least started in their mounting hole. This will make it easier to align the various components you have to reinstall. Once all the screws are installed tighten everything down.

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Page last updated: Wed 12/7/2016 02:05:10 AM