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Blower Motor & Blower Motor Resistor Replacement
 
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Pelican Technical Article:

Blower Motor & Blower Motor Resistor Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$200

Talent:

****

Tools:

Phillips screwdriver, plastic prying tool

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Blower motor, blower motor resistor

Hot Tip:

Be careful not to damage blower housing

Performance Gain:

Replace faulty blower motor

Complementary Modification:

Replace blower motor and resistor together

BMW E60 vehicles are equipped with a climate control system (IHKA) with multiple sensors, controls, air temperature units and ducts. The blower motor, which controls airflow into the passenger cabin, is among the most consequential components in the climate control system. The blower motor resistor (or final stage) varies voltage to the blower motor to achieve the desired speed. The blower motor is a D/C electric motor driven by varying current supplied by the blower motor final stage unit.

If your blower motor fails, replace the blower and resistor together. You don't want to have to go back in if one fails later. Over time, a blower motor may become noisy as the motor electrical contacts wear. The blower fan cages also fracture, creating a vibration when the blower is ON. If it fails or becomes noisy, you can use this procedure for the repairs.

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

The blower motor is located behind the center of the dashboard and is serviced from the interior of the vehicle. The blower motor resistor is mounted to the rear of the blower motor.

Remove the IHKA control panel, radio and seat heat controls. See our tech article on the IHKA control panel, radio and seat heat controls replacement.

Remove the right and left side lower dashboard trim. See our tech article on lower dashboard trim replacement.

Remove the center console. See our tech article on center console replacement.

With the radio removed, remove the component mounting bracket Phillips head screws (red arrows).
Figure 1

With the radio removed, remove the component mounting bracket Phillips head screws (red arrows).

Then, remove the component-mounting bracket from the dashboard.
Figure 2

Then, remove the component-mounting bracket from the dashboard. Note the routing and position of the wiring harnesses before removing. This will help to get things back in the right place when reinstalling.

Working at the center compartment duct, unclip the two retaining clips (red arrows).
Figure 3

Working at the center compartment duct, unclip the two retaining clips (red arrows). Press the center of the clip and pull the bottom of the clip off the duct to detach it.

Next, slide the duct down far enough to access the stepper motor electrical connector.
Figure 4

Next, slide the duct down far enough to access the stepper motor electrical connector. Pull the electrical connector (red arrow) straight out of the stepper motor to remove it.

Slide the duct down.
Figure 5

Slide the duct down. Then remove the duct from the dashboard, feeding the top out first.

With the center compartment duct removed, remove the left side air duct (red arrow).
Figure 6

With the center compartment duct removed, remove the left side air duct (red arrow).

To remove the duct, lift it up and pull the bottom out.
Figure 7

To remove the duct, lift it up and pull the bottom out. Then slide it toward the right side of the vehicle. Rotate the bottom of the duct up, while disconnecting it from the under dash duct. Reach up from the left side footwell, if needed, to detach the opposite side of the duct. Note the removal position for reinstallation.

Next, remove the right side air duct (red arrow).
Figure 8

Next, remove the right side air duct (red arrow). First, disconnect the blower motor electrical connector (blue arrow). Squeeze the release tabs and pull the lower portion of the connector out (top inset). To remove the duct, lift it up and pull the bottom out. Then slide it toward the left side of the vehicle. Rotate the bottom of the duct up, while disconnecting it from the under dash duct. Reach up from the right side footwell, if needed, to detach the opposite side of the duct. Note the removal position for reinstallation. Then remove the upper portion of the blower motor electrical connector from the blower motor housing. Press the center-retaining tab (green arrow) to the left and hold it as you slide the connector up.

Next, remove the four T20 Torx screws from the blower motor housing (red arrows).
Figure 9

Next, remove the four T20 Torx screws from the blower motor housing (red arrows).

Remove the blower motor housing cover, feeding the left side out first.
Figure 10

Remove the blower motor housing cover, feeding the left side out first.

Remove the two T20 Torx blower motor screws (red arrows).
Figure 11

Remove the two T20 Torx blower motor screws (red arrows). Note the placement of the blower motor wiring (blue arrow). It is fed through the housing cover via a round notch. Be sure it is in this notch when reinstalling, or the cover will not seat.

Remove the blower motor, feeding the left side out first.
Figure 12

Remove the blower motor, feeding the left side out first.

To detach the blower resistor (aka final stage) from the blower motor, lever the retaining tab away from the resistor (red arrow) while pulling the resistor off the blower motor.
Figure 13

To detach the blower resistor (aka final stage) from the blower motor, lever the retaining tab away from the resistor (red arrow) while pulling the resistor off the blower motor.

Disconnect the electrical connectors by squeezing the release tabs and pulling them straight off the resistor.
Figure 14

Disconnect the electrical connectors by squeezing the release tabs and pulling them straight off the resistor. Install the new resistor. Be sure it is seated properly and flush with the blower motor. Reverse the removal instructions for the blower installation. When installing the blower motor into the housing, be sure that the wiring is orientated as it was before. The motor will drop into the housing and sit evenly, with both blower cages in about the same position on each side of the housing.









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Comments and Suggestions:
juhapas Comments: Hi. How will I know which one is broken? The motor or final stage?
October 20, 2016
  Followup from the Pelican Staff: By testing them. Use a wiring diagram. Located in repair manual.

I would grab a repair manual.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Macdaddy Comments: Awesome instruction great site worked likea charm nowi want to replace my oil filter housing cooler gasket do you have infirmation on it for 525 i bmw awesome job guys love the valuble information baught a fan motor complete off salvage place complete unit for 75 bucks all in! Thanks again
October 19, 2016
  Followup from the Pelican Staff: See this:

http://www.pelicanparts.com/techarticles/BMW-E60/104-ENGINE-6_Cylinder_Oil_Filter_Housing_Gasket_Replacement/104-ENGINE-6_Cylinder_Oil_Filter_Housing_Gasket_Replacement.htm - Nick at Pelican Parts
 
Koenhen Comments: Thank you very much for this very detailed step by step manual. I used it and it helped me a lot.
October 14, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
ali Comments: Hi is this applicable for BMW 528ia 1997 ... i want to change mine also its not working
Regards
August 31, 2016
  Followup from the Pelican Staff: No, but this article is for your vehicle:

http://www.pelicanparts.com/BMW/techarticles/BMW-5-Series-E39/16-BODY-Blower_Motor_Repair/16-BODY-Blower_Motor_Repair.htm

- Nick at Pelican Parts
 
Bash Comments: Hi thank you very much for infor .i have changed my bmw e61 blower.very easy thanks to ilastration.
August 16, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Beaso Comments: I have a 2010 520d... heater fan works but very slow even when switch is on flat out... then on other days will work fine ? any ideas ?
July 20, 2016
  Followup from the Pelican Staff: Could be a faulty fan or final stage. - Nick at Pelican Parts  
Burt Comments: just completed final stage resistor and motor. Blower motor works from fan switch, mode is floor. I can't change mode or temperature.
July 2, 2016
  Followup from the Pelican Staff: If the flap actuator didn't get unplugged, you may have a faulty control u nit or flap actuator. I would check the vehicle for fault codes. - Nick at Pelican Parts  
Flanker35M Comments: This article was exactly what I was looking for. Need to replace the blower and right foot well stepping motor on my 2004 535d. Good to see I do not need to tear open the whole dashboard for this! Thank You very much for the article!
June 28, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
deylo Comments: Hello, I have been searching for a writeup to replace my evaporator on the E60 2004. There seems to be a lack of information regarding this. I have just looked at this article and I can see the evaporator behind the blower motor. Is there another/easier way to access the evaporator or do i have to follow all these steps?
June 22, 2016
  Followup from the Pelican Staff: The entire instrument panel has to be removed. We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Shiftbmw Comments: Will a faulty fsr or hedgehog cause battery drain? My fan is making noise at low speeds and battery drain happening everyday. Thank you in advance!
April 26, 2016
  Followup from the Pelican Staff: Yes, the blower resistor can cause a battery drain. - Nick at Pelican Parts  
jam Comments: My fsu was failung so, i followed specific instructions and after putting everything back in no air blows out. Everything was bench tested and works. All of tge lights come on for tge fan, but no air. What could it be?
March 11, 2016
  Followup from the Pelican Staff: Possible control unit. I would test the power and ground to the blower from the final stage. - Nick at Pelican Parts  
Miguel B Comments: I would like to let you know I have purchased the fan from you guys I installed it and it was a breeze following your tutorial. Customer service was awesome ordering was easy and shipped quickly. A BIG thank you
January 24, 2015
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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Page last updated: Sat 12/3/2016 02:39:35 AM