BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

Control Cables

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REMOVAL & INSTALLATION



E30 3 Series
FOOTWELL FLAP
  1. Disconnect the negative battery terminal. Remove the left side lower instrument panel trim and the center console tray. Remove the radio.
  2.  
  3. Remove the switches or covers from the openings above the radio opening. Disconnect the switches from the wiring harness.
  4.  
  5. Remove the screws holding the control panel at the top. The screws are accessible at the openings above the radio opening. Pull the control panel forward.
  6.  
  7. Disconnect the cable clamp and remove the cable end from the lever. Do this at each end of the cable.
  8.  

To install:
  1. Connect the cable at the flap lever and fit the clamp in place. The cable housing must be flush with the clamp.
  2.  
  3. Connect the control lever cable and move the lever fully to the right. Turn the cable sleeve until the cable can be placed in the holder and the clamp secured.
  4.  
  5. Affix the control panel and replace the switches and covers. Install the radio, console tray and the trim panel. Connect the negative battery terminal.
  6.  

DEFOGGER FLAP & FRESH AIR FLAP
  1. Disconnect the negative battery terminal. Remove the left side lower instrument panel trim and the center console tray. Lower the glove compartment door and disconnect the straps. Remove the radio.
  2.  
  3. Remove the switches or covers from the openings above the radio opening. Disconnect the switches from the wiring harness.
  4.  
  5. Remove the screws holding the control panel at the top. The screws are accessible at the openings above the radio opening. Pull the control panel forward.
  6.  
  7. Disconnect the cable clamp and remove the cable end from the lever. Do this at each end of the cable.
  8.  

To install:
  1. Connect the cable at the flap lever and fit the clamp in place. The cable housing must be flush with the clamp.
  2.  
  3. Connect the control lever cable and move the lever fully to the right. Turn the cable sleeve until the cable can be placed in the holder and the clamp secured.
  4.  
  5. Affix the control panel and replace the switches and covers. Install the radio, console tray, glove compartment door straps and the trim panel. Connect the negative battery terminal.
  6.  

MIXING FLAP
  1. Disconnect the negative battery terminal. Remove the left side lower instrument panel trim and the center console tray. Lower the glove compartment door and disconnect the straps. Remove the radio.
  2.  
  3. Remove the switches or covers from the openings above the radio opening. Disconnect the switches from the wiring harness.
  4.  
  5. Remove the screws holding the control panel at the top. The screws are accessible at the openings above the radio opening. Pull the control panel forward.
  6.  
  7. Disconnect the cable clamp and remove the cable end from the lever. Do this at each end of the cable.
  8.  

To install:
  1. Connect the cable at the flap lever and fit the clamp in place.
  2.  
  3. Connect the temperature selector wheel cable end and move the wheel to the WARM position. Turn the cable knurl nut so the flap moves to the WARM position. Adjust the nut so the cable can be placed in the holder and the clamp secured.
  4.  
  5. Affix the control panel and replace the switches and covers. Install the radio, console tray, glove compartment door straps and the trim panel. Connect the negative battery terminal.
  6.  

E36 3 Series
FRESH AIR FLAP
  1. Insert a feeler gauge blade between the bottom of the trip computer display and the frame at the right side. Move the blade towards the right to release the display. Disconnect the wiring from the display and remove.
  2.  
  3. Remove the ashtray or lower console bin, as equipped, by pulling out.
  4.  
  5. Remove the knobs from the heater control panel. Remove the panel mounting screws in the depressions for the knobs and pull the panel out.
  6.  
  7. Push the controls back and guide downwards to be able to disconnect the wiring, shaft and cable.
  8.  
  9. Place the vents above the glove compartment straight forward and remove from the dashboard.
  10.  
  11. Remove the 6 screws holding the glove compartment and remove the unit.
  12.  
  13. Disconnect the cable from the retainer and squeeze the tabs together to remove the cable from the holder.
  14.  

To install:
  1. Connect the wiring, cable and shaft to the control panel. Install the panel and knobs. Install the ashtray or bin and the trip computer display.
  2.  
  3. Install the cable into the holder and the retainer.
  4.  
  5. Turn the blower control to 4 and press the control lever towards the holder. This will adjust the cable.
  6.  
  7. Install the glove compartment and vents.
  8.  

E34 5 Series
  1. Remove the radio and the heater control panel.
  2.  
  3. Remove the desired cable by squeezing the clip and releasing from the holder.
  4.  
  5. Remove the glove compartment and the lower trim panel. Remove the desired cable by squeezing the clip and releasing from the holder.
  6.  

To install:
  1. The control cables and the levers are color coded. Install the cable on the control and clip into place.
  2.  
  3. Install the cable to the control lever and install the panel in the dashboard. The cables will be automatically adjusted by moving the levers fully in both directions.
  4.  
  5. Install the glove compartment and the lower trim panel. Install the radio.
  6.  

 
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