I've owned my 2002 R50 for about 4 years now, and I've never been able to successfully get my AC system working. It's never really bothered me too much, but I know it bothers passengers! So I wanted to get it finally fixed.

I've asked a few BMW Master Techs at dealerships and none have been able to come up with a solution or have heard of my issues before so NAM don't let me down!

- My AC does not work and my Recirculate light is permenantly stuck on Green, and has been stuck on since I got the mini with a bad BCM. I replaced the BCM and it fixed all of my other issues! Except the Recirculate light. (my rear defrost is also broken and never turns on but my connector has been snapped off)

I believe the issues are related, which is why I'm combining my information:

- I replaced the AC pressure switch (the one below the battery box) and checked the system for leaks. No leaks detected.

- I replaced the radiator fan module just in case. I got the correct one for my year and it tested perfect. Never had any overheating.

- I have the fancy climate control, so I found a deal on some used Modules and I tested 2 different ones. No fix or difference.
I wished I could resort to the not-fancy module if it would fix it.

- I can jumper #30 to #87 at the K19 under-hood relay and it sends power to the AC clutch, it kicks on and the fan motor jumps up to speed to compensate.
This is ruling out my AC clutch and relay as a culprit.
Fuse #7 is GOOD
Fuse #3 is GOOD

What I've always had issues with:

- My passenger footwell door flap is not functional, and the previous owner disconnected the control-arm for it. So I pulled it out and sent 12v power to the switch and it actuates. I put it back into the car and the motor FORCES closed back into recirculate instantly. If i keep the arm disconnected I can turn the car from HOT to NOT SO HOT for the summer months, but it's brutal.


What's left? My DME?

thanks guys. I have a Bentley Manual if anyone knows some good pages to check in there.

Here are some pics:


ON The foot, head and defroster doors actuate.



OFF the recirc is lit.

 

""- I have the fancy climate control, so I found a deal on some used Modules and I tested 2 different ones. No fix or difference.""

I don't have the fancy climate control, but my first reaction is that the recirc button is simply "stuck" - coffee, coke, whatever. It may feel like it operates but is electrically "stuck". Have you tried a little squirt of electrical contact cleaner? or a different switch panel?
If that fixes the recirc, it just might fix the door flap issue.
It doesn't look as though you can swap it for a non-fancy panel as the plugs look different, but it might be possible.

 

I've tried the different switch panel, but I just now realized that you can set the panel into a "calibrate mode" by holding down OFF and PLUS on the top buttons. I ran a diagnostic on the doors and it operates all of them and comes back with a FF 00 code. ( I included the link )

The 00 code is the door in accordance to which is failed. and I get back 00 which means no doors are faulting. The only issue is I have my glove box off and I can see the blend door not moving. There must be something in the system telling my ECU that everything is fine but the blend door is not actuating. I even tried disconnecting the motor and running the check again and no difference.

I removed the blend door motor and sent 12v power to the according pins and it MOVED! it moved OPEN instead of RECIRC but now its stuck open and the button is still lit.

I checked the faults again and it came back 00 with no errors again. I have checked countless times and my AC refrigerant is perfectly charged when I jumper the AC relay and kick it on.

Stumped.

 

I'm still having this weird issue, but my idea now has been to get into the BCM with NCSexpert and see if I can figure out of its a programming issue.

I've messed with it a little bit (to get a digital speedometer working on my tach menu) but other than that I'm expecting to be digging around for a while.