Rumor or Truth? Another sword post...

[Mike-AZ]

OK, my question is, I have read a previous post by someone who said that all V-8 cars had a sword regardless of build date. Is this tue? I ask because I am having all sorts of problems with my HVAC system (IHKR) and I have already replaced the $18 blue resistor cube and that did nothing to help. My HVAC system either does not shut off after turning off the 540i, or it will completely shut off on it's own while driving, making me have to pull the car over and restart it in 105+ degree heat just to get it going again. So, in summation, I know I have a blue resistor cube, and a IHKR control box mounted in front of the micro-filter. Anything else I'm missing? My fan blows hard and does not squeel. Thanks -- Mike

[632 Regal]

i do think we have a sword but it isnt actually a sword but more of a litle circuit controller, ill see if I can find it on real oem.

[632 Regal]

#2 is the sword I think:
http://www.realoem.com/bmw/diagrams/e/h/15.png
http://www.realoem.com/bmw/showparts.do?model=HE23&mospid=47406&btnr=64_0168&hg=64&fg=45

#5? no clue what this is but I thought it looked cool:
http://www.realoem.com/bmw/diagrams/m/q/12.png
http://www.realoem.com/bmw/showparts.do?model=HE23&mospid=47406&btnr=64_0122&hg=64&fg=40

[JonE]

I thought we either had a sword or a resistor pack, but not both. If you're sure you replaced the resistor pack then you probably won't have a sword as well. Is the system only shutting off during AC cooling or is it also shutting off during heating?

[Mike-AZ]

The system does it in both a/c and heat/vent modes.




I thought we either had a sword or a resistor pack, but not both. If you're sure you replaced the resistor pack then you probably won't have a sword as well. Is the system only shutting off during AC cooling or is it also shutting off during heating?

[Mike-AZ]

So, if there is indeed a sword in the '94 540i, where is it located? I can't seem to find it where it is shown on the write-up on bmwe34.net. On that site, it shows the sword sliding into a slot that is part of the cover for the micro-filter, but my micro-filter cover is one solid piece of off-white plastic with no slot for a sword. Arg. -- Mike



#2 is the sword I think:
http://www.realoem.com/bmw/diagrams/e/h/15.png
http://www.realoem.com/bmw/showparts.do?model=HE23&mospid=47406&btnr=64_0168&hg=64&fg=45

#5? no clue what this is but I thought it looked cool:
http://www.realoem.com/bmw/diagrams/m/q/12.png
http://www.realoem.com/bmw/showparts.do?model=HE23&mospid=47406&btnr=64_0122&hg=64&fg=40

[JonE]

If that blue box you replaced was to the left of the center column and it is the resistor pack, then I would guess that you don't have the sword resistor as well. The sword on my '90 535 was to the right side of the center column above the passengers feet by to the left of the glove box on a left hand drive car.

[Ausmpower]

Do you have Automatic climate control?

Control module is known to fault (Shut off, cycle hot/cold of it's own accord).

[Mike-AZ]

I have the standard system with the three dials on the front and semi-auto for heat. -- Mike




Do you have Automatic climate control?

Control module is known to fault (Shut off, cycle hot/cold of it's own accord).

[tim s]

tim s.

[Morgenster]

The nr. 5 in the picture above is indeed the 'resistor pack'. If you have it then there's no SWORD. The SWORD should be right behind the glovebox compartment according to my Bentley manual. If you take out the glovebox you'll be able to see part nr. 1 in the first picture.

[Ausmpower]

Sounds like a dodgy relay somewhere.

When you say it runs on are you sure? I mean does the blue aircon light stay illuminated after you switch the ignition off?
Or can you just hear a wirring noise from behind the dash? (electricly moved air mixing control flap moving after switching off is normal)

The other symtom: switching itself off; as in blows hot air but the a/c switch lamp remains lit and compressor clutch cuts out? (could indicate low a/c gas, over pressure, intermittent clutch fault or failing thermostat/ iced evaporater core)

[Mike-AZ]

Great...well, that means I have no clue what's wrong with my system as well as there will be a nice refurbished un-opened sword from bmaparts on ebay any day now. :o) -- Mike


The nr. 5 in the picture above is indeed the 'resistor pack'. If you have it then there's no SWORD. The SWORD should be right behind the glovebox compartment according to my Bentley manual. If you take out the glovebox you'll be able to see part nr. 1 in the first picture.

[Mike-AZ]

[QUOTE=Ausmpower]
Sounds like a dodgy relay somewhere.
- that's what I think too.

When you say it runs on are you sure?
- Yes, the system is still fully activated with the car off, with the exception of the a/c compressor because the engine is not running.

I mean does the blue aircon light stay illuminated after you switch the ignition off?
- The light is a green LED, this is an E34, not an E28...and yes, it stays on. I can even press the a/c button and the green light goes out and vice versa.

The other symtom: switching itself off; as in blows hot air but the a/c switch lamp remains lit and compressor clutch cuts out?
- The system definitely just shuts off completely, well I think it does. It is completely non-communicative at that point until the car is restarted, even for vent/heat functions. It just completely stops. After a few minutes of driving with the system shut off like that, it will eventually start wafting out full heat no matter what I try to do.

[Ausmpower]

Sorry I meant green light! god damn beer goggles!

Back in a sec.

I'm just going to go and find out which relay controls the A/C.

[Ausmpower]

This is going to sound silly but check your fuses!

[Ausmpower]

Is your a/c control like this?

real oem 540i manual a/c control (http://www.realoem.com/bmw/showparts.do?model=HE61&mospid=47384&btnr=64_0182&hg=64&fg=20)

If so THIS (http://www.realoem.com/bmw/showparts.do?model=HE61&mospid=47384&btnr=61_0552&hg=61&fg=25) is the main A/c control module (relay).

[Mike-AZ]

Yes, that's my system. Thank you for the diagrams and stuff. So, to narrow it down, it could be either control box 01, 02, or 09? I'll take a look in my relay box after work and see what I have in there. I hope this is it. It would be hard for me to believe it's anything other than a relay problem. -- Mike

1994 BMW 540i
141,000 Nikasil Miles
Phoenix, Arizona



Is your a/c control like this?

real oem 540i manual a/c control (http://www.realoem.com/bmw/showparts.do?model=HE61&mospid=47384&btnr=64_0182&hg=64&fg=20)

If so THIS (http://www.realoem.com/bmw/showparts.do?model=HE61&mospid=47384&btnr=61_0552&hg=61&fg=25) is the main A/c control module (relay).

[mikell]

The Sword is the speed controller for the fan. If it goes toes up, you replace some FETs or something. The symptom is that the fan blows full blast or not at all - no in between. But, I agree, your problem sounds more like a relay that quit relaying correctly. Good luck - be sure to report back on your results.