11 61 362 Replacing right charge-air duct

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

11 8 670

Necessary preliminary tasks:

Remove COOLANT EXPANSION TANK
REMOVE UNDERBODY PROTECTION

IMPORTANT: Coat sealing rings of quick-connect couplings with antiseize agent.
Pressure pipes cannot be fitted without antiseize agent.

Mark vacuum hoses (1) and detach.

Unfasten bolts and nuts.

Tightening torque bolt 11 65 6AZ .

Raise bracket (2) slightly.

Mark vacuum hoses on underside and detach.

Remove holder (2).

Fig 1: Identifying Vacuum Hoses And Bracket With Bolts And Nuts

G05502067

Courtesy of BMW OF NORTH AMERICA, INC.

Release nuts and remove heat shield.

Fig 2: Identifying Heat Shield With Nuts

G05502068

Courtesy of BMW OF NORTH AMERICA, INC.

Release clamp and detach charge-air duct (1).

Fig 3: Identifying Charge-Air Duct

G05502069

Courtesy of BMW OF NORTH AMERICA, INC.

Release clamp and detach charge-air duct (1).

Fig 4: Identifying Charge-Air Duct

G05502070

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check O-rings and replace if necessary.

Prior to fitting, coat O-ring with suitable antiseize agent.

Fig 5: Locating O-Rings

G05502071

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock and detach coolant hose (1).

Unlock quick-connect coupling.

Detach charge-air duct (2) from intercooler (3) and remove.

Fig 6: Identifying Coolant Hose And Charge-Air Duct

G05502072

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Risk of damage! to sealing rings!
Special tool 11 8 670 is essential.

Attach charge-air duct (1) with special tool 11 8 670 to intercooler.

Installation:

Coat sealing rings of quick-connect couplings with antiseize agent.
Pressure pipes must audibly snap into place.

Fig 7: Identifying Charge-Air Duct And Intercooler With Special Tool 11 8 670
Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Check DME (turbocharger) for correct operation.