11 61 365 Replacing front 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 FAN COWL
Remove front UNDERBODY PROTECTION

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

Unlock quick-connect coupling.

Detach charge-air duct (1) from intercooler (2).

Installation:

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

Fig 1: Identifying Charge-Air Duct And Intercooler
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 (2).

Installation:

Text refers to, and illustrations show the right side.

The procedure is identical for the left side.

Fig 2: Identifying Charge-Air Duct And Intercooler With Special Tool 11 8 670

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Charge-air hoses with clamp fastenings must be installed dry and free from grease!
If charge-air hoses with clamp fastenings are not installed dry and free from grease, this may result in turbocharger failure!

Unfasten clip.

Tightening torque 13 71 6AZ .

Detach front charge-air duct (1) from charge-air duct (2).

Feed out front charge-air duct (1) towards top and remove.

Installation:

Install charge-air hose (charge-air duct) dry and free from grease.

Fig 3: Identifying Charge-Air Hose And Charge-Air Duct

Courtesy of BMW OF NORTH AMERICA, INC.