17 51 001 Removing and installing/replacing right intercooler (N63)

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WARNING: Danger of scalding!
Only perform this work after engine has cooled down.

Necessary preliminary tasks:

Remove acoustic cover from top of engine.

Fig 1: Removing Acoustic Cover

Courtesy of BMW OF NORTH AMERICA, INC.

Remove front underbody protection . See 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION .
Remove fan cowl
Drain coolant for intercooler.

Release clamp (1).

Tightening torque 13 71 8AZ, see 13 71 AIR INTAKE DUCT

Release clamp (2).

Replace clamp (2).

Remove right charge-air duct (3).

Check gasket on turbocharger, replacing if necessary.

Fig 2: Identifying Right Charge-Air Duct And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: When detaching the coolant hoses from the intercooler, make sure that the connector remains connected to the throttle valve assembly. Do not allow any coolant to get into the plug connection on the throttle valve assembly.

Release and disconnect coolant hoses (1).

Detach coolant hose (2) from intercooler.

Replace faulty clamps.

Fig 3: Identifying Coolant Hoses And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock plug (1) and remove.

Release screw (2).

Tightening torque 13 71 6AZ, see 13 71 AIR INTAKE DUCT

Installation:

Screw (2) is longer than screws (3)

Unscrew screws (3).

Tightening torque 13 71 6AZ, see 13 71 AIR INTAKE DUCT

Release clamp (4) on throttle valve unit.

Tightening torque 13 71 7AZ, see 13 71 AIR INTAKE DUCT

Lift out intercooler.

Fig 4: Identifying Plug, Clamp And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Only when replacing intercooler .

Modify pressure sensor on intercooler. See 13 62 591 REMOVING AND INSTALLING/REPLACING PRESSURE SENSOR ON LEFT INTERCOOLER (N63) .

Modify charge-air hose.

Replace faulty hose clamps.

After completing work, fill intercooler with coolant.

Vent cooling system for intercooler .

Check cooling system for leaks.

Assemble engine.