Removing and installing/replacing intercooler expansion tank (S55 engine)

Follow notes for CARRYING OUT REPAIR WORK ON THE COOLING SYSTEM .

Necessary preliminary work: 

• Pinch off coolant hoses on coolant expansion tank using the appropriate pinch-off tools.
• Remove charge-air ducts. Refer to REMOVING AND INSTALLING/REPLACING THE CHARGE AIR DUCT FOR CYLINDERS 1-3 and REMOVING AND INSTALLING/REPLACING CHARGE AIR DUCT OF CYLINDER 4-6 .

Removal: 

Release clamp (2).

Unlock and disconnect the plug connection (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Release clamp (1) on coolant hose.

Pull charge air cooler (2) upwards out of rubber mounts.

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect coolant hose between expansion tank and charge air cooler with pinch-off pliers (1).

Release clamp (3) and detach coolant hose.

Unfasten screws (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Raise charge air cooler slightly.

Disconnect coolant hose between expansion tank (3) and charge air cooler with pinch-off pliers (1).

Release clamp (2) and detach coolant hose.

Remove expansion tank (3).

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Connect coolant hose to expansion tank (3) and fasten clamp (2).

Release pinch-off pliers (1) from coolant hose.

Courtesy of BMW OF NORTH AMERICA, INC.

Insert expansion tank into rubber mount.

Tighten down screws (2).

Tightening torque 17 10 7AZ .

Connect coolant hose to expansion tank and fasten with clamp (3).

Release pinch-off pliers (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Engage charge air cooler (2) in rubber mount.

Fasten coolant hose at clamp (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten clamp (2).

Tightening torque 17 10 9AZ .

Connect and lock the connector (1).

Connector (1) must snap audibly into place.

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

• Install charge air ducts. Refer to REMOVING AND INSTALLING/REPLACING THE CHARGE AIR DUCT FOR CYLINDERS 1-3 and REMOVING AND INSTALLING/REPLACING CHARGE AIR DUCT OF CYLINDER 4-6 .
• Check coolant level for charge air cooler, top up if necessary.