17 51 001 Removing and installing/replacing left charge air cooler (N63 hybrid)

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work:

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INFORMATION for handling with hybrid cars

WARNING: Risk of scalding!
Only perform this repair work after engine has cooled down!

Necessary preliminary tasks:

Remove POWER ELECTRONICS BOX BRACKET .
Remove FAN COWL
Remove front UNDERBODY PROTECTION
FOLLOW instructions for repair work on the cooling system.

Release clamp (1).

Tightening torque 13 71 8AZ .

Release clamp (2).

Replace clamp (2).

Remove left charge-air duct (3).

Installation note:

Check seal on exhaust turbocharger, renew if necessary.

Fig 1: Identifying Left Charge-Air Duct And Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: When loosening the coolant hoses from the charge air cooler, make sure that the connector remains connected to the throttle body. Coolant may not penetrate the plug connection at the throttle body.

Disconnect coolant hoses from charge air cooler using PINCH-OFF TOOLS (to prevent coolant from escaping).

Catch and dispose of escaping coolant.

Release and disconnect coolant hoses (1).

Remove tank vent valve (2) from charge air cooler (3).

Fig 2: Identifying Coolant Hoses, Tank Vent Valve And Charge Air Cooler

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock connector (1) and remove.

Release screw (2).

Tightening torque 13 71 6AZ .

Installation note:

Screw (2) is longer than screws (3)

Fig 3: Identifying Clamp, Connector And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (3).

Tightening torque 13 71 6AZ .

Release clamp (4) on throttle valve unit.

Tightening torque 13 71 7AZ .

Lift out charge air cooler.

Installation note:

Only when replacing charge air cooler.

Remount holder of tank vent valve.

Remount FUEL PRESSURE SENSOR at charge air cooler.

Remount charge air hose.

Replace faulty hose clamps.

After having completed repair work, coolant level for charge air cooler and top up if necessary.

Check cooling system for water-tightness.

Assemble engine.