17 51 001 Removing and Installing/Replacing Right Intercooler

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





Warning!
High-voltage system - danger to life!





Warning!
The following points must be strictly observed prior to starting work:
^ De-energise the high-voltage system
^ Observe safety instructions for handling with hybrid vehicles





Warning!
Danger of scalding!

Only perform this work after engine has cooled down.





Necessary preliminary tasks:
^ Remove power electronics box bracket.
^ Remove fan cowl
^ Remove front underbody protection
^ Drain coolant for intercooler





Release clamp (1).

Tightening torque 13 71 8AZ.

Release clamp (2).

Replace clamp (2).

Remove right charge-air duct (3).

Check gasket on turbocharger, replacing if necessary.

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.





Unlock plug (1) and remove.

Release screw (2).

Tightening torque 13 71 6AZ.

Installation:
Screw (2) is longer than screws (3)

Unscrew screws (3).

Tightening torque 13 71 6AZ.

Release clamp (4) on throttle valve unit.

Tightening torque 13 71 7AZ.

Lift out intercooler.

Installation:
Only when replacing intercooler.

Modify pressure sensor on intercooler.

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.