7B1500 - BMW 1 & 3 Series N54/N55 Front Mount Intercooler
7B1500 – BMW 1 & 3 Series Front Mount Intercooler
2008-2011 135i
2013 135is
2007-2011 335i, 335xi, 335i xDrive
2011-2013 335is
Congratulations on your purchase of the COBB Tuning BMW 1 & 3 Series N54/N55 Front Mount Intercooler! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
IMPORTANT! Installing this kit will require custom tuning or utilizing an appropriate Stage Power Package map if you have a matching mechanical configuration. Please consult with COBB or an authorized ProTuner in your area if you have any questions!
Parts List
Front Mount Intercooler Core
Inlet Coupler
Outlet Coupler
Elbow Pipe
(4)T-bolt Clamps
(2) Phillips Screws
(2) M6x20mm Hex Screws
(2) Rubber Bushings
(2) M6 Stainless Steel Washers
Tools Needed
Phillips head screwdriver
Flathead screwdriver
3/8" ratchet
3/8" 7mm socket
3/8" 8mm socket
3/8" 10mm socket
3/8" 11mm socket
3/8" T20 Torx Bit
3/8" T25 Torx Bit
3/8" 12" extension
3/8" 6" extension
3/8" Socket Swivel
Removal of Stock Front Mount Intercooler
Remove the air intake snorkel. There are two T20 screws that hold the snorkel in. Use the T20 Torx Socket.
Use a flat head screwdriver to pull back on the tabs that hold the snorkel to the air intake box. Once pulled back, the snorkel can be removed.
Loosen the factory worm clamp on the charge pipe and stock elbow pipe with a 7mm socket.
Remove the underbody plastic tray. The underbody tray is secured by 19 8mm bolts.
Remove the two C-clips on the stock FMIC using pliers. These clips are located on the outlets of the intercooler.
Position a stand or floor jack under the FMIC to support it.
Loosen the inlet coupler and outlet elbow from the intercooler using a flat head screwdriver.
Unclip and remove the plastic piece that is on the bottom of the stock intercooler. To do this there are two tabs that need to be unlocked. Do this by rotating them up to the other square notch.
Unscrew two T25 Torx bolts that secure intercooler to the fan shroud. Once the bolts are removed, the only thing holding the intercooler up will be the elbow pipe and OEM inlet coupler that are loosely supporting the intercooler.
Lower the intercooler and remove from the vehicle.
Remove the factory turbo outlet coupler. The factory coupler should be held together to the turbo outlet pipe via a metal band. On the metal band there should be a saw/zipper pattern. Using a screwdriver gently pry at the saw/zipper pattern until the metal band pops loose. Now the factory inlet coupler can be removed.
Note: Be gentle with the screwdriver because it is connected to the turbo outlet pipe which is made out of aluminum and can be easily bent. Another alternative is using a dremel to cut the metal band but once again, caution must be used.The factory worm clamp that connects the elbow pipe to the charge pipe should already be loosened. Start from above the car and push back on the charge pipe and pull on the elbow pipe until it is freed from the charge pipe.
Next the factory elbow pipe will need to be removed from the rubber grommet holding it to the vehicle. From above the car, pull on the elbow upwards to free the elbow pipe from the grommet. Once freed, you will need to wiggle the pipe out from below the car, it is a pretty tight fit.
Remove the factory elbow pipe.
Remove the passenger side plastic bracket. This will require some wiggling and the use of a screwdriver. This piece needs to be removed or the new intercooler core will not fit properly. Be aware of the tabs that hold this piece in. Push back on the tabs with the a screwdriver and it should come out easily.