BMW E46 320D FRONT MOUNTED INTERCOOLER FITTING

BMW E46 320D FRONT MOUNTED INTERCOOLER
FITTING INSTRUCTIONS.
Tools needed
T25 Male Torx drive
Flat head screwdriver
Philips screwdriver
13mm spanner
Sharp knife
1/ Remove the engine under tray by unscrewing the Philips screws.
2/ Remove the bayonet clips from each of the intercooler hose couplers and pull the hose
clear of the intercooler.
3/ Remove the plastic intercooler to radiator cover. To do this you need to pull the tabs
shown to release it.
4/ Whilst supporting the intercooler remove the two T25 Torx from the bottom of the
intercooler then pull down to remove the whole intercooler.
5/ You will need to trim the front bumper cowling as per the image using a sharp knife.
This can be done with the bumper left on.
6/ Refit the intercooler C clips onto the new Forge intercooler.
7/ Slide the new intercooler up into the original location whilst hooking the upper support
brackets onto the unused studs shown below. Tighten the 13mm nuts and washers
provided to the upper intercooler support brackets. To do this you will need to raise the
bonnet and enter through the front cowling opening.
This picture is for illustration only you do not need to remove the bumper.
9/ Screw the two lower intercooler T25 torx screws in to secure the intercooler.
10/ Push the intercooler hose bayonet connectors back into the new intercooler making
sure they locate properly.
11/ Check all nuts bolts and hoses are tight and refit the under tray
12/ Test drive the vehicle.
Thank you for buying Forge Motorsport products.
As always, with any questions or concerns about this product, please feel free to contact your local or
preferred Forge Motorsport dealer/installer, or you may contact us directly.
Forge Motorsport UK (+ 44) 1 452 380 999 / info@forgemotorsport.co.uk
Forge Motorsport US (407) 447-5363 / sales@forgemotorsport.com