1. Preparation and AC Refrigerant Removal

Before starting the job, take the BMW X5 to a local shop to have the AC refrigerant safely removed from the system
This step is essential to avoid releasing refrigerant during the condenser replacement

2. Remove Front Panel and Disconnect Sensors

Using a trim tool or pliers, remove the push pins holding the front panel
Disconnect the mass air flow sensor connector and slide the panel out of the way to access the engine bay components

3. Remove Clips and Airbox

Use a straight blade screwdriver to pop out two clips securing parts in place
Remove two 10 mm bolts with a socket, then slide the airbox out
Loosen the clamp on the back using a screwdriver and disconnect the wiring retainer and connectors

4. Disconnect Additional Electrical Connectors

Locate the tab under electrical connectors and use a small straight blade screwdriver to push the tab aside, allowing removal of connectors below the fan clutch area

5. Loosen and Remove Fan Clutch

Use a 32 mm fan clutch removal tool to loosen the fan clutch by turning clockwise (due to reverse threads)
Once loose, remove the tool and hand-loosen the fan clutch further

6. Remove Fan Shroud Push Pins

Using side cutters or push from behind, remove the fan shroud push pins on both sides
Carefully loosen the fan shroud and fan assembly, making sure not to drop it into the radiator

7. Remove Under Vehicle Panel

Use an 8 mm socket to remove fasteners along the front, sides, and back of the under vehicle panel
Slide the panel down to gain access to the radiator base

8. Drain Coolant from Radiator

If the radiator plug is broken, remove the lower radiator hose on the passenger side to drain coolant
Disconnect the hose connector carefully, have a drain bucket ready, and let coolant drain completely

9. Disconnect Reservoir and Associated Hoses

Disconnect the level sensor wire from the coolant reservoir
Use a pick to pop clips securing hoses
Gently pry hoses off with a screwdriver, then remove the reservoir by sliding it upward, using gentle prying if necessary

10. Remove Coolant Cooler from Radiator

11. Disconnect AC Lines and Loosen Radiator Brackets

Use a pick and pry bar to carefully unlock and remove AC hose connectors
Loosen (but do not remove completely) the 13 mm bolts on the radiator brackets and remove side bolts with a 10 mm socket

12. Remove Radiator Top Screws and Slide Radiator Out

Use T-25 socket to remove top screws on both sides
Carefully lift and slide the radiator upwards, working it free around transmission lines and AC lines

13. Disconnect Condenser Lines

Using a 6 mm hex socket, remove bolts securing AC condenser lines
Gently pry connectors loose with a screwdriver, ensuring refrigerant is already evacuated to avoid pressure release

14. Install Roll Pins and Insert New Condenser

Using pliers, insert roll pins into the new condenser
Slide the condenser down into place, aligning with the lower bracket, and secure it with screws and bolts, tightening snugly

15. Lubricate O-rings and Reattach AC Lines

Apply a small amount of AC oil to the condenser O-rings if they are in good condition; replace if damaged
Align and press AC lines onto the condenser, then start and tighten bolts to torque specifications (14 ft-lb)

16. Reinstall Radiator and Brackets

Slide the radiator back into place, carefully maneuvering it around transmission, AC, and oil cooler lines
Align bolt holes and reinstall upper screws and side bolts, tightening them snugly

17. Reconnect Cooler and Reservoir Components

Attach the coolant cooler lines and locks
Position and secure the front cover panel with bolts
Reinstall the reservoir by attaching hoses and locking connectors, ensuring all clips and wiring harnesses are properly connected

18. Reconnect Hose Locks, Clips and Wiring

Apply a thin coat of silicone to pipes if needed
Reinstall hose clips and locks, connect electrical connectors, and secure lower shields with screws, ensuring everything is aligned and tightened

19. Reinstall Fan Shroud and Fan

Slide fan shroud and fan into place, lining up tabs and ears with radiator slots
Start the fan using the removal tool with reverse threads (counterclockwise), then insert push pins to secure the shroud

20. Tighten Fan and Reattach Wiring

Finish tightening the fan clutch with the removal tool, aiming for about 29 ft-lb torque
Reconnect the wiring harness and ensure connectors lock firmly

21. Reinstall Airbox and Final Panels

22. Refill Coolant and Bleed the System

Remove coolant cap and loosen the bleeder screw slightly
Using a funnel, fill the cooling system with a 50/50 coolant mix
Watch for coolant to come out of the bleeder to remove trapped air, squeezing the upper hose to help bleeding

23. Run Engine and Final Coolant Level Check

Start the engine and let it run for 15-20 minutes until warmed up, monitoring temperature to avoid overheating
After shutting off and cooling, recheck the coolant level and top off if necessary

How to Replace AC Condenser 2000-2006 BMW X5 30L L6