11 65 020 Removing and installing/replacing exhaust turbocharger (N55)

WARNING: The module consists of exhaust turbo charger and exhaust manifold.
The weight of the turbocharger is approx. 15 kg.

Necessary preliminary tasks:

Remove FAN COWL with electric fan.
Drain COOLANT .
Remove COOLANT THERMOSTAT .
Remove COOLANT PUMP .
Remove CHARGE AIR COOLER .
Remove right engine support arm.
Remove right engine mount.
Remove CATALYTIC CONVERTERS .

Release screws (1).

Tightening torque 11 53 4AZ .

Fig 1: Identifying Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque 11 53 10AZ .

If necessary, use appropriate tool to loosen coolant return line (3) and coolant flow line (2) at connection point.

Installation note:

Replace sealing rings.

Fig 2: Identifying Coolant Return Line And Coolant Flow Line

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Loosen screws (3) but do not remove.

Release screw (1).

Fig 3: Identifying Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Tightening torque 11 42 6AZ .

If necessary, use appropriate tool to loosen oil return lines (2).

Installation note:

Replace sealing ring.

Fig 4: Identifying Oil Return Line And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque 11 42 7AZ .

If necessary, use appropriate tool to loosen oil return lines (2).

Possibility of oil escaping when oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 5: Identifying Oil Return Line And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque: 11 42 4AZ .

If necessary, use appropriate tool to loosen coolant return lines (2) at connection point.

Installation note:

Replace sealing ring.

Fig 6: Identifying Coolant Return Line And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Loosen plug connection (1) at blow-off valve.

Release screw (2).

Tightening torque 11 65 4AZ

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (3).

Possibility of oil escaping when oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 7: Identifying Oil Return Line And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect vacuum hose (1) from vacuum line.

Fig 8: Identifying Vacuum Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect vacuum hose (1) from cylinder head cover.

Fig 9: Identifying Vacuum Hose And Cylinder Head Cover

Courtesy of BMW OF NORTH AMERICA, INC.

Remove heat shield (1).

Tightening torque: 11 65 2AZ

Loosen all flange nuts (2) along the line.

Remove module by maneuvering downwards on gearbox side.

NOTE: Overall weight of module is approximately 15 kg .

Fig 10: Locating Flange Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Oil supply line (2) can only be replaced after removal of the turbocharger.

Release screw (1).

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (2).

Fig 11: Identifying Oil Supply Line And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

Replace all sealing rings (1).

Fig 12: Identifying Sealing Rings

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

Replace all graphite seals (1).

Fig 13: Identifying Graphite Seals

Courtesy of BMW OF NORTH AMERICA, INC.

Position turbocharger on cylinder head and hold in place with two bolts.

Insert bolt (1) but do not tighten at this point.

Fig 14: Identifying Screws

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: The module consists of exhaust gas turbo loader and exhaust gas manifold and must be installed stress-free.
Torque and torque sequence must be observed without fail.
Tightening torque: 11 65 1AZ .

Join all flange nuts in sequence 1 to 15 to 8 Nm .
Tighten all flange nuts to a torque of 13 Nm in sequence (1 to 15).

Fig 15: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:
Flange nuts 1 to 5 are accessible from above.
Flange nuts 6 to 15 are accessible from below.

Secure screws (3).

Tightening torque: 11 65 9AZ .

Tighten bolt (1).

Fig 16: Identifying Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Tightening torque 11 65 8AZ .

Assemble engine.

Observe BMW Diagnostics System instruction.

Carry out BMW leak test for intake system.