11 65 020 Removing and installing/replacing exhaust turbocharger (N55) all-wheel drive vehicle

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

Necessary preliminary work

Drain coolant. See 17 00 005 DRAINING AND ADDING COOLANT (N55) .
Remove COOLANT THERMOSTAT .
Remove COOLANT PUMP .
Remove CHARGE AIR COOLER .
Remove CATALYTIC CONVERTERS .

Release screws (1).

Tightening torque: 11 53 4AZ .

Fig 1: Identifying Catalytic Converters Mounting Screws

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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 Mounting Screws

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Release screw (1).

Loosen screws (3) but do not remove.

Fig 3: Identifying Flange Bolts And Nuts

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Release screw (1).

Tightening torque: 11 42 6AZ .

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

Installation note:

Replace sealing ring.

Fig 4: Identifying Oil Return Lines With Mounting Screws

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Release screw (1).

Tightening torque: 11 42 7AZ .

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

Possibility of oil escaping when oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 5: Identifying Oil Return Lines Screw

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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 Oil Return Lines Screw

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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 Plug Connection At Blow-Off Valve, Screws

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Disconnect vacuum line (1) from vacuum unit.

Fig 8: Identifying Vacuum Line From Vacuum Unit

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Disconnect vacuum line (1) from cylinder head cover.

Fig 9: Identifying Vacuum Line From Cylinder Head Cover

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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: Total weight of module is approximately 15 kg.

Fig 10: Identifying Heat Shield And Flange Nuts

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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 Screw

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Installation note:

Replace all sealing rings (1).

Fig 12: Identifying Sealing Rings

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Installation note:

Replace all graphite seals (1).

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

Fig 13: Identifying Graphite Seals

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

Fig 14: Identifying Exhaust Turbocharger Bolts

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Fig 15: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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IMPORTANT: The module consists of exhaust turbocharger and exhaust manifold and must be installed stress-free.

Torque and tightening 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).

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).

Tightening torque: 11 65 8AZ .

Fig 16: Identifying Flange Bolts And Nuts

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Assemble engine.

Observe BMW Diagnosis System instruction.

Carry out BMW leakage test for intake system.