11 65 020 Removing and installing/replacing exhaust turbocharger (N20)

WARNING: The module consists of exhaust turbo charger and exhaust manifold.

Necessary preliminary tasks:

Remove the CATALYTIC CONVERTER .
Remove ACOUSTIC COVER .
Remove heat shield on side member.
Remove front right SUSPENSION CROSS-BRACE .
Drain COOLANT .
Remove the right coolant hose.
REMOVE bottom clean air pipe.
Remove RIGHT CHARGE-AIR DUCT .
Drain ENGINE OIL .

Unlock coolant hose (1) from expansion tank and pull off.

Fig 1: Identifying Expansion Tank Coolant Hose

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Release screws (1) from heat shield.

Remove heat shield

Tightening torque 11 65 5AZ .

Fig 2: Identifying Heat Shield Screws

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Disconnect vacuum hose (1) from vacuum line.

Disconnect plug connection (2) on blow-off valve.

Fig 3: Identifying Vacuum Hose And Plug Connection

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Unlock retaining clip (1) with a screwdriver in direction of arrow and hold.

Pull off retaining clip (1) with suitable pliers in direction of arrow.

Pull off wastegate linkage (2) from wastegate flap.

Fig 4: Identifying Wastegate Linkage And Retaining Clip

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Release screws (1).

Tightening torque: 11 65 4AZ .

Remove vacuum unit.

Fig 5: Identifying Screws

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Unclamp engine wiring harness (1) from bracket.

Release screw (2) and remove holder (3).

Tightening torque: 11 00 2AZ .

Fig 6: Identifying Engine Wiring, Screw, And Bracket

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Slacken bolt (1).

Release and remove screws (2).

Holder (3) remains on exhaust turbocharger.

Fig 7: Identifying Holder, Screws, And Bolt

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Unfasten screws (2).

Release oil return pipe (3) and place to one side.

Tightening torque 11 42 6AZ .

NOTE: Replace gasket.

Fig 8: Identifying Oil Return Pipe And Screws

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Release screw (1).

Fig 9: Identifying Screw

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Release screw (1).

Tightening torque 11 42 6AZ .

Remove oil return line (2).

Installation note:

Replace O-ring.

Fig 10: Identifying Oil Return Line And Screw

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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 11: Identifying Coolant Return Line, Coolant Flow Line, And Screw

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Release screw (1).

Tightening torque: 11 42 4AZ .

Release connection of oil feed line (2), if necessary with a suitable tool.

Installation note:

Replace sealing ring.

Fig 12: Identifying Oil Feed Line Connection And Screw

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Pull off cable plug (2) of coolant pump.

Fig 13: Identifying Coolant Pump Screw And Connector

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Tape off engine support at front right with suitable auxiliary materials (risk of damage.) .

Release nuts (1) to (10).

Fig 14: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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Feed out exhaust turbocharger (1) towards top front and remove.

Fig 15: Removing Exhaust Turbocharger

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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 16: Identifying Oil Supply Line And Screw

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Installation note:

Replace all sealing rings (1).

Replace sealing rings of coolant RETURN and FEED LINES .

Fig 17: Identifying Sealing Ring

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Installation note:

Replace all graphite seals (1).

Fig 18: Identifying Graphite Seal

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Installation note:

In order to be able to feed out the exhaust turbocharger more easily, twist holder (1) as far as possible in direction of arrow and lightly fasten with screw (2).

Tightening torque: 11 65 6AZ .

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

Fig 19: Installing Exhaust Turbocharger Holder And Screw

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Fig 20: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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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 flange nuts to a torque of 8 Nm in sequence (1) to (10).
Tighten flange nuts to a torque of 13 Nm in sequence (1) to (10).

Assemble engine.

Observe BMW Diagnostics System instruction.

Carry out BMW leak test for intake system.