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

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

Necessary preliminary tasks:

Remove the CATALYTIC CONVERTER .
Remove CHARGE AIR DUCT .
Drain COOLANT .
Remove EXPANSION TANK .
Remove AIR DUCT
Remove right engine mount . See 22 11 001 REPLACING RIGHT ENGINE MOUNT (N55) or 22 11 001 REPLACING RIGHT ENGINE MOUNT (N55) AWD .

Release screws (1).

Tightening torque 11 53 4AZ .

Fig 1: Identifying Catalytic Converters 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 Coolant Flow Line

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Release screw (1).

Loosen screws (3) but do not remove.

Fig 3: Identifying Flange Nuts

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Release screw (1).

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 Lines And Screw

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Release screw (1).

Tightening torque 11 42 7AZ .

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

Oil may escape when the oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 5: Identifying Oil Return Lines And 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 Return Lines And 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).

Oil may escape when the oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 7: Identifying Blow-Off Valve Plug Connection And Screw

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Disconnect vacuum hose (1) from vacuum line.

Fig 8: Identifying Vacuum Hose

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Disconnect vacuum hose (1) from cylinder head cover.

Fig 9: Disconnecting Vacuum Hose 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: Overall 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 exhaust turbocharger.

Release screw (1).

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

Fig 11: Identifying Oil Feed Line And 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 exhaust 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 Flange Bolt

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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 Nuts

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Top up with COOLANT .

Assemble engine.

Observe BMW Diagnosis System instruction.

Carry out BMW leakage test for intake system.