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
Drain COOLANT .
REMOVE bottom clean air pipe.
Drain ENGINE OIL .

Release screws (1) from heat shield.

Remove heat shield

Tightening torque 11 65 5AZ .

Fig 1: Identifying Heat Shield Screws

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Unlock snap fastener (1) and tie charge air duct to one side.

NOTE: Shown with engine/cooling package removed for better overview.

Fig 2: Identifying Tie Charge Air Duct Snap Fastener

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Disconnect vacuum hose (1) from vacuum line.

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

Fig 3: Identifying Plug Connection On Blow-Off Valve

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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.

IMPORTANT: Do not bend the wastegate linkage.

Pull off wastegate linkage (2) from wastegate flap.

Fig 4: Pulling Wastegate Linkage From Wastegate Flap

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Release screws (1).

Tightening torque: 11 65 4AZ .

Remove vacuum unit.

Fig 5: Identifying Vacuum Unit 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: Locating Bracket

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Release screws (1) and remove holder (2).

Fig 7: Identifying Holder And Screws

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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 Line And Screws

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Release screw (1).

Fig 9: Identifying Oil Return Pipe 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 And Coolant Flow Line

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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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Fig 13: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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

Release nuts (1) to (10) and feed exhaust turbocharger out toward the top (watch out for coolant line). Remove turbocharger towards bottom.

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 14: Identifying Oil Feed Line And Screw

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Installation note:

Replace all sealing rings (1).

Renew sealing rings of coolant RETURN and FEED LINES .

Fig 15: 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 16: Identifying Graphite Seals

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Fig 17: 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).

Installation note:

If screw (1) cannot be secured, holder must be released.

Secure screws (1).

Tightening torque: 11 65 6AZ .

Fig 18: Identifying Oil Return Line And Screws

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Assemble engine.

Observe BMW Diagnostics System instruction.

Carry out BMW leak test for intake system.