11 65 020 Removing and installing/replacing turbocharger (230i and 230i xDrive coupe/convertible)

WARNING: Risk of burning!
Only perform this repair work on an engine that has cooled down .

CAUTION: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) .

NOTE: Troubleshooting on exhaust turbocharger.

Necessary preliminary work:

Refer to DRAINING COOLANT .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE CATALYTIC CONVERTER .
Refer to REMOVING OIL FEED LINE .
Refer to REMOVING THE COOLANT RETURNING LINE .
Refer to REMOVING COOLANT FEED LINE .
Refer to REMOVING OIL RETURN LINE .

Removal:

Undo screw (1) from heat shield (2).

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Release screw (1).

Disconnect heat shield (2) in the marked area and remove.

Unfasten screws (3).

Remove heat shield (4).

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Unlock connector (1) and pull off of exhaust turbocharger.

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CAUTION: Exhaust turbocharger is not bolted to the underside, but clamped instead.
When removing/replacing the exhaust turbocharger, clamping strip (6) remains screwed on.
Only the upper bolting connection has to be released.

Release screws in sequence (5 - 1).

Fig 1: Reinforcement Plate Screws Loosening Sequence

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Remove reinforcement plate (1).

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Remove the exhaust turbocharger (1) to the front upwards.

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Preparation for installation:

Installation note:

Risk of damage to the exhaust turbocharger!

An insufficient initial filling of the exhaust turbocharger leads to dry running.

While replacing the exhaust turbocharger, it is mandatory to ensure that the initial filling is correctly carried out.

Filling the exhaust turbocharger with the appropriate additive (see applicable BMW parts catalogue)

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Installation:

NOTE: The following components must be checked before installation of the exhaust turbocharger:
Engine oil, coolant and screw connection: Check supply and return lines for dirt contamination and obstructions, clean and replace if necessary.
Check air filter for dirt contamination (particles) and replace if necessary.
In the case of heavy dirt contamination on supply and return lines it is recommended to change the engine oil with oil filter.
Check correct functioning of crankcase ventilation.
Replace all gaskets.

NOTE: Part number (1) points in the direction of the exhaust turbocharger.

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Parts: Replace seal (1).

Install gasket (1) on cylinder head.

Ensure gasket (1) is installed correctly in the marked area.

Feed in exhaust turbocharger (1) and position on the clamping strip.

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Mount reinforcement plate (1).

NOTE: Part number points in the direction of right wheel arch.

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Ensure correct installation of exhaust turbocharger (6) on the clamping strip.

CAUTION: Observe tightening specifications.

Screw in nuts and tighten in sequence (1 - 5) .

See: TIGHTENING TORQUE .

Fig 2: Reinforcement Plate Screws Tightening Sequence

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Connect connector (1) to the exhaust turbocharger and lock.

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Position heat shield (4).

Tighten screws (3).

Tightening torque 11 65 1AZ .

Connect heat shield (2) in the marked area.

Tighten screw (1).

Tightening torque 11 65 1AZ .

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Tighten screw (1) on heat shield (2).

Tightening torque 11 65 2AZ .

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Required follow-up work:

Refer to INSTALLING OIL RETURN LINE .
Refer to INSTALLING COOLANT FEED LINE .
Refer to INSTALLING COOLANT RETURNING LINE .
Refer to INSTALLING OIL FEED LINE .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to TOPPING UP COOLANT .