11 65 020 Removing and installing/replacing turbocharger (PHEV)

WARNING: High-voltage system - danger to life

Observe SAFETY INFORMATION for working with electric vehicles.

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

Necessary preliminary tasks:

Remove the CATALYTIC CONVERTER .
Remove ACOUSTIC COVER .
Remove front right SUSPENSION CROSS-BRACE .
Drain COOLANT .
Remove BOTTOM CLEAN AIR PIPE .
Remove RIGHT CHARGE-AIR DUCT .
Drain ENGINE OIL .

Removal:

Unlock snap fastener (1).

Detach coolant hose (2) and lay to one side.

Fig 1: Identifying Coolant Hose And Snap Fastener

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Release clamp (1).

Detach coolant hose (2) and lay to one side.

Fig 2: Identifying Coolant Hose And Clamp

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Release screws (1) from heat shield.

Remove heat shield.

Tightening torque 11 65 5AZ .

Fig 3: Identifying Heat Shield Screws

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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: Pulling Wastegate Linkage From Wastegate Flap

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Unfasten screws (2).

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

Fig 5: Identifying Oil Return Line And Screws

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Slacken bolt (1).

Release and remove screws (2).

Holder (3) remains on turbocharger.

Fig 6: Identifying Holder, Screws And Bolt

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Slacken nut (1).

Fig 7: Identifying Nut

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Release screw (1).

Remove oil return line (2).

Fig 8: Identifying Oil Return Line, Vent Line And Screw

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Release screw (1).

If necessary, use appropriate tool to loosen coolant return line (3) and coolant flow line (2) at connection point.

Fig 9: Identifying Coolant Return Line, Coolant Flow Line And Screw

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Release screw (1).

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

Fig 10: Identifying Oil Feed Line And Screw

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Disconnect plug connector (2) of coolant pump.

Fig 11: Identifying Coolant Pump Connector And Screw

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

Release nuts (1) to (10).

Fig 12: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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

Fig 13: Removing 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 14: Identifying Oil Feed Line And Screw

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Installation:

Parts: Seals

Installation note:

Replace all sealing rings (1).

Replace sealing rings of coolant RETURN and FEED LINES .

Fig 15: Identifying Sealing Ring

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Connect oil feed line (2).

Tighten screw (1).

Fig 16: Identifying Oil Feed Line And Screw

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Installation note:

Replace all graphite seals (1).

Fig 17: Identifying Graphite Seal

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Installation note:

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

Fig 18: Twisting Holder

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Feed in turbocharger (1) to the bottom rear.

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

Fig 19: Positioning Turbocharger On Cylinder Head

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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).

Fig 20: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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Connect plug connector (2) of coolant pump.

Fig 21: Identifying Coolant Pump Connector And Screw

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Installation note:

Replace sealing ring.

Position oil feed line (2) at the connection point.

Tighten screw (1).

Tightening torque: 11 42 4AZ .

Fig 22: Identifying Oil Feed Line And Screw

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Installation note:

Replace sealing rings.

Position coolant return line (3) and coolant feed line (2) at the connection.

Tighten screw (1).

Tightening torque 11 53 10AZ .

Fig 23: Identifying Coolant Return Line, Coolant Flow Line And Screw

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Installation note:

Replace O-ring.

Connect oil return line (2).

Tighten screw (1).

Tightening torque 11 42 6AZ .

Fig 24: Identifying Oil Return Line, Vent Line And Screw

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Tighten screw (1).

Fig 25: Identifying Nut

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Position holder (3).

Tighten down screws (2).

Tighten screw (1).

Fig 26: Identifying Holder, Screws And Bolt

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NOTE: Replace gasket.

Position oil return line (3).

Tighten down screws (2).

Tightening torque 11 42 6AZ .

Fig 27: Identifying Oil Return Line And Screws

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Attach wastegate linkage (2) to the wastegate valve.

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

Fig 28: Attaching Wastegate Linkage To Wastegate Valve

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Connect coolant hose (2).

Fix clamp (1) in place.

Fig 29: Identifying Coolant Hose And Clamp

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Position coolant hose (2).

The snap fastener (1) must latch audibly into place.

Fig 30: Identifying Coolant Hose And Snap Fastener

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Installation note:

Top up COOLANT .
Top up ENGINE OIL .

Observe BMW Diagnostics System instruction.

Carry out BMW leakage test for air intake system.