Replace turbocharger

Turbocharger with assembly sleeves

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CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

NOTE: RISK OF DAMAGE
Damage of the electric wastegate valve controller .
Excessive force when removing and installing a jammed turbocharger may damage the electric wastegate valve controller .

Do not pull on the electrical wastegate valve controller or on the coupling rod.
Apply force only at the turbine housing and exhaust manifold.
Do not pull on the compressor housing.

When replacing the turbocharger: Remounting the oil feed line, coolant feed line and coolant return line

NOTE: RISK OF DAMAGE
Dry running due to insufficient initial filling of the turbocharger .
Damage to the turbocharger .

Be sure to do the initial filling when replacing the turbocharger.
Fill the turbocharger with the matching additive (see applicable BMW parts catalogue).

NOTE: RISK OF DAMAGE
Contaminant or foreign body .
Contamination can result in malfunctions, loss of function or leaks .

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Loosen screw (1).
Feed the coolant return line (2) out and remove it.

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Feed out and remove oil feed line (1).

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Twist the coolant feed line (1) in the arrow direction.

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Guide out the coolant feed line (1) and remove.

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Using the special tool 0 496 714 (00 9 030) , replace the sealing rings (1) on the coolant feed line (2).
Parts: Sealing ring

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Using the special tool 0 496 714 (00 9 030) , replace the sealing rings (1) on the coolant return line (3).
Parts: Sealing ring

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Check the sealing ring (2) on the coolant return line (3) for damage and if required, replace the coolant return line (3).
Replace the sealing rings (1) and (2) at the oil feed line (3) for the turbocharger using the special tool 0 496 714 (00 9 030) .
Parts: Sealing ring

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Insert the coolant feed line (1) and install.

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Twist the coolant feed line (1) in the arrow direction .

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Initial filling with the additive when replacing the turbocharger
NOTE:
RISK OF DAMAGE
Dry running due to insufficient initial filling of the turbocharger .
Damage to the turbocharger .
- Be sure to do the initial filling when replacing the turbocharger.
- Fill the turbocharger with the matching additive (see applicable BMW parts catalogue).
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Fill turbocharger additive (1) into the bore (2) of the oil feed line.

CONSUMABLE SPECIFICATION

Exhaust turbocharger additive, gasoline MSP

17 ml, Tube

83192457276

Insert and install the oil supply line (1).

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Insert and install the coolant return line (2).

Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Coolant return line/oil feed line to exhaust turbocharger
M6 x 12	tightening torque	8 Nm

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Check screw-in depth (A) of upper stud bolts (1).

TECHNICAL DATA SPECIFICATION

Screw-in depth of upper stud bolts on cylinder head
	Dimension A	30 mm

If necessary, screw in or unscrew the stud bolts further.

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NOTE:
RISK OF DAMAGE
Damage to the surface .
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage .
- Do not use any metal-cutting tools.
Clean the sealing surfaces (1) on the cylinder head using special tool 0 495 102 (11 4 470) .

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Replace the seal (1).
Parts: Seal
Feed in the seal (1) in the marked area and install.

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NOTE:
RISK OF DAMAGE
Damage to the surface .
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage .
- Do not use any metal-cutting tools.
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Clean the sealing surfaces (1) on the turbocharger using special tool 0 495 102 (11 4 470) .
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
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Insert and install the turbocharger (1).
Feed in and install the shifting strip (1).
Install the sliding rail (1) in such a way that the part number is visible .

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Replace nuts (1) to (7).
Parts: Nuts

Tighten the nuts in the sequence (1) to (7).

TIGHTENING TORQUES SPECIFICATION

Exhaust manifold to cylinder head
Flange nut M7 Replace flange nuts	1. Joining torque	10 Nm
	2. Joining torque	10 Nm
	3. Joining torque	16 Nm
	4. Joining torque	16 Nm
	5. Joining torque	16 Nm

Fig 1: Exhaust Manifold To Cylinder Head Nuts Tightening Sequence

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Unlock and release the assembly sleeves (1).

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Feed out the assembly sleeves (1) and remove.

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Replace the sealing rings (1) on the coolant feed line (2) for the turbocharger using the special tool 0 496 714 (00 9030) .
Parts: Sealing ring

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Feed in and install the coolant feed line for the turbocharger (3).

Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Coolant feed line to crankcase
M6X12	tightening torque	8 Nm

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Tighten down screw (2).

TIGHTENING TORQUES SPECIFICATION

Coolant feed line to crankcase
M6X12	tightening torque	8 Nm

Replace screws (1) and (2).
Parts: Screws
Feed in and install support (3).

Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Exhaust turbocharger support to crankcase
M8x20 Replace screws.	Tightening torque	19 Nm

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Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Exhaust turbocharger to support
M8x25 Replace screw.	Tightening torque	19 Nm

Replace the sealing rings (1) at the oil feed line (2) for the turbocharger using the special tool 0 496 714 (00 9 030) .
Parts: Sealing ring

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Feed in and install the oil feed line (2) for the turbocharger.

Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Oil feed line for exhaust turbocharger to crankcase
M6 x 12 Replace sealing ring.	tightening torque	8 Nm

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Tighten screw (1) on the coolant return line (2).

TIGHTENING TORQUES SPECIFICATION

Coolant return line holder to crankcase
M6X12	tightening torque	8 Nm

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Connect and lock the coolant return line (1) to the coolant pump (2) for the turbocharger.
The coolant return line (1) must engage audibly.

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Feed in and install the heat shield (2).

Replace screws (1).

Parts: Screws

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Heat shield to cylinder head
M8X12 Replace screws.	tightening torque	19 Nm

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Feed in and install the heat shield (3).

Replace screws (1).

Parts: Screws

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Heat shield to cylinder head
M8X12 Replace screws.	tightening torque	19 Nm

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Replace the screw (2).
Parts: Screw
Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Heat shield to trim strip
M6X16 Replace screw.	Tightening torque	8 Nm