Removing and installing/replacing exhaust turbocharger (B48 and B46 engine) (Cooper S and John Cooper Works)

WARNING: Risk of burning!

Only perform this repair work on an engine that has cooled down.

IMPORTANT:

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

Preliminary work needed:

Drain COOLANT .
Remove CATALYTIC CONVERTER .
Remove OIL FEED LINE .
Remove COOLANT RETURN LINE .
Release COOLANT FEED LINE from exhaust turbocharger
Remove OIL RETURN LINE .
Partially remove FRONT RIGHT WHEEL ARCH TRIM PANEL .

Removal:

Release expanding rivet and remove mounting for gasket (1).

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Release screw and remove tension strut (1).

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Unscrew the screws (1).

Remove securing eye (2).

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Release wiring harness (1) from partition wall (2).

Remove partition wall (2) upwards and in front direction.

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Release expansion rivet (1).

Remove partition wall (2).

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Release screws (1 and 2).

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Unclip fuel delivery line (1).

Unscrew nuts (2).

Slightly bend heat shield (3) towards front.

Remove partition wall (4).

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Release screws (1 and 2).

Remove heat shield (3).

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Unscrew the screws (1).

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Unlock lock (1) on both sides with suitable tool.

Detach charge air duct (2) from exhaust turbocharger (3).

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Attention!

Exhaust manifold/exhaust turbocharger (1) is not bolted to the underside, but clamped instead.

The trim strip (2) remains screwed in when the exhaust manifold/exhaust turbocharger (1) is removed/exchanged.

Only the upper bolting connection has to be released.

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Secure exhaust manifold/exhaust turbocharger against falling.

Release upper bolting connection in sequence (5 - 1 ).

Fig 1: Exhaust Manifold/Exhaust Turbocharger Nuts Loosening Sequence

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Remove reinforcement plate (1).

Feed out exhaust manifold/exhaust turbocharger (2) from trim strip (3) upwards and towards rears.

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Lift out exhaust manifold/exhaust turbocharger (1).

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Preparation for installation:

Installation note:

Risk of damage to the exhaust turbocharger!

Inadequate initial filling of the exhaust turbocharger leads to dry running.

When replacing the exhaust turbocharger, the correct initial filling must be ensured.

Fill the exhaust turbocharger with a suitable additive (see the appropriate BMW parts catalogue).

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Installation:

NOTE: The following components must be checked before installation of the exhaust manifold/exhaust turbocharger:

Motor oil and coolant and screw connection: Check supply and return lines for dirt contamination and obstructions, clean and replace if necessary.

Check air cleaner 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 motor oil with oil filter.

Check correct functioning of crankcase ventilation.

Replace all gaskets.

Parts : Replace seal (1).

Install gasket (1) on cylinder head.

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Feed in exhaust manifold/exhaust turbocharger (1) downwards.

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Feed in exhaust manifold/exhaust turbocharger (1) downwards into the trim strip (2) and bring in contact with cylinder head.

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NOTE: Reinforcement plate (1) can be installed improperly.

Original BMW - part number needs to be legible from the rear.

Mount reinforcement plate (1).

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Attention!

Observe tightening specifications.

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

Tightening torque: 11 62 2AZ .

Fig 2: Exhaust Manifold/Exhaust Turbocharger Nuts Tightening Sequence

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Fill exhaust turbocharger additive (1) in bore hole (2) of the oil feed line.

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Connect charge air duct (1) to exhaust turbocharger (2) until lock (3) engages on both sides.

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Position charge air duct and tighten screws (1).

Tightening torque 11 00 2AZ .

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Install heat shield (3).

Tighten screw (1).

NOTE: Position screw (2) until it abuts and do not tighten.

Only tighten screw (2) when all the other heat shields are installed.

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Install partition wall (4).

Attach heat shield (3).

Tighten down nuts (2).

Attach fuel delivery line (1).

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Tighten down screws (1 and 2).

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Install partition wall (2) and secure with expanding rivet (1).

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NOTE: Make sure the partition wall (2) is installed properly in the marked area.

Install partition wall (2).

Attach wiring harness (1).

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Join tension strut (1) and tighten with screws.

Tightening torque 61 21 5AZ .

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Join mounting for gasket (1) and secure with expanding rivet.

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Required follow-up work:

Install FRONT RIGHT WHEEL ARCH TRIM PANEL .
Install OIL RETURN LINE .
Install COOLANT FEED LINE .
Install COOLANT RETURN LINE .
Install OIL FEED LINE .
Install CATALYTIC CONVERTER .
Add COOLANT .