11 65 020 Removing and installing/replacing exhaust turbocharger (B36A/B38A)

WARNING: This page is about a different variant/trim than selected.

Necessary preliminary work:

Drain COOLANT .
Remove the CATALYTIC CONVERTER .
Remove OIL RETURN LINE .
Remove OIL FEED LINE .
Remove right CHARGE-AIR DUCT .
Remove COWL PANEL COVER .

Removal:

Release expanding rivet (2).

Release screw (3).

Lay cover (4) to one side.

Fig 1: Cover, Screw, Expanding Rivet, And Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Lay wiring harness (2) with cover to one side.

Fig 2: Wiring Harness And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Unclip fuel line (1).

Unfasten screws (2).

Remove bulkhead upper part (3) upwards.

Fig 3: Bulkhead Upper Part, Fuel Line, And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten connector (1) from wastegate valve actuator (2) and disconnect.

Fig 4: Wastegate Valve Actuator Connector

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

Further coolant may escape!

Release screw (1).

Remove cap (2).

Drain coolant.

Fig 5: Locating Cap And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Parts: Replace O-ring.

Install cap (2).

Tighten screw (1).

Tightening torque: 11 00 2AZ .

Fig 6: Locating Cap And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

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

The clamping strip (2) remains bolted when the exhaust manifold/exhaust turbocharger (1) is removed/exchanged.

Only the upper bolting connection has to be released.

Fig 7: Clamping Strip And Exhaust Manifold/Turbocharger

Courtesy of BMW OF NORTH AMERICA, INC.

Release upper bolting connection in sequence (4 - 1).

Fig 8: Turbocharger Upper Bolts Tightening/Loosening Sequence

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

Risk of damage!

If the exhaust turbocharger (1) is jammed:

Only apply force to the turbine housing or on the exhaust manifold!

Do not pull on the compressor housing or the wastegate valve controller!

Exhaust manifold is water-cooled.

Further coolant may escape!

Release exhaust manifold/exhaust turbocharger (1) from cylinder head (see arrows) and feed in upward direction out of clamping strip (2).

Fig 9: Releasing Exhaust Manifold/Turbocharger From Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

Unclip tank ventilation line (1).

Fig 10: Locating Tank Ventilation Line

Courtesy of BMW OF NORTH AMERICA, INC.

Lift out exhaust manifold/exhaust turbocharger (1).

Fig 11: Removing/Installing Exhaust Manifold/Turbocharger

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

The following components need to be checked prior to the installation of the exhaust manifold/exhaust turbocharger:

Engine oil and 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.

Parts: Replace seal (1).

Check installed direction. Part number is on the cylinder head.

Install gasket (1) on cylinder head.

Fig 12: Exhaust Manifold Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

Risk of damage!

If the exhaust turbocharger (1) is jammed:

Only apply force to the turbine housing or on the exhaust manifold!

Do not pull on the compressor housing or the wastegate valve controller!

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

Fig 13: Removing/Installing Exhaust Manifold/Turbocharger

Courtesy of BMW OF NORTH AMERICA, INC.

Clip in the ventilation line (1).

Fig 14: Locating Tank Ventilation Line

Courtesy of BMW OF NORTH AMERICA, INC.

Feed exhaust manifold/exhaust turbocharger (1) downwards into clamping strip (2) and set down on the cylinder head (see arrows).

Fig 15: Feeding Exhaust Manifold/Exhaust Turbocharger Downwards Into Clamping Strip

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Observe tightening specifications.

Screw in nuts and tighten down in sequence (1 - 4).

Tightening torque: 11 62 1AZ .

Fig 16: Turbocharger Upper Bolts Tightening/Loosening Sequence

Courtesy of BMW OF NORTH AMERICA, INC.

Attach connector (1) of wastegate valve actuator (2).

Fig 17: Wastegate Valve Actuator Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Install bulkhead upper part (3).

Tighten down screws (2).

Clip in the fuel line (1).

Fig 18: Bulkhead Upper Part, Fuel Line, And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Mount wiring harness (2) with cover on bulkhead upper part.

Tighten bolt (1).

Fig 19: Wiring Harness And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Position cover (4).

Tighten screw (3).

Mount expanding rivet (2).

Fig 20: Cover, Screw, Expanding Rivet, And Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work:

Add COOLANT .