Removing and installing/replacing exhaust turbocharger (Cooper base)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2021 MINI Cooper, 2020 MINI Cooper, 2019 MINI Cooper, 2018 MINI Cooper, and 2017 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

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

Removal:

Release expanding rivet (2).

Remove screw (3).

Lay cover (4) to one side.

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Remove screw (1).

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

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Unclip fuel line (1).

Unscrew the screws (2).

Remove cowl upper part (3) upwards.

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

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Only for use with externally position coolant lines:

Release screw (1), remove the coolant lines (2) and (3).

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Attention!

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

When removing/replacing the exhaust manifold/exhaust turbocharger (1), the trim strip (2) remains screwed on.

Only the top threaded connection has to be loosened.

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Loosen the top threaded connection in sequence (4 - 1) .

Fig 1: Exhaust Manifold And Turbocharger Nuts Loosening Sequence

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Risk of damage!

If the exhaust turbocharger (1) jams:

Exert force on the turbine housing or on the exhaust manifold only!

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

Attention!

Exhaust manifold is water-cooled.

Further coolant may leak!

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

Unclip tank vent line (1).

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Lift out exhaust manifold/exhaust turbocharger (1).

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Preparation for installation:

Installation note:

Risk of damage to exhaust turbocharger!

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

Be sure to do the initial filling promptly and correctly when replacing the exhaust turbocharger.

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

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Installation:

NOTE: The following components need to be checked prior to the 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.
If there is strong contamination in the supply lines and return lines, the recommended course of action is to change the engine oil with oil filter.
Check correct functioning of crankcase ventilation.
Replace all gaskets.

Parts : Replace seal (1).

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

Install gasket (1) on cylinder head.

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Attention!

Risk of damage!

If the exhaust turbocharger (1) jams:

Exert force on the turbine housing or on the exhaust manifold only !

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

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

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Clip in the ventilation line (1).

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Guide the exhaust manifold/exhaust turbocharger (1) down into the trim strip (2) and bring it into contact with the cylinder head (see arrows).

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Attention!

Observe tightening specifications!

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

Tightening torque: 11 62 1AZ .

Fig 2: Exhaust Manifold And Turbocharger Nuts Tightening Sequence

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Only for use with externally position coolant lines:

Parts: O-rings.

Replace O-rings.

Position the coolant lines (2) and (3).

Tighten screw (1).

Tightening torque: 11 65 2AZ .

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

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Install cowl upper part (3).

Tighten down screws (2).

Clip in the fuel line (1).

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

Tighten bolt (1).

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Position cover (4).

Tighten screw (3).

Mount expanding rivet (2).

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Required follow-up work:

Install right CHARGE AIR DUCT .
Install OIL FEED LINE .
Install OIL RETURN LINE .
Install the CATALYTIC CONVERTER .
Install the WINDSHIELD PANEL COVER .
Add COOLANT .