11 65 020 Removing and installing/replacing exhaust turbocharger (B48, B46)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Necessary preliminary tasks:

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

Removal:

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

Fig 1: Locating Expanding Rivet And Gasket

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Release screw and remove tension strut (1).

Fig 2: Locating Tension Strut Screw

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Release screws (1).

Remove securing eye (2).

Fig 3: Securing Eye And Screws

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

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

Fig 4: Removing Partition Wall Upwards

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Release expansion rivet (1).

Remove partition wall (2).

Fig 5: Partition Wall And Expansion Rivet

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Release screws (1 and 2).

Fig 6: Partition Wall Screws

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Unclip fuel delivery line (1).

Unscrew nuts (2).

Slightly bend heat shield (3) towards front.

Remove partition wall (4).

Fig 7: Fuel Delivery Line, Partition Wall, Bend Heat Shield And Nuts

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Release screws (1 and 2).

Remove heat shield (3).

Fig 8: Heat Shield And Screws

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Release screws (1).

Fig 9: Charge Air Duct Screws

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

Pull off charge air duct (2) from exhaust turbocharger (3).

Fig 10: Pulling Off Charge Air Duct From Exhaust Turbocharger

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Attention !

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 11: Exhaust Manifold/Exhaust Turbocharger And Clamping Strip

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Secure exhaust manifold/exhaust turbocharger against falling.

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

Fig 12: Exhaust Manifold / Turbocharger Bolts Loosening/Tightening Sequence

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Remove reinforcement plate (1).

Feed out exhaust manifold/exhaust turbocharger (2) from clamping strip (3) upwards and in rear direction.

Fig 13: Feeding Out Exhaust Manifold/Exhaust Turbocharger From Clamping Strip

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Lift out exhaust manifold/exhaust turbocharger (1).

Fig 14: Lifting Out Exhaust Manifold/Exhaust Turbocharger

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Installation:

NOTE: The following components must be checked before 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.

NOTE: Replace gasket (1).

Install gasket (1) on cylinder head.

Fig 15: Cylinder Head Gasket

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

Fig 16: Lifting Out Exhaust Manifold/Exhaust Turbocharger

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

Fig 17: Exhaust Manifold/Exhaust Turbocharger And Clamping Strip

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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).

Fig 18: Reinforcement Plate

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Attention !

Observe tightening specifications.

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

Tightening torque: 11 62 2AZ .

Fig 19: Exhaust Manifold / Turbocharger Bolts Loosening/Tightening Sequence

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

Fig 20: Connecting Charge Air Duct To Exhaust Turbocharger Until Lock

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Position charge air duct and tighten screws (1).

Tightening torque 11 00 2AZ .

Fig 21: Charge Air Duct Screws

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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.

Fig 22: Heat Shield And Screws

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Install partition wall (4).

Attach heat shield (3).

Tighten down nuts (2).

Attach fuel delivery line (1).

Fig 23: Fuel Delivery Line, Partition Wall, Bend Heat Shield And Nuts

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Tighten down screws (1 and 2).

Fig 24: Partition Wall Screws

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

Fig 25: Partition Wall And Expansion Rivet

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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).

Fig 26: Partition Wall And Wiring Harness

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Join tension strut (1) and tighten with screws.

Tightening torque 61 21 5AZ .

Fig 27: Locating Tension Strut Screw

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

Fig 28: Locating Expanding Rivet And Gasket

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Required follow-up work:

Add COOLANT