11 65 020 Removing and Installing/Replacing Exhaust Turbocharger

11 65 020 Removing and installing / replacing exhaust turbocharger (N55)





Warning!
The module consists of exhaust turbo charger and exhaust manifold.
The weight of the turbocharger is approx. 15 kg.





Necessary preliminary work:
^ Remove the catalytic converter.
^ Remove charge air duct.
^ Remove coolant pump.
^ Remove clean air pipe.





Release screws (1).

Tightening torque 11 53 4AZ.





Release screw (1).

Tightening torque 11 53 10AZ.

If necessary, use appropriate tool to loosen coolant return line (3) and coolant flow line (2) at connection point.

Installation note:
Replace sealing rings.





Release screw (1).

Loosen screws (3) but do not remove.





Release screw (1).

Tightening torque 11 42 6AZ.

If necessary, use appropriate tool to loosen connection of oil return lines (2).

Installation note:
Replace sealing ring.





Release screw (1).

Tightening torque 11 42 7AZ.

If necessary, use appropriate tool to loosen connection of oil return lines (2).

Possibility of oil escaping when oil return line is disconnected.

Installation note:
Replace sealing ring.





Release screw (1).

Tightening torque: 11 42 4AZ.

If necessary, use appropriate tool to loosen coolant return lines (2) at connection point.

Installation note:

Replace sealing ring.





Loosen plug connection (1) at blow-off valve.

Release screw (2).

Tightening torque 11 65 4AZ.

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (3).

Oil may escape when the oil return line is disconnected.

Installation note:
Replace sealing ring.





Disconnect vacuum line (1) from vacuum unit.





Disconnect vacuum line (1) from cylinder head cover.





Remove heat shield (1).

Tightening torque: 11 65 2AZ

Loosen all flange nuts (2) along the line.

Remove module by manoeuvreing downwards on gearbox side.

Note:
Total weight of module is approximately 15 kg.





Note:
Oil supply line (2) can only be replaced after removal of the turbocharger.

Release screw (1).

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (2).





Installation note:
Replace all sealing rings (1).





Installation note:
Replace all graphite seals (1).

Position turbocharger on cylinder head and hold in place with two bolts.





Insert bolt (1) but do not tighten at this point.





Important!
The module consists of exhaust turbocharger and exhaust manifold and must be installed stress-free.

Torque and tightening sequence must be observed without fail.

Tightening torque: 11 65 1AZ.
1. Join all flange nuts in sequence 1 to 15 to 8 Nm.
2. Tighten all flange nuts to a torque of 13 Nm in sequence (1 to 15).

Installation note:
Flange nuts 1 to 5 are accessible from above.

Flange nuts 6 to 15 are accessible from below.





Secure screws (3).

Tightening torque: 11 65 9AZ.

Tighten bolt (1).

Tightening torque 11 65 8AZ.





Assemble engine.

Observe BMW Diagnosis System instruction.

Carry out BMW leakage test for intake system.