F30 B48 Turbo repair, Do I have to remove the Cat?

[kingr]

Did you come right with the o-rings? I would suggest taking the part that needs an o-ring to an engineering shop that deals with oil lines/hydraulics, they will be able to supply you with the correct size o-ring seal if it's not a "funny" shape. I've done this many times.

 

[Mytfine]

@Mytfine Thanks, What is the FCP?

Fcp euro, online spares shop

 

[zippy320]

Hi guys!

Sorry for the delayed update . So here an update so far , handed in the turbo at TurboExchange in Prospecton on Friday morning , they called me on Monday to say that the turbo is ready . Excellent service from them , and the lady Fareeda was super helpful . Turbo came back looking like new . I'm super excited by just looking at it . They returned it in a nice box with bubble wrap and the turbo in a bag . I haven't removed it from the plastic bag yet . I'm very impressed with their workshop , the machines they use and all the staff were super friendly and professional . And better yet the workshop was so clean! it was like a lab . They did advise me to replace the inlet and outlet oil pipes . Lets hope it works properly once installed and this project is complete .

@kingr Hi! Thanks for the info , I did come right with the o-rings , purchased them from Goldwagen , they had the exact part needed , I have fitted them to the pipes but I might not use it though as Iv decided to just replace all the pipes , any pipe that's linked to the turbo , and the CCV / Valve cover , ill be replacing . Its going to take me a little more time but the cars been sitting anyway and is not really needed so might as well replace as much as I can .
@Mytfine Thanks! Will check on their costs , at BMW the part costs are around R1000 - 1300 each for the oil pipes and cooling pipes . For convenience , I may buy all the remaining parts from BMW . I have checked with a few local parts suppliers and the price differences are of around R100 to R200 , sometimes almost the same . And some parts are only available from BMW .

My parts list so far is as follows This is , replacing the turbo and the Valve cover,CCV .

Oil Pipe Outlet

Oil Pipe Inlet

Gasket for Outlet Pipe

Turbo Gasket Ring

Exhaust Manifold Gasket

Manifold Nuts M7

Turbo Coolant Supply Line

Turbo Coolant Supply line Exit

Filter Engine

OIL

CCV Vent Pipe Top

CCV Vent Pipe Bottom

Turbo Oil Additive

Cylinder head Ventilation line

Valve Cover Complete with seals

Injector seals

Im not sure if im missing anything ?

So far , all I have is 1) Rebuilt turbo
2) Manifold Gasket

Got to save up for more parts lol

 

[zippy320]

Hi Guys!

Just an Update , Still working on the car , been buying parts for it monthly , I decided to just buy the parts from BMW .
Importing , The risk, if the part gets damaged in transit , Wrong parts sent , and the issues with returning the item , the wait , the Prices that I had seen on so many of these sites just did not make sense . Our exchange rate is not that good anyway . And with respect to BMW SA , The prices that I have paid for the Original parts thus far was at times a lot cheaper then the online places and sometimes just a tad cheaper so costing was very reasonable . The only thing that I felt was a bit pricy was that special oil that you need to fill in the turbo before starting it up . R320 for a small tube ouch .
I wanted to buy the Liqui Molly one but nobody had stock .

Anyway .

I have all the new oil pipes , and new cooling pipes , new manifold gasket and oil gasket .

Is it easier to attached the pipes to the engine block first before putting the turbo in place and then attaching them to the turbo/manifold

or

Should I attach the pipes onto the turbo first , then attach those pipes to the engine block after the turbo is in place?

 

[zippy320]

So just an update

I ordered new Bolts and ASA-stud bolts for the car , These are the bolts and studs that hold the turbo at the top onto the head .
I was told by a tech there that the studs must be replaced as they stretch , the bolt is fine .

Any one can tell me whats the torque value for installing the studs to the head?

Also picked up a new CCV vent pipe as well .

I was advised that once I complete the installation , knowing that the turbo had failed due to over spinning or speed or something like that ., I must replace the Valve cover as its most likely the built in CCV that caused the failure .

Dumbest thing I have ever seen (apart from all the plastics used on this car ) having the CCV built into the Valve Cover , second dumbest , being forced to remove the injectors to be able to remove the Valve cover . Third Dumbest , needing special tools to remove the Injector because its so fragile apparently and can easily break if not removed correctly with the correct torque .

 

[sash]

Don't worry...there's alot more dumb shit BMW thought up....

 

[zippy320]

Don't worry...there's alot more dumb shit BMW thought up....

Man , its so costly to replace that Valve cover ,The pipes and all the other pieces look daunting but are simple , on my E46 its outside the engine and so simple to replace .

I can theoretically replace it myself as Iv taken the valve covers of my E30 , E46 and the W124 but the injector issue is what stops me .

 

[Mytfine]

Check adendorff machinery for for the injector removal tool.

Man , its so costly to replace that Valve cover ,The pipes and all the other pieces look daunting but are simple , on my E46 its outside the engine and so simple to replace .

I can theoretically replace it myself as Iv taken the valve covers of my E30 , E46 and the W124 but the injector issue is what stops me .

 

[zippy320]

Hi Guys!

Just an update
This evening I fitted the new stud bolts , it was kind of tricky as the car is lifted on stands , Could not find loctite at any of the spares shops and BMW didn't have it either so I bought the elring version of it and used that . Was told that it needs 24 hours to set .

That loctite though is crazy expensive , R900 for a small bottle , The elring version was about R120 from goldwagen . Same specs as the loctite needed . At BMW it was around R500 for a bottle . I wouldn't have purchased it , you only need to use one drop per bolt so the elring will have to do .

Once that's set , I will begin the installation of the turbo .

 

[sash]

Getting there..

 

[Mytfine]

Hi Guys!

Just an update
This evening I fitted the new stud bolts , it was kind of tricky as the car is lifted on stands , Could not find loctite at any of the spares shops and BMW didn't have it either so I bought the elring version of it and used that . Was told that it needs 24 hours to set .

That loctite though is crazy expensive , R900 for a small bottle , The elring version was about R120 from goldwagen . Same specs as the loctite needed . At BMW it was around R500 for a bottle . I wouldn't have purchased it , you only need to use one drop per bolt so the elring will have to do .

Once that's set , I will begin the installation of the turbo .

I also found that crazy last year when i needed loctite. Found a suitable alternative for much cheaper but also spent 10 minutes procastinating how product 15 % of the price can do the same job ! Loctite has gone insane on pricing because of brand recognition!

 

[zippy320]

Update

Fitted on the Turbo this evening , It went well , surprisingly simple and easier to fit it then it was to take it off. I connected up all the pipes to and from the turbo besides the oil inlet pipe , I now have to fill the turbo with that additive , then screw down the pipe .

Any idea how long I have until I have to start the car , once I fill it up and close up the pipe , then reattach everything else , the cars still going to sit for a while as my next step will be to replace the valve cover, fill the cooling system etc and that's going to be a long time .

Will the additive that I fill into the turbo drain away? I don't want it to run dry on its first startup .

 

[zippy320]

Update

This Evening I refitted the cat to the back of the exhaust and connected the cat to the rest of the exhaust . Lots of twisting and turning , After a while I realised there was an odd way where it just slides in and avoids the brackets . Sign , Would have saved me alot of cuts and nicks on my hands .

My other problem was its weight , not easy holding it up with one hand , then trying to put the bolts in with the other .

Project, seems to be taking shape now .

 

[zippy320]

Hi Guys!

Another Update! Exciting Update for me personally lol

I finally put everything back together again . All the pipes , covers , undercarriage engine covers , etc
There are still a few things that I want to do and have done to the car before even thinking about driving it , but I have finally completed replacement of its turbo

I can actually say that I have removed and replaced a Turbo on a newer BMW engine , B48 engine car Yay!

Here are some pictures .





So the car needs to have its cooling system refilled ,

I have looked at the manual and it looks really complicated , nothing like that of any of my other cars , it requires the cooling system to be under pressure?? While Filling? I really cant understand the instructions that well and I don't have tools for that .

I also need to have the Valve Cover and whatever seals and parts are associated with it , replaced , I want the CCV replaced ( already installed new pipes )

I will also need to replace the Diff Fluid , Engine Oil , Oil Filter , Air Filter , Spark Plugs , Cabin filter at 120k mileage , I might as well just replace it all . And I need the gearbox linkage or whatever it is that BMW on call did to the car all those years ago to keep it in neutral , reattached .

And it needs a new battery as the original one in the car has gone completely dead .

At least though the car is whole again .

 

[TurboLlew]

You use this

https://www.adendorff.co.za/mac-afric-coolant-cooling-system-vacuum-purge-and-refill-kit-gtestr004?gad_source=1&gclid=Cj0KCQiAz8GuBhCxARIsAOpzk8zWFOmsf3UmNP-mKF3i55_41_D-Mc9qO75j5vtq_rtC6woA1mOaHnAaAmzjEALw_wcB

and you can see how here:

Pull a vacuum using the tool, leave it to check that it is not leaking, pop the other side into your coolant bottle (probably 5L?) and then it sucks everything into your system with minimal air

There might be a process you need to trigger via a diagnostic tool/ISTA to fully bleed the system.

You will need a compressor to do this.

It might be one too many things for a once-off DIY job - may want to tow it to a workshop to do it or see if anyone has the tools to help?

 

[DarrylvanNiekerk]

You use this

https://www.adendorff.co.za/mac-afric-coolant-cooling-system-vacuum-purge-and-refill-kit-gtestr004?gad_source=1&gclid=Cj0KCQiAz8GuBhCxARIsAOpzk8zWFOmsf3UmNP-mKF3i55_41_D-Mc9qO75j5vtq_rtC6woA1mOaHnAaAmzjEALw_wcB

and you can see how here:

Pull a vacuum using the tool, leave it to check that it is not leaking, pop the other side into your coolant bottle (probably 5L?) and then it sucks everything into your system with minimal air

There might be a process you need to trigger via a diagnostic tool/ISTA to fully bleed the system.

You will need a compressor to do this.

It might be one too many things for a once-off DIY job - may want to tow it to a workshop to do it or see if anyone has the tools to help?

I've read you also put the heater on in the car and then switch on the ignition, not start the car, so the secondary pump can circulate fluid as well.

 

[TurboLlew]

I've read you also put the heater on in the car and then switch on the ignition, not start the car, so the secondary pump can circulate fluid as well.

This is part of the bleeding procedure - you still have to vacuum fill the system before doing that IIRC.

 

[zippy320]

Hi Guys!

@TurboLlew Thanks so much for the suggestion!! I purchased the kit from Addendorf ! It wasnt so badly priced! Im going to try and fill the cooling system . I was told I could use this on the E46 N42 engine as well?

But this car has Two cooling systems , A low pressure and a high pressure , Big Cap and little cap.

Man does this car need a lot of coolant! 9.3 ltr for the high and 3.6 for the low , and then after you do the bleed procedure for both systems , you may have to fill another 2 liters apparently .

I haven't done the filling yet , still need to buy a few more bottles of that Blue Gold Bmw sells , its become really pricy these days! Still cheaper then some other brands , but not as pricey as what MB charged me for the w124 .
I might do the fill tomorrow , Iv sort of did a test set up to see where everything goes and how it should work , will let you know how it goes .

 

[zippy320]

I did it ! Filled both Cooling systems , I had to do the pressure procedure a few times as I dont think my compresser was as powerfull but it seemed to work . I had purchased a compressor last year for filling my tyres and filling up my nieces toys ( Jumping castle and other kids blow up toys)
Its so handy to have one around compared to those electric ones that plug into your cigg lighter .

My next step on this car will be replacing the oil , I have the oil and filter , which I may do later this evening .

After that's done , Will complete the bleeding procedure ( after I attempt to charge up the cars battery ) Its probably totally dead but lets see if this battery repair gizmo works on this battery.

 

[zippy320]

So an update!

Replaced the Oil , drained as much as I could out of the engine , measured how much came out and refilled with the same amount , I also replaced the filter . ( that filter is in such a stupid spot compared to my E46) I used a 27mm socket to remove the cover .

The Filter housing is Mahle , Seems to be alot of Mahle parts on this car , even the oil and air filter was Mahle . All original as well with the BMW stamps and part numbers.

I could not do the bleed procedure as the battery is totally dead , I will need to get a new battery for the car . Is it possible for me to use a good battery from another car thats not an AGM battery?

I can erm "borrow" for a bit the battery from my brothers C55 Merc thats parked here lol It seems about the same size .