11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)

IMPORTANT: Risk of fire if oil lines are leaking.

Risk of mixing up vacuum hoses.

Necessary preliminary tasks:

Remove catalytic converter , cylinders 5-8. See 18 32 050 REMOVING AND INSTALLING/REPLACING CATALYTIC EXHAUST GAS CONVERTER, CYLINDERS 5-8 (N63) .

Disconnect plug connection (1) on electric changeover valve (2).

Fig 1: Identifying Plug Connection On Electric Changeover Valve

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Release screw (1).

Tightening torque 11 42 7AZ, see 11 42 OIL FILTER AND PIPES

Unfasten banjo bolt (2).

Tightening torque 11 42 4AZ, see 11 42 OIL FILTER AND PIPES

Lay oil line from turbocharger to side.

Installation:

Replace all sealing rings .

Fig 2: Identifying Banjo Bolt And Screw

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Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Release banjo bolt (2).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Lay coolant return line to one side.

Installation:

Replace all sealing rings .

Fig 3: Identifying Coolant Return Line With Banjo Bolt

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Open hose clip (1).

Detach coolant feed line (2).

Installation:

Replace hose clamp (1) .

Fig 4: Identifying Coolant Feed Line And Hose Clip

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Release screw (4) with a suitable tool.

NOTE: Oil return pipe (3) can only be removed with turbocharger.

Tightening torque 11 42 10AZ, see 11 42 OIL FILTER AND PIPES

Fig 5: Identifying Oil Return Pipe With Screw

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Release screw (1).

Open V-band clamp (2).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction.

Fig 6: Identifying V-Band Clamp

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If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Fig 7: Identifying Banjo Bolt

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Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Modify coolant feed line (2).

Fig 8: Identifying Coolant Feed Line And Screw

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Release screws (1).

Tightening torque 11 42 9AZ, see 11 42 OIL FILTER AND PIPES

Remove oil return pipe (2).

Installation:

Replace seal .

Fig 9: Identifying Oil Return Pipe With Screws

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IMPORTANT: A deformed oil return pipe can result in leaks.

Risk of fire if oil line is leaking.

The thermal linear compensators (see arrows) on the oil return pipe (1) must not be mechanically deformed.

Installation:

Moisten oil return pipe at end with engine oil.

Fig 10: Identifying Oil Return Pipe

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IMPORTANT: The O-rings can easily fall into the oil duct.

Installation:

Replace O-rings on oil return cover (2) .

NOTE: Picture shows turbocharger removed.

Fig 11: Identifying Oil Return Cover With Screws

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Replace gasket (1) on exhaust manifold.

Installation:

Check locating apparatus on exhaust manifold.

Fig 12: Identifying Exhaust Manifold Gasket

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Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (2).

Insert screw (1).

Tightening torque 11 65 1AZ, see SUPERCHARGER

Fig 13: Identifying V-Band Clamp

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Installation:

The ends of the V-band clamp must rest parallel to each other.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Fig 14: Identifying V-Band Clamp End Position

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Screw connection of V-band clamp is too loose:

If you can see a gap between the ends of the V-band clamps, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Fig 15: Identifying Gap Between Ends Of V-Band Clamps

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Screw connection of V-band clamp is too tight:

If the ends of the V-band clamp are positioned under each other, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Fig 16: Identifying Ends Of V-Band Clamp Position

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IMPORTANT: Risk of mixing up vacuum hoses.

Vacuum hose (1) Black/Blue for cylinders 5-8

Fig 17: Identifying Vacuum Hose

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Assemble engine.

Check vacuum connections .

Observe BMW diagnosis instructions.

Complete vehicle
Drive
Engine electrics
Air supply
Boost pressure control