11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63 O1)

IMPORTANT: Risk of fire if engine oil pipes are leaking.
Risk of mixing up vacuum hoses.

Necessary preliminary tasks:

Remove both CATALYTIC CONVERTERS .

Pull off vacuum line (1) on vacuum unit.

Fig 1: Identifying Vacuum Line On Vacuum Unit

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque 11 42 5AZ .

Fig 2: Identifying Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release banjo bolt (1).

Tightening torque 11 42 4AZ .

Lay engine oil pipe from turbocharger to one side.

Installation note:

Replace all sealing rings .

Fig 3: Identifying Banjo Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque 11 53 3AZ .

Fig 4: Identifying Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release banjo bolt (1).

Tightening torque 11 53 2AZ .

Lay coolant return line to one side.

Installation note:

Replace all sealing rings .

Fig 5: Identifying Banjo Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque: 11 53 3AZ .

Fig 6: Identifying Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release banjo bolt (1).

Tightening torque: 11 53 2AZ .

Installation note:

Coolant feed line (2) can be left in engine compartment and does not have to be removed.

Replace all sealing rings .

Fig 7: Identifying Coolant Feed Line And Banjo Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (4) with a suitable tool.

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

Tightening torque 11 42 6AZ .

Fig 8: Identifying Oil Return Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

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 9: Identifying V-Band Clamps And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1).

Tightening torque 11 42 8AZ .

Remove oil return pipe (2).

Installation note:

A new oil return pipe must always be fitted .

Replace seal .

Fig 10: Identifying Oil Return Pipe And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: A deformed oil return pipe can result in leaks.
Risk of fire when an engine oil pipe is leaking.

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

Installation note:

Moisten oil return pipe at end with engine oil.

Fig 11: Locating Thermal Linear Compensators On Oil Return Pipe

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation note:

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

NOTE: Graphic shows exhaust turbocharger removed.

Fig 12: Identifying O-Rings On Oil Return Cover

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

Replacing seal and V band clamps on exhaust manifold .

Installation note:

Check locating apparatus on exhaust manifold.

Fig 13: Identifying Exhaust Manifold Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (2).

Insert screw (1).

Tightening torque 11 65 1AZ .

Fig 14: Identifying V-Band Clamps And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

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

Tightening torque 11 65 1AZ .

Fig 15: Ensuring Ends Of V-Band Clamp Rest Parallel To Each Other

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Fig 16: Identifying Gap Between Ends Of V-Band Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Fig 17: Identifying Misalignment Of V-Band Clamp Ends

Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Check vacuum connections.

Observe BMW diagnosis instructions.

Complete vehicle
Drive
Engine electrical system
Air supply
Charging pressure control