11 65 025 Removing and installing/replacing right exhaust turbocharger, cylinders 1-4 (S63)

Special tools required:

32 1 260
2 249 171 .

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

Necessary preliminary tasks:

Remove CATALYTIC CONVERTER for cylinders 1-4

Release hose clamps (1 to 4).

Detach coolant hoses.

Place coolant lines to one side.

Fig 1: Identifying Coolant Hose Clamps

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Release clamp (1).

If necessary, replace clamp.

Release screw (2).

Tightening torque 13 71 5AZ .

Detach left air duct (4) from exhaust turbocharger and remove.

Graphic without charge air cooler.

Fig 2: Identifying Left/Right Air Duct, Clamps, And Screw

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Installation note:

Secure central bolt with special tool 32 1 260.

Fig 3: Identifying Central Bolt And Special Tool (32 1 260)

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Release screws (1).

Tightening torque 13 71 4AZ .

Unlock and detach engine vent line (2).

Disconnect clean air pipe (3) from exhaust turbocharger and remove.

Fig 4: Identifying Engine Vent Line, Clean Air Pipe, And Screws

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Release screw (1) with a suitable tool.

NOTE: Oil return pipe (2) can only be removed with turbocharger.

Tightening torque 11 42 6AZ .

Fig 5: Identifying Oil Return Pipe And Screw

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Release screw (1).

Tightening torque 11 42 5AZ .

Release banjo bolt (3).

Tightening torque 11 42 4AZ .

Installation note:

Replace sealing ring.

Fig 6: Identifying Banjo Bolt And Screw

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Release screw of V-band clamp (3).

Open V-band clamp (3).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction .

Fig 7: Identifying V-Band Clamps

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Release screws (1).

Tightening torque 11 42 8AZ .

Remove oil return pipe (2).

Installation note:

Replace seal .

Fig 8: Identifying Oil Return Pipe And Screws

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IMPORTANT: A deformed oil return pipe can result in leaks.
Risk of fire if 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 9: Locating Thermal Linear Compensators On Oil Return Pipe

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IMPORTANT: The O-rings (1) can easily fall into the oil duct.

Installation note:

If necessary, remove OIL RETURN COVER .

Replace O-rings (1) on oil return cover (2) .

Fig 10: Identifying O-Rings On Oil Return Cover

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Replace gaskets (1).

Fig 11: Identifying Gaskets

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Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (2).

Tightening torque 11 65 1AZ .

Fig 12: Identifying V-Band Clamps

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Fit special tool 2 249 171 on left and right cylinder head covers with screws (1 and 2).

Fig 13: Fitting Special Tool 2 249 171 On Cylinder Head Covers With Screws

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Installation note:

Both exhaust turbochargers must be adapted to the catalytic converters.

Exhaust turbocharger (2) must be aligned in the vertical axis on the left and right.

Move screw (1) of setting gauge up against exhaust turbocharger (2) by hand.

Adjust exhaust turbocharger (2) parallel to setting gauge.

Secure V-band clamps.

Fig 14: Identifying Exhaust Turbocharger, Screw, And Setting Gauge

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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 .

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 .

Fig 16: Identifying Misalignment Of V-Band Clamp Ends

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Installation note:

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

Tightening torque 11 65 1AZ .

Fig 17: Ensuring Ends Of V-Band Clamp Rest Parallel To Each Other

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Assemble engine.

Check vacuum connections.

Observe BMW diagnosis instructions.

Complete vehicle
Electric motor
Engine electrical system
Air supply
Charging pressure control