11 65 030 Removing and installing/replacing left exhaust turbocharger, cylinders 5-8 (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 CONVERTERS 5 to 8.

Release hose clamps (1 to 4).

Detach coolant hoses.

Place coolant lines to one side.

Fig 1: Identifying Coolant Hose Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Release clamps (1).

Replace clamps.

Release screw (2).

Tightening torque 13 71 5AZ .

Detach right air duct (3) from exhaust turbocharger and remove.

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

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

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

Secure central bolt with special tool 32 1 260.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1) with a suitable tool.

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

Tightening torque 11 42 8AZ .

Fig 5: Identifying Oil Return Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw of V-band clamp (1).

Open V-band clamp (1).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction.

Fig 6: Identifying V-Band Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Tightening torque 11 42 5AZ .

Release banjo bolt (3).

Tightening torque 11 42 4AZ .

Installation note:

Replace sealing ring.

Fig 7: Identifying Banjo Bolt And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Replace gaskets (1).

Fig 11: Identifying Gaskets

Courtesy of BMW OF NORTH AMERICA, INC.

Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (1).

Tightening torque 11 65 1AZ .

Fig 12: Identifying V-Band Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Graphic of cylinders 1 to 4.

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

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 15: 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 16: Identifying Misalignment Of V-Band Clamp Ends

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

Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Check vacuum connections.

Observe BMW diagnosis instructions.

Complete vehicle
Power train
Engine electrical system
Air supply
Charging pressure control