11 65 025 Removing and installing/replacing exhaust turbocharger, right, cylinders 1-4 (N63)

WARNING: This page is about a different car, the 2013 BMW X5, 2012 BMW X5, and 2011 BMW X5. However, it is still accessible from the selected car via links, so may be relevant.

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

Necessary preliminary tasks:

Remove CATALYTIC CONVERTER for cylinders 1-4.

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 .

Unfasten banjo bolt (2).

Tightening torque: 11 42 4AZ .

Lay oil line (3) from turbocharger to side.

Installation note:

Replace all sealing rings.

Fig 2: Identifying Turbocharger Oil Line And Banjo Bolt

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Release screw (1).

Tightening torque: 11 53 3AZ .

Unfasten banjo bolt (2).

Tightening torque: 11 53 2AZ .

Lay coolant return line (3) to one side.

Installation note:

Replace all sealing rings.

Fig 3: Identifying Coolant Return Line And Banjo Bolt

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Open hose clamp (1).

Detach coolant feed line (2).

Installation note:

Replace hose clamp (1).

Fig 4: Identifying Coolant Feed Line And Hose Clamp

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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 10AZ .

Fig 5: Identifying Oil Return Pipe And Screw

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Release screw (4).

Open V-band clamp (3).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction.

Fig 6: Identifying V-Band Clamp And Bolt

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If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque: 11 53 2AZ .

Fig 7: Identifying Banjo Bolt

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Release screw (1).

Tightening torque: 11 53 3AZ .

Modify coolant feed line (2).

Fig 8: Identifying Feed Line And Screw

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Release screws (1).

Tightening torque: 11 42 9AZ .

Remove oil return pipe (2).

Installation note:

A new oil return pipe must always be fitted.

Replace seal.

Fig 9: Identifying Oil Return Pipe And 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 note:

Moisten oil return pipe at end with engine oil.

Fig 10: Locating Thermal Linear Compensators

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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 11: Identifying O-Rings On Oil Return Cover

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Installation note:

Replace gasket on exhaust manifold.

Installation note:

Check locating apparatus on exhaust manifold.

Fig 12: Identifying Gasket On Exhaust Manifold

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Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (3).

Insert bolt (4).

Tightening torque: 11 65 1AZ .

Fig 13: Identifying V-Band Clamp And Bolt

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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 14: Identifying V-Band Clamp

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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: Locating V-Band Clamps Gap

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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: Locating Screw Connection Of V-Band

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IMPORTANT: Risk of mixing up vacuum hoses.

Vacuum hose (1) black/red for cylinders 1-4.

Fig 17: Identifying Vacuum Hose

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Assemble engine.

Check VACUUM CONNECTIONS .

Observe BMW diagnosis instructions.

Complete vehicle
Drive
Engine electrical system
Air supply
Charging pressure control