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

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

Necessary preliminary tasks:

Remove CLEAN AIR PIPE .
Remove both CATALYTIC CONVERTERS .

Release screw (1).

Tightening torque 11 42 5AZ .

Fig 1: Identifying Screw

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Unfasten banjo bolt (2).

Tightening torque 11 42 4AZ .

Lay engine oil pipe from turbocharger to one side.

Installation note:

Replace all sealing rings.

Fig 2: Identifying 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 to one side.

Installation note:

Replace all sealing rings.

Fig 3: Identifying Banjo Bolt And Screw

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Open hose clamp (2).

Pull off coolant feed line from T-piece.

Installation note:

Replace hose clamp (1).

Fig 4: Identifying Hose Clamps

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Pull off vacuum line (1) on vacuum unit.

Fig 5: Identifying Vacuum Line

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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 6: Identifying Oil Return Pipes And Screws

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Release screw (4).

Open V-band clamp (3).

Remove turbocharger cylinders (1 to 4) with oil return line towards top.

Fig 7: Identifying V-Band Clamps And Screws

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If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque 11 53 2AZ .

Fig 8: Identifying Banjo Bolt

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Release screw (1).

Tightening torque 11 53 3AZ .

Modify coolant feed line (2).

Fig 9: Identifying Coolant Feed Line And Screw

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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

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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 11: Locating Oil Return Pipe 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: Illustration shows turbocharger removed.

Fig 12: Identifying Oil Return Cover And Screws

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Fig 13: Identifying Oil Return Cover And Screws

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Installation note:

Replace gasket on exhaust manifold.

Installation note:

Check securing device on exhaust manifold.

Fig 14: Identifying Exhaust Manifold Gasket

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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 15: Identifying V-Band Clamps And Screws

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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 16: Identifying V-Band Clamp Ends

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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 17: 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 18: Identifying Misalignment Of V-Band Clamp Ends

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Assemble engine.

Check VACUUM CONNECTIONS .

Observe BMW diagnosis instructions.

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