Installing the exhaust turbocharger for the cylinders 1 to 4

WARNING: Hot surfaces .
Risk of burning!

Perform all work only on components that have cooled down.

CAUTION: Heavy component .
Heavy components can lead to injury or damage .

Remove and install heavy components with the aid of another person/other persons.

NOTE: RISK OF DAMAGE
Contaminant or foreign body .
Contamination can result in malfunctions, loss of function or leaks .

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

NOTE: TECHNICAL INFORMATION
The sealing surfaces must be free of oil, grease and cleaning agents.

Prepare for the installation of the exhaust turbocharger

Check the oil feed and oil return lines for contamination or obstruction and clean or replace as needed.
If the oil feed and/or oil return lines are heavily contaminated, we recommend changing the motor oil and the oil filter.
If installed: Check the coolant feed and coolant return lines for the exhaust turbocharger for contamination or obstruction and clean or replace as needed.
Check the screw connections and plug connections of all lines for accuracy.
Check air filter for contamination and clean or replace as needed.
Check correct functioning of crankcase ventilation.
Replace all gaskets.
Parts: Seals

Replace the seal (1).
Parts: Gasket
Check the pin (arrow) for damage, replace exhaust manifold if necessary.

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Make sure that the O-ring (1) does not fall into the oil duct in the engine block.
Replace O-ring (1).
Parts: O-ring

If the O-ring (1) cannot be disassembled, the oil return lid must be disassembled.
Coat O-ring (1) with engine oil.

Engine oil

Technically suitable engine oils for BMW Group engines

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Loosen screws (2).
Remove the oil return line (1).
Ensure that the sealing surfaces in the area of the oil return line are planar and free from oil and grease.

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Replace oil return line (3) after each disassembly of the exhaust turbocharger.
Parts: Oil return line
Replace the seal (1).
Parts: Gasket
Replace screws (2).
Parts: Screws
Position screws (2) in oil return line (3).
Position the seal (1) on the screws (2).

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Position the oil return line (1).
Screws (2) must be tightened with the aid of an support person.

TIGHTENING TORQUE SPECIFICATIONS

Oil return line at the exhaust turbocharger
M6x16 Replace screws.	Joining torque	5 Nm
	Angle of rotation	60°

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Feed in and install the exhaust turbocharger (2) at right with the coolant lines and oil return line.
When installing the right exhaust turbocharger (2), make sure that the oil return line is correctly positioned in the oil return cover.
Make sure the oil feed line (1) is positioned correctly.

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Insert the holder (3).
Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Holder of sensor system
M6x16 screw	tightening torque	8 Nm

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Connect connectors (1) and lock.
Secure the wiring harness mounting (1).
Secure cables (3) in the bracket (2).

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Replace the V-clip (2).
Parts: V-band clamp
Position V-clip (2).
Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Exhaust turbocharger to exhaust manifold
V-band clamp Replace V-band clamp.	Tightening torque	20 Nm

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Tighten the screw (1) on the oil return pipe (2).

TIGHTENING TORQUE SPECIFICATIONS

Oil return line to oil return cover
M6	tightening torque	10 Nm

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Replace sealing ring (1) of the coolant line (2).
Parts: Sealing ring

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Connect coolant lines (4).
Connect coolant lines (3).
Tighten down screws (2).

TIGHTENING TORQUE SPECIFICATIONS

Coolant line from exhaust turbocharger to bracket
M6x30	tightening torque	8 Nm

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Remove the lint-free rag (1).
Connect connectors (1) and lock.

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Replace the screw (1).
Parts: Screw
Replace the sealing ring or sealing rings (2).
Parts: Sealing ring or sealing rings
Make sure that when installing sealing rings without a fitting aid (bridge), both sealing rings are replaced.
Position screw (1) with the sealing ring or sealing rings (2) on the oil feed line.

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Determining the screw type and selecting the appropriate socket wrench:

Screw type	Matching socket wrench
Hexagon screw (3)	Commercial socket wrench (1)
Multi-tooth screw (4)	Multi-tooth socket wrench (2)

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Position oil feed line.
Screw in the banjo bolt (2) several threads.
Hand-tighten the bolt (1).
Tighten the banjo bolt (2).

TIGHTENING TORQUE SPECIFICATIONS

Banjo bolt for oil feed line to exhaust turbocharger
M10x1 Replace the screw and sealing rings.	Joining torque	8 Nm
	Angle of rotation	70°

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Oil feed line to exhaust turbocharger
M6x16	tightening torque	10 Nm

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Follow-up work

Refer to INSTALLING THE INTAKE PIPE OF THE ENGINE VENTILATION LINE .
Refer to INSTALLING LEFT CLEAN AIR PIPE .
Refer to INSTALLING RIGHT CLEAN AIR PIPE .
Refer to PARTIALLY INSTALLING LEFT ENGINE VENTILATION LINE .
Refer to PARTIALLY INSTALLING THE RIGHT ENGINE VENTILATION LINE .
Refer to CONNECTING THE RIGHT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
Refer to CONNECTING THE LEFT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE CARRIER PLATE .
Refer to INSTALLING THE CATALYTIC CONVERTER OF CYLINDERS 5 TO 8 .
Refer to INSTALLING THE RIGHT OXYGEN SENSOR MONITOR .
Refer to INSTALLING THE LEFT OXYGEN SENSOR MONITOR .
Refer to INSTALLING HEAT SHIELD, TOP .
Refer to INSTALLING THE LEFT INTAKE SILENCER BRACKET .
Refer to INSTALLING THE LEFT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE RIGHT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE LEFT AND RIGHT REAR DIFFUSER .
Refer to INSTALLING THE REAR LEFT AND RIGHT TENSION STRUT .
Refer to INSTALLING THE LEFT AND RIGHT UNDERSHIELD (TANK COVER) .
Refer to CONNECTING THE COOLANT HOSES TO THE HIGH-TEMPERATURE COOLANT RADIATOR .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING THE RIGHT AND LEFT UNFILTERED-AIR DUCT .
Refer to INSTALLING BOTH INTAKE FILTER HOUSING .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING TENSION STRUT ON LEFT AND RIGHT SHOCK TOWER .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT , and INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE TOP RIGHT .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .