11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)

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

Necessary preliminary tasks:

Remove CATALYTIC CONVERTER , cylinders 5-8.

Disconnect plug connection (1) on electric changeover valve (2).

Fig 1: Identifying Electric Changeover Valve Plug Connection

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Release screw (1).

Tightening torque 11 42 4AZ .

Unfasten banjo bolt (2).

Tightening torque 11 42 7AZ .

Lay oil line from turbocharger to side.

Installation note:

Replace all sealing rings.

Fig 2: Identifying Screw And Banjo Bolt

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Release screw (1).

Tightening torque 11 53 3AZ .

Release 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 (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 (4) with a suitable tool.

NOTE: Oil return pipe (3) 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 (1).

Open V-band clamp (2).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction.

Fig 6: Identifying Wastegate Valves

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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 Coolant 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 With 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: Identifying Thermal Linear Compensators On Oil Return Pipe

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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: Picture shows turbocharger removed.

Fig 11: Identifying Oil Return Cover And Screws

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Replace gasket (1) on exhaust manifold.

Installation note:

Check locating apparatus on exhaust manifold.

Fig 12: Identifying Exhaust Manifold Gasket And Locating Apparatus On Exhaust Manifold

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Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (2).

Insert screw (1).

Tightening torque 11 65 1AZ .

Fig 13: Identifying Wastegate Valves

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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 Correct Position Of 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 15: Identifying Improper Screw Connection Of V-Band Clamp - Too Loose

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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 Improper Screw Connection Of V-Band Clamp - Too Tight

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IMPORTANT: Risk of mixing up vacuum hoses.

Vacuum hose (1) for cylinders 5-8

Old version: black/blue

New version: black/yellow

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