11 65 025 Removing and Installing/Replacing Exhaust Turbocharger, Right, Cylinders 1-4 (N63O1)

Necessary Preliminary Tasks: 

• Remove VACUUM PUMP .
• Remove CATALYTIC CONVERTER for Cylinders 1-4.

Release Screw (1).

Tightening torque 11 42 5AZ .

Fig 1: Identifying Screw

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Unfasten Banjo Bolt (1).

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.

Tightening torque 11 42 6AZ .

Fig 6: Identifying Oil Return Pipe and Screws

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Release Screw (4).

Open V-Band Clamp (3).

Remove Exhaust Turbocharger Cylinders (1 To 4) with Oil Return Line Towards Top.

Fig 7: Identifying V-Band Clamp and Screw

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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 Screw

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The Thermal Linear Compensators (See Arrows In Illustration) On The Oil Return Pipe (1) Must Not Be Mechanically Deformed.

Installation Note: 

Moisten Oil Return Pipe At End with Engine Oil.

Fig 11: Identifying Oil Return Pipe

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Installation Note: 

Replace O-Rings On Oil Return Cover (2). 

Fig 12: Identifying Oil Return Cover and Screws

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Installation Note: 

Replacing Seal and V Band Clamps On Exhaust Manifold. 

Installation Note: 

Check Locating Apparatus On Exhaust Manifold.

Fig 13: 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 14: Identifying V-Band Clamp and Screw

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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 15: Identifying V-Band Clamps 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 16: 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 17: Identifying Misalignment of V-Band Clamp Ends

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Assemble Engine.

Check Vacuum Connections.

Observe BMW Diagnosis Instructions.

1. Complete Vehicle
2. Drive
3. Engine Electrical System
4. Air Supply
5. Charging Pressure Control