11 65 030 Removing and Installing/Replacing Exhaust Turbocharger, Left, Cylinders 5-8

11 65 030 Removing And Installing/Replacing Exhaust Turbocharger, Left, Cylinders 5-8 (N63)







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).







Release screw (1).
Tightening torque 11 42 7AZ.
Unfasten banjo bolt (2).
Tightening torque 11 42 4AZ.
Lay oil line from turbocharger to side.

Installation note:
Replace all sealing rings.







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.







Open hose clamp (1).
Detach coolant feed line (2).

Installation note:
Replace hose clamp (1).







Release screw (4) with a suitable tool.

NOTE: Oil return pipe (3) can only be removed with turbocharger.

Tightening torque 11 42 10AZ.







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.







If necessary, convert coolant feed line to new turbocharger.
Release banjo bolt (1).
Tightening torque 11 53 2AZ.







Release screw (1).
Tightening torque 11 53 3AZ.
Modify coolant feed line (2).







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 gasket.







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.







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.







Replace gasket (1) on exhaust manifold.

Installation note:
Check locating apparatus on exhaust manifold.







Position turbocharger with oil return line on exhaust manifold.
Position V-band clamp (2).
Insert screw (1).
Tightening torque 11 65 1AZ.







Installation note:
The ends of the V-band clamp must rest parallel to each other.

Tightening torque 11 65 1AZ.







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.







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.







IMPORTANT: Risk of mixing up vacuum hoses.

Vacuum hose (1) for cylinders 5-8
Old version: black / blue
New version: black/yellow







Assemble engine.
Check vacuum connections.
Observe BMW diagnosis instructions.
1. Complete vehicle
2. Powertrain
3. Engine electrical system
4. Air supply
5. Charging pressure control