BMW 7 Series: Removing And Installing/Replacing Exhaust Turbocharger, Right, Cylinders 1-4 (N63)

Notes

IMPORTANT: Risk of fire if oil lines are leaking.

Risk of mixing up vacuum hoses.

Necessary preliminary work

• Remove CATALYTIC CONVERTER , cylinders 1-4

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

Fig. 496: Identifying Plug Connection On Electric Changeover Valve

Release screw (1).

Tightening torque 11 42 7AZ.

Unfasten banjo bolt (2).

Tightening torque 11 42 4AZ.

Lay oil line (3) from turbocharger to side.

Installation note:

Replace all sealing rings

Fig. 497: Identifying Oil Line With Banjo Bolt And Screw

Release screw (1).

Tightening torque 11 53 3AZ.

Release banjo bolt (2).

Tightening torque 11 53 2AZ.

Lay coolant return line (3) to one side.

Installation note:

Replace all sealing rings

Fig. 498: Identifying Coolant Return Line With Banjo Bolt And Screw

Open hose clamp (1).

Detach coolant feed line (2).

Installation note:

Replace hose clamp (1)

Fig. 499: Identifying Coolant Feed Line And Hose Clamp

Release screw (1) with a suitable tool.

NOTE: Oil return pipe (2) can only be removed with turbocharger.

Tightening torque 11 42 10AZ.

Fig. 500: Identifying Oil Return Pipe With Mounting Screws

Release screw (4).

Open V-band clamp (3).

IMPORTANT: Do not mechanically deform oil return line.

Remove turbocharger with oil return line in upward direction.

Fig. 501: Identifying V-Band Clamp With Mounting Screws

If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque 11 53 2AZ.

Fig. 502: Identifying Banjo Bolt

Release screw (1).

Tightening torque 11 53 3AZ.

Modify coolant feed line (2).

Fig. 503: Identifying Coolant Feed Line With Mounting Screw

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.

Fig. 504: Identifying Oil Return Pipe

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. 505: Identifying Thermal Linear Compensators On Oil Return Pipe

Illustration shows special tools.

Fig. 506: Identifying Special Tool (11 6 120)

To install the exhaust turbocharger, special tool 11 6 120, consisting of 11 6 122 and 11 6 123, can be used.

Place special tool (1) on turbocharger and secure with screw (2).

Slide in screw shaft (3) up to mounting bolt (4).

Secure screw shaft (3) with knurled screw (5).

NOTE: Pipe must not be deformed.

Fig. 507: Sliding Screw Shaft Up To Mounting Bolt

To screw the oil return pipe, it is necessary to release knurled screw (5) again.

Screw oil return pipe to screw shaft (3).

Tightening torque 11 42 10AZ.

Fig. 508: Identifying Knurled Screw And Screw Shaft

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. 509: Identifying Oil Return Cover And Screws

Installation note:

Replace gasket on exhaust manifold

Installation note:

Check locating apparatus on exhaust manifold.

 Fig. 510: Identifying Apparatus On Exhaust Manifold

Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (3).

Insert bolt (4).

Tightening torque 11 65 1AZ.

Fig. 511: Identifying V-Band Clamp With Mounting Bolt

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

Tightening torque 11 65 1AZ.

Fig. 512: Identifying V-Band Clamp Installation Position

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. 513: Locating V-Band Clamp Gap

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. 514: Locating V-Band Clamp Position

IMPORTANT: Risk of mixing up vacuum hoses.

Vacuum hose (1) black/red for cylinders 1-4.

Fig. 515: Identifying Vacuum Hose

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

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