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 lines and oil return lines for contamination or obstruction, clean or replace if necessary.
If the oil feed lines or oil return lines are heavily contaminated, it is recommended that the engine oil and oil filter are changed.
If installed: Check the coolant feed lines 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 cleaner 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 and replace the 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).
Position the oil return line (1).

Screws (2) must be tightened with the aid of an support person.

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TIGHTENING TORQUES SPECIFICATION

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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Fasten the wiring harness mounting (1) to the holder (2).

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Insert the holder (2).

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Holder of sensor system
M6x16 screw	tightening torque	8 Nm

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Replace the V-clip (2).
Parts: V-band clamp
Position V-clip (2).

Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

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 TORQUES SPECIFICATION

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 TORQUES SPECIFICATION

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 TORQUES SPECIFICATION

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 TORQUES SPECIFICATION

Oil feed line to exhaust turbocharger
M6x16	tightening torque	10 Nm

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