Removal and installation a turbocharger (BMW 7 Series E38)

If the installed boost air hoses are not degreased and are damp, this may result in supercharger failure.

Models with M57 engine

1. Remove the upper engine covers.

2. Loosen the bolts and remove the molded hose in the direction of the arrow (see illustration).

When installing, lubricate the mating surfaces with a thin layer of Vaseline and install new O-rings

3. Remove the corrugated casing assembly (1).

4. Remove the air cleaner filter element (see section Replacing the air cleaner filter element Chapters Vehicle settings and routine maintenance).



5. Loosen the clamp (1) and remove the boost air line (2) together with the boost air hose. Seal the turbocharger holes (for example, with a rag).



6. Unscrew the hollow bolt (1) and remove the oil line (2).

Seal the oil line nipple and the hole in the crankcase. Replace the sealing rings when installing.

7. Remove the bolts (1), remove both brackets and set them aside.



8. Remove the locking cover (1) of the heat shield and take out the plugs (arrows).

During installation, damaged plugs must be replaced.

9. Unscrew the bolts located under the plugs.

When installing, lubricate the bolt threads with a thin layer of copper-containing paste (CRC).

10. Loosen the clamp (1) and disconnect the hose. Unscrew the bolts (2) and remove the turbocharger (3) downwards.



11. Installation is carried out in reverse order. Please note the following points:

• If necessary, relocate the drain line and oil line to the new turbocharger;
• Replace all gaskets;
• Clean the mating surface of the exhaust manifold;
• The clamp (1) on the locking cover (2) must be inserted into the heat shield.

Models with M67 engine (left turbocharger)

1. Remove the fuel injection pump (see section Removal and installation of fuel injection pump).

2. Remove the engine cooling system fan housing and impeller (see chapter Engine cooling, heating, ventilation and air conditioning systems).

3. Drain the coolant from the radiator of the cooling system (see chapter Vehicle settings and routine maintenance).



4. Raise the hood, detach the struts from it and fix the hood in a vertical position by inserting M8 bolts into the hinges.



5. Disconnect the connector (1) and release the wire from the holder (2). Unscrew the bolt (4), loosen the clamp (5) and remove the resonator housing (6) assembled with the air flow meter.



6. Release the wire (1) from the holder, loosen the nuts (2), disconnect the connector (3) and set the fuel filter assembly (4) aside.





7. Loosen the nuts (1) and set the power steering fluid reservoir (2) aside.



8. Remove the bolt (1) and set the fuel cooler (2) together with the air duct (3) aside.



9. Loosen the nut (1) of the left engine mount cushion. Unscrew the bolt (2).

10. Using a special lifting device, raise the engine by the lifting eyes by 25 mm.



11. Loosen the clamps (1), remove the pressure hose (2) and disconnect the connector (3).



12. Loosen the clamps (1) and place the hose (2) on the turbocharger return pipe.



13. Unscrew the hollow bolts (1) and remove the pressure pipe (2).

Replace the hollow bolt sealing rings when installing.

14. Remove the bolts and remove the turbocharger assembly forward.

When installing, clean the mating surfaces without damaging them and replace the gasket.

15. Remove the bolts (1) and move the return pipe (2) to the new turbocharger.

When installing, clean the mating surfaces on the turbocharger and return pipe and replace the gasket.

16. Installation is carried out in reverse order.

Models with M67 engine (right turbocharger)

The right turbocharger is removed together with the pressure oil line, deformation and damage of which is not allowed.

1. Disconnect the negative cable from the battery.

2. Remove the front and rear underbody trim.

3. Remove the right air cleaner housing assembly.

4. Remove the right upstream catalytic converter.



5. Loosen the clamp (1), unscrew the bolts (2) and remove the oil drain line (3). Loosen the clamp (4), slide it back and disconnect the connector (5) from the turbocharger.

When installing, clean the mating surfaces and replace the gasket.

6. Remove the bolt.



7. Open the retainer (1), disconnect the plug (2) of the diagnostic connector and set it aside.



8. Unscrew the bolt (1), disconnect the hose (2) and remove the air duct (3).

Replace the sealing ring if necessary.

9. Remove the three bolts securing the turbocharger to the exhaust manifold.



10. Release the wire from the holders on the AT. Unscrew the hollow bolt (1) and bolt (2).

Replace the hollow bolt sealing rings when installing.

11. Disconnect the boost air hose (1) and move it to the side.

When installing, the hose must be degreased and dry. Carefully remove the turbocharger (2) by moving it downwards towards the right suspension strut, between the front axle beam and the transverse steering rod.

12. Relocate the oil pressure line to the new turbocharger. To do this, follow these steps:

• Determine the dimension (A) between the pressure oil line (1) and the turbocharger flange;
• Remove the hollow bolt (2) and replace its sealing rings;
• Install the oil pressure line to the new turbocharger using the hollow bolt;
• Tighten the hollow bolt to adjust the dimension (A).

13. Installation is carried out in the reverse order. Replace the sealing gasket.