Installing the Arma Performance Turbocharger on the S63 Engine: A Comprehensive Step-by-Step Guide

Upgrading the turbocharger system on your BMW S63 V8 engine is one of the most effective ways to unlock significant horsepower and torque gains. The ARMA Performance Turbocharger has earned a reputation for delivering robust boost, improved spool characteristics, and long-term reliability when paired with the S63 powerplant found in models like the F10 M5, F06 M6, and X5/X6 M. This guide provides a detailed, mechanic-level walkthrough of the entire replacement process—from preparation and stock removal to installation, final checks, and tuning considerations. By following these steps carefully, you can complete the job with confidence and enjoy the substantial performance increase that the ARMA turbo offers.

Understanding the ARMA Performance Turbocharger

Key Features and Benefits

The ARMA Performance Turbocharger is engineered as a direct bolt-on upgrade for the twin-turbo S63 engine. Unlike stock units that are optimized for emissions and durability, the ARMA unit features upgraded compressor and turbine wheels, a larger billet aluminum compressor housing, and a high-flow wastegate assembly. These modifications allow it to flow up to 35% more air compared to the factory turbos, translating into gains of 100–150 whp (wheel horsepower) on a stock vehicle and even greater gains when combined with supporting modifications like a catless downpipe and intercooler.

The turbo also includes a reinforced center cartridge with dual ball bearings, which reduces friction and improves transient response while extending service life. ARMA backs the unit with a comprehensive warranty and includes all necessary gaskets and hardware in the kit.

Compatibility with the S63 Engine

The S63 is a 4.4-liter twin-turbo V8 found in various BMW M and Alpina models from 2011 onward. The ARMA Performance Turbocharger is designed to replace the stock Mitsubishi TD03s and TD04s units directly. It mounts onto the factory turbine housing flanges and intercooler pipes, requiring no custom fabrication. However, it is crucial to verify your specific S63 variant—S63B44T0 (pre‑2014), S63B44T1 (2014+), or S63B44T2 (Competition)—as oil line fittings and wastegate actuators may have slight differences. ARMA provides specific kit versions for each sub‑model; confirm compatibility before ordering.

View the ARMA Performance Turbocharger product page for detailed fitment information and dyno charts.

Tools and Materials Required

Before starting, gather all necessary tools and supplies. Having everything on hand will prevent frustrating interruptions.

  • ARMA Performance Turbocharger kit (includes turbo, gaskets, bolts, wastegate actuator if applicable)
  • Socket set: 8mm, 10mm, 13mm, 15mm, 18mm (1/4″ and 3/8″ drive)
  • Torque wrench with range 10–80 ft-lb
  • Screwdrivers: flathead and Phillips (long reach)
  • Combination wrenches: 10mm, 13mm, 17mm
  • Pliers: standard and locking (Vice‑Grip)
  • Gasket sealant (high-temp RTV, e.g., Permatex Ultra Copper)
  • Oil catch pan (at least 2‑quart capacity)
  • Shop towels and brake cleaner
  • Safety goggles and mechanic gloves
  • Jack and jack stands (or lift for easier access)
  • Extension bars and universal joints for hard‑to‑reach bolts
  • Small mirror and flashlight (for visual inspection)

Optional but recommended: E‑socket set for E‑torx fasteners (E10, E12), a compressed air blower, and a vacuum pump for coolant refilling.

Preparation for Installation

Workspace and Safety

Park the vehicle on a level, clean surface and engage the parking brake. If using jack stands, raise the front of the car high enough to work comfortably underneath—the S63 turbochargers are located low on the engine, making under‑car access necessary. Allow the engine to cool completely; metal components can reach 300°F+ after driving. Disconnect the negative battery terminal and wait at least 5 minutes for capacitors to discharge.

Engine Cooling and Electrical Isolation

Drain the engine oil and coolant partially. The turbocharger is cooled by engine oil and coolant; removing the stock unit will cause fluid loss. Place the oil catch pan under the oil filter housing and the coolant drain under the radiator petcock. Remove the engine cover (unscrew the four 8mm bolts) and set aside. Disconnect the MAF sensors, boost pressure sensors, and any electrical connectors attached to the turbo housings—label them with tape for reinstallation.

Removing the Stock Turbocharger

Removing Engine Cover and Accessories

Remove the plastic engine cover and the air intake ductwork. Unbolt the heat shields above the turbochargers using a 10mm socket. On the driver’s side, you may need to remove the coolant expansion tank (unscrew two 10mm bolts and rest it aside without disconnecting hoses). On the passenger side, the secondary air injection pump bracket may interfere; unbolt it and reposition.

Disconnecting Lines and Electricals

Disconnect the oil feed line from the top of each turbocharger using a 17mm wrench. Be prepared for residual oil to drip. Remove the coolant return lines—these use a spring clip; pinch with pliers and slide the line off. Unplug the wastegate actuator electrical connectors and the boost solenoids. These connectors can be brittle; use gentle pressure and a small flathead to release tabs.

Unbolting and Lifting Out Stock Unit

Working from underneath, remove the bolts securing the exhaust downpipes to the turbochargers (four bolts per side, typically 13mm or E12 torx). Support the downpipe with a jack stand to avoid stressing the flex joint. Remove the three bolts holding each turbocharger to the exhaust manifold (15mm) and the two bolts to the engine oil return pipe (10mm). Carefully lift the stock turbocharger out through the wheel well or from above with the intake manifold removed—whichever gives you better access. Clean the mating surfaces thoroughly with a scraper and brake cleaner.

Installing the ARMA Performance Turbocharger

Positioning and Alignment

Place the new ARMA turbocharger onto the exhaust manifold studs. Ensure the oil drain flange aligns perfectly—do not force it. Apply a thin layer of gasket sealant to both sides of the provided metal gasket. The turbo should seat evenly without rocking. Hand‑tighten the manifold nuts (included in the kit) to 22 ft‑lb in a crisscross pattern using a torque wrench. Do not overtighten as this can warp the housing.

Torquing to Specifications

Critical: Refer to ARMA’s torque spec sheet supplied with your kit. Typical values are:

  • Exhaust manifold to turbo mounting nuts: 22 ft‑lb
  • Oil return flange bolts: 89 in‑lb (7.4 ft‑lb)
  • Coolant line banjo bolts: 24 ft‑lb
  • Downpipe to turbo bolts: 32 ft‑lb

Use a beam‑type torque wrench for accuracy on these small fasteners. Mark each bolt with a paint pen after torquing.

Reconnecting Intake, Exhaust, and Oil Lines

Attach the oil feed line to the top of the ARMA turbo using new copper washers (included). Torque to 18 ft‑lb. Connect the coolant lines—ensure the O‑rings are seated and clip fully engages. Reinstall the downpipes with new gaskets. Apply anti‑seize to the threads of the downpipe bolts to prevent galling. Tighten progressively.

Electrical Connections and Sealing

Plug in the wastegate actuator harness and boost sensor. The ARMA turbo uses the factory wastegate controller; your ECU will manage boost targets. Apply a small amount of dielectric grease to the connectors to prevent corrosion. Reinstall heat shields in the reverse order of removal, ensuring no wires or hoses are pinched.

Post-Installation Checks and Tuning

Initial Start-Up and Leak Inspection

Refill the engine oil (7.5 quarts of 5W‑30 or 0W‑40 meeting LL‑01 spec) and top off coolant with a 50/50 mix. Reconnect the battery. Start the engine and let it idle for 30 seconds. Listen for any unusual noise from the turbo area. Inspect all oil and coolant connections for leaks using a flashlight. If leaks are present, shut down immediately and tighten or replace the gasket.

Oil Pressure and Coolant Circulation

Monitor the oil pressure gauge; it should rise above 20 psi at idle when cold. Watch the coolant temperature—ensure no air pockets cause overheating. You can manually “burp” the cooling system by squeezing the upper radiator hose and topping off the expansion tank.

Break‑In Procedure

ARMA recommends a break‑in period of 200–300 miles. During this time, avoid sustained full‑throttle runs and keep boost below 15 psi. Vary engine speed during driving to allow the bearings to seat properly. After break‑in, perform an oil change (use high‑quality synthetic) and inspect the turbo for any debris.

ECU Tuning for Optimal Performance

The ARMA Performance Turbocharger flows significantly more air than stock. A custom ECU tune or a flash from a reputable S63 tuner is mandatory to avoid overboost conditions and lean fuel mixtures. Without tuning, the engine may enter limp mode or suffer detonation.

We recommend contacting BootMod3 or Dinantronics for S63‑specific calibration that matches the ARMA turbo’s flow characteristics. A proper tune also adjusts wastegate duty cycles and vanos timing for a smooth, linear power delivery.

Performance Gains and Driving Impressions

After installation and tuning, the ARMA turbo delivers immediate, noticeable improvements. On a dyno, expect a peak gain of 120–150 horsepower and 100–130 ft‑lb of torque at the wheels on a stock S63. Throttle response is sharper, and the turbo reaches full spool 300–500 rpm earlier than the stock units. The exhaust note becomes more aggressive without being obtrusive.

On the road, the reduced lag transforms the driving experience, especially on downshifts and exits from corners. The vehicle pulls hard to redline without falling off. Many owners report that the car feels a “full second faster” in the quarter mile—with the right tune, low 11s at 125+ mph are achievable in a 4300‑lb sedan.

Conclusion

Installing the ARMA Performance Turbocharger on the BMW S63 engine is a challenging but highly rewarding upgrade. By carefully following the removal, installation, and tuning steps outlined here, you can dramatically increase your vehicle’s power, responsiveness, and driving enjoyment. Always use quality components, adhere to torque specs, and never skip professional calibration. For additional support and owner experiences, check the F10 M5 Post forum—a valuable community resource for S63 turbo upgrades.

With the ARMA turbo installed, your S63‑powered BMW will deliver exhilarating performance that rivals much more expensive machinery. Take your time, stay organized, and enjoy the results of your labor.