Removing and Installing/Replacing Exhaust-Gas Turbocharger for Cylinders 4-6

11 65 024 - Removing and installing/replacing exhaust-gas turbocharger for cylinders 4-6 (N54)





Necessary preliminary tasks:
- Remove both catalytic exhaust-gas converters
- Remove intercooler
- Drain coolant
- Remove coolant expansion tank
- Remove both vacuum reservoirs
- Remove right charge-air duct Replacing Right Charge-Air Duct (N54)
- Remove right engine support arm





Release screws (1).
Tightening torque 11 42 7AZ 11 42 Oil Filter and Pipes.

Installation:
Replace seal.

Release screw (2).

Tightening torque 11 42 8AZ 11 42 Oil Filter and Pipes.
Remove oil return pipe in direction of arrow.

Installation:
Replace O-ring.





Release screws (1 and 2).
Tightening torque 11 53 10AZ 11 53 Thermostat and Connections.
Release coolant feed lines (3 and 4) if necessary with suitable pliers.

Important!
Do not place pliers on pipes. Risk of damage!

Installation:
Replace O-rings.





Release screws (1).
Tightening torque 11 53 3AZ 11 53 Thermostat and Connections.
Remove feed line (2).

Installation:
Replace O-ring.





Release screw (1).
Tightening torque 11 53 9AZ 11 53 Thermostat and Connections.
Release coolant return pipe if necessary with suitable pliers.

Important!
Do not place pliers on pipes. Risk of damage!

Installation:
Replace O-ring.





Release screw (1).
Tightening torque 11 53 8AZ 11 53 Thermostat and Connections.

Important!
When detach coolant feed pipe (3), pay attention to linkage of vacuum unit (wastegate valve).
Risk of damage!

Release coolant feed pipe (3) if necessary with suitable pliers.

Release coolant return pipe (2) if necessary with suitable pliers and remove.

Important!
Do not place pliers on pipes. Risk of damage!

Installation:
Replace O-ring.





Release screws (1).
Tightening torque 11 65 2AZ 11 65 Turbocharger and Control.
Remove retaining plate (2).
Unfasten screws (3 and 4).
Tightening torque 11 65 2AZ 11 65 Turbocharger and Control.





Important!
Carefully swing out heat shields (2 and 3) in direction of arrow.
Risk of damage!

Remove heat shield (3) in direction of arrow.

Remove heat shield (2) in direction of arrow.

Note:
Coolant feed pipe (1) can be removed with heat shield (2).





Release screw (1).
Tightening torque 11 42 4AZ 11 42 Oil Filter and Pipes.
Detach oil feed line in direction of arrow.

Installation:
Replace O-ring.





Release screws (1).
Tightening torque 11 65 3AZ 11 65 Turbocharger and Control.
Set holder (2) down on cylinder head cover.





Detach vacuum hose from vacuum unit (wastegate valve).
Unscrew nuts (1).
Remove turbocharger towards bottom.
Tightening torque 11 65 1AZ 11 65 Turbocharger and Control.

Important!
Do not misuse linkage of vacuum unit (wastegate valve) for transportation.
Risk of damage!





Release screw (2).
Tightening torque 11 42 5AZ 11 42 Oil Filter and Pipes.

Important!
Where necessary, to release the oil feed line (3), do not place pliers on the pipe.
Risk of damage!

If necessary, release oil feed line (3) with suitable pliers at connection and remove.

Installation:
Replace O-rings.

Installation:
Replace graphite sealing rings (1).





Assemble engine.
Clear fault memory in DME control unit.
Check air intake system for leaks.
Observe DME instructions.