Wastegate: Service and Repair

11 65 075 Removing And Installing/Replacing Vacuum Unit For Turbine Control Flap (M57T2 TOP)

Special tools required:







WARNING:
Risk of burning.
Only perform this repair work on an engine that has cooled down.







IMPORTANT:
If the exhaust turbocharger or the vacuum unit is released, it will be necessary to adjust the vacuum unit.
Excess pressure and vacuum lines are identified by the size of the seals and colour-coded Red and Blue and must not be mixed up with each other
Build up pressure with Blue colour.
Generate vacuum pressure with Red colour.







Necessary preliminary tasks:
- Remove air filter housing.







Slacken nut (2).







Detach vacuum line (Blue) from vacuum unit.
Release all hoses and cable connections on vacuum unit.







Release screws (1).
Lift out vacuum unit.







Adjusting vacuum unit for main control flap:
Prepare special tool 81 29 0 426 464.
Generate vacuum pressure with Red colour.
Connect diagnosis tester.
Measuring technique: Select pressure sensor.







Vacuum pressure measurement:
Prepare BMW diagnosis system on vacuum diagnosis unit.
1. Screw in adapter for IMIB 81 29 158 850 .
2. Connect stimulus cable (1 and 2) plus and minus.
3. Connect 12-volt cable terminal 30 and negative terminal to the battery.
3. Connect 12V battery cables (3) to vehicle battery positive and negative (pump operation max. 3 mins.).
5. Vacuum connection (red) 81 29 0 428 217.







Vacuum pressure measurement:
Prepare BMW diagnosis system on vacuum diagnosis unit.
1. Screw in pressure sensor.
2. Connect 12V battery cables (2) to vehicle battery positive and negative.
3. Connect 12V battery cables (3) to vehicle battery positive and negative (pump operation max. 3 mins.).
4. Controller for vacuum connection.
5. Vacuum connection (Red).







Calibration for vacuum pressure measurement:
Release lock nut on controller (1).
Press setting with measurement.
- Determine ambient pressure.
- Seal stop cock (2) in direction of arrow.
- Set controller (1) to 200±10 mbar below ambient pressure (e.g. 0.980 - 0.200 = 0.780 bar).







Detach vacuum line (2) - coloured Blue -from pressure converter (1), see arrow.
Connect vacuum line (2) - coloured Blue -to vacuum line (3) - coloured Red.
Reopen shutoff tap (2) on special tool 82 29 0 426 464.
The linkage on the vacuum unit is now actuated.







Turn flap control (1) of main control flap in direction of arrow (clockwise) to closed.







Bring adjusting nut into contact with linkage (1), see arrow.







Pretension linkage on vacuum unit.

Installation note:
Apply a coloured mark on special tool 11 6 050.
Pre-tension adjusting nut on linkage with special tool 11 6 050 by 4 turns.
After adjusting linkage, secure with lock nut(1).







Functional check of turbine control flap, refer to Test module, turbine control flap.
Check function of DDE.