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

Necessary preliminary tasks:

Remove both catalytic exhaust-gas converters
Remove intercooler
Drain coolant
Remove coolant expansion tank
Remove COOLANT THERMOSTAT
Remove COOLANT PUMP
Remove both vacuum reservoirs
Remove right CHARGE-AIR DUCT

Release bolts (1).

Tightening torque 11 42 7AZ .

Installation note:

Replace seal.

Release screw (2).

Tightening torque 11 42 8AZ .

Remove oil return pipe in direction of arrow.

Installation note:

Replace O-ring.

Fig 1: Removing Oil Return Pipe

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Release screws (1 and 2).

Tightening torque 11 53 10AZ .

Release coolant feed lines (3 and 4) if necessary with suitable pliers.

IMPORTANT: Do not place pliers on pipes. Risk of damage!

Installation note:

Replace O-rings.

Fig 2: Identifying Screws And Coolant Feed Lines

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Release screws (1).

Tightening torque 11 53 3AZ .

Remove feed line (2).

Installation note:

Replace O-ring.

Fig 3: Identifying Bolts And Feed Lines

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Release screw (1).

Tightening torque 11 53 9AZ .

Release coolant return pipe if necessary with suitable pliers.

IMPORTANT: Do not place pliers on pipes. Risk of damage!

Installation note:

Replace O-ring.

Fig 4: Identifying Screws

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Release screw (1).

Tightening torque 11 53 8AZ .

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.

Fig 5: Identifying Coolant Feed Pipe, Coolant Return Pipe And Screws

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IMPORTANT: Do not place pliers on pipes. Risk of damage!

Installation note:

Replace O-ring.

Release screws (1).

Tightening torque 11 65 2AZ .

Remove retaining plate (2).

Unfasten screws (3 and 4).

Tightening torque 11 65 2AZ .

Fig 6: Identifying Bolts, Retaining Plate And Screws

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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).

Fig 7: Removing Heat Shield

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Release screw (1).

Tightening torque 11 42 4AZ .

Detach oil feed line in direction of arrow.

Installation note:

Replace O-ring.

Fig 8: Detaching Oil Feed Line

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Release screws (1).

Tightening torque 11 65 3AZ .

Set holder (2) down on cylinder head cover.

Fig 9: Identifying Holder And Bolts

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Detach vacuum hose from vacuum unit (wastegate valve).

Unscrew nuts (1).

Remove turbocharger towards bottom.

Tightening torque 11 65 1AZ .

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

Fig 10: Identifying Nuts

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Release screw (2).

Tightening torque 11 42 5AZ .

IMPORTANT:

Risk of damage!

Where necessary, to release the oil feed line (3), do not place pliers on the pipe.

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

Installation note:

Replace O-rings.

Installation note:

Replace graphite sealing rings (1).

Fig 11: Identifying Oil Feed Lines And Screws

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Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.