11 65 040 Remove and install/replace high pressure exhaust turbocharger (small exhaust turbocharger) (M57T2-SCR)

WARNING: Risk of burning!

Only perform this repair work on an engine that has cooled down.

Recycling

Catch escaping engine oil with auxiliary materials.

Observe country-specific waste disposal regulations.

Necessary preliminary work:

Remove acoustic cover at rear
Remove intake silencer housing. See 13 71 000 REMOVING AND INSTALLING/REPLACING THE INTAKE SILENCER HOUSING (M57T2 WITH AND WITHOUT SCR) .
Remove trailing link on spring strut dome. See 51 71 372 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS ON SPRING STRUT DOMES

IMPORTANT: In event of turbocharger damage:

Pressure pipes
Charge air cooler
Intake plenum

Check the above for foreign bodies, damage and correct function, replacing if necessary.

Release banjo bolt (1) on exhaust manifold.

Tightening torque, see 13 62 9AZ in DIESEL SENDERS FOR CONTROL UNIT

IMPORTANT: To ensure operational reliability, use stainless steel sealing washers.

Fig 1: Identifying Banjo Bolt On Exhaust Manifold

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Unlock and disconnect connector (1) on electropneumatic pressure converter.

Detach blue vacuum hose from vacuum unit (turbine control flap).

If necessary, disconnect red vacuum hose from vacuum unit (compressor bypass).

Fig 2: Identifying Electropneumatic Pressure Converter Connector

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Unlock and release connector (1) under vacuum reservoir of EPPT valve.

Fig 3: Identifying Vacuum Reservoir Of EPPT Valve Connector

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Release screws (1) on vacuum reservoir.

Tightening torque: 11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Unlock, detach and disconnect connectors (2, 3 and 4).

Release fuel differential-pressure sensor (5) from vacuum reservoir.

Tightening torque: see 13 62 7AZ in 13 62 SENSOR, DDE CONTROL UNIT

Unlock and detach all connectors.

Fig 4: Identifying Vacuum Reservoir Screws, Connectors And Fuel Differential-Pressure Sensor

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Remove vacuum reservoir (1) from stud bolts (2).

Fig 5: Removing Vacuum Reservoir From Stud Bolts

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Feed out vacuum reservoir upwards and to side.

Fig 6: Disconnecting Vacuum Reservoir

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Release screws (1 and 2) and remove vacuum reservoir carrier.

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Fig 7: Identifying Vacuum Reservoir Carrier Screws

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Unlock electronic changeover valve (1) from holder (2), slide forwards and remove from retaining plate.

Fig 8: Releasing Electronic Changeover Valve From Holder

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Release screws (1).

Remove retaining plate (2).

NOTE: Picture shows vacuum unit removed (turbine control flap).

Fig 9: Identifying Retaining Plate And Screws

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Release screws on heat shield (1).

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Lift out heat shield.

Fig 10: Locating Heat Shield Screws

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Release screw (1).

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Detach clean air pipe (2) from low-pressure turbocharger towards front.

Fig 11: Identifying Clean Air Pipe And Screw

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Slacken nut (1).

Pull line clip from stud bolt.

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Fig 12: Identifying Line Nut

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Detach engine oil pipe (1).

Tightening torque 11 42 5AZ in 11 42 OIL FILTER AND PIPES

Detach engine oil pipe (2).

Tightening torque 11 42 5AZ in 11 42 OIL FILTER AND PIPES .

Unfasten hose clamp (3).

Tightening torque: 11 00 7AZ in 11 00 STANDARD SCREW CONNECTION .

Release screw (4).

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Release screws (5) and (6) from connecting pipe.

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Fig 13: Identifying Engine Oil Pipe, Hose Clamp And Screws

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(E70 only)

Replace O-rings (1) on oil return line.

Fig 14: Identifying O-Rings On Oil Return Line

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Release bolts (1) through 180°.

Tightening torque: 11 00 2AZ in 11 00 STANDARD SCREW CONNECTION

Turn retaining plates (2) to side until compressor inlet pipe (3) to low-pressure turbocharger can be detached.

Installation note:

Replace O-rings.

Fig 15: Identifying Retaining Plates, Compressor Inlet Pipe And Bolts

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Release bolts (1) through 180°.

Tightening torque:11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Turn retaining plates (2) to side until compressor outlet pipe (3) to charge air cooler/connecting pipe can be detached.

Installation note:

Replace O-rings.

Fig 16: Identifying Retaining Plates, Compressor Outlet Pipe And Bolts

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Release screws (1).

Tightening torque, see 11 65 1AZ in TURBOCHARGER AND CONTROL .

Unfasten screws (2).

Tightening torque, see 11 65 2AZ in TURBOCHARGER AND CONTROL .

Remove exhaust turbocharger.

Installation note:

Clean sealing surfaces and replace gasket.

Apply a thin coating of copper paste to bolt thread.

To avoid damaging the threads and prevent exhaust turbocharger leaks, insert mounting bolts in 1/2 turns simultaneously.

Fig 17: Identifying Exhaust Turbocharger Screws

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Release screws (1) on oil return pipe.

Tightening torque, see 11 00 2AZ in 11 00 STANDARD SCREW CONNECTION .

Installation note:

Replace beaded metal gasket.

Fig 18: Identifying Screws On Oil Return Pipe

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NOTE: Cover opening of manifold to prevent swarf from falling in.

IMPORTANT: Clean threads (1) prior to assembly with extension (2) and thread cutter (3)

Fig 19: Cleaning Threads Using Extension And Thread Cutter

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Assemble engine.

Observe arrangement of vacuum lines.

Perform check of vacuum control.

Check function of Digital Diesel Electronics.

Activities

Function structure

Power train

Diesel fuel electronics

Air mass system

Charging pressure control