11 65 022 Removing and installing/replacing exhaust-gas turbocharger for cylinders 1-3

IMPORTANT: It is not necessary to carry out a chassis/wheel alignment check to release the steering tie rod.

Necessary preliminary tasks:

Remove both catalytic exhaust-gas converters
Release tie rod on steering gear. See REPLACING LEFT OR RIGHT TIE ROD and REPLACING (REMOVING AND INSTALLING) LEFT OR RIGHT TIE ROD .
Remove intercooler
Draining 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.

Fig 1: Removing Oil Return Pipe

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Installation note:

Replace O-ring.

Undo 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!

Fig 2: Identifying Screws And Coolant Feed Lines

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Release bolts (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 8AZ .

Release coolant return pipe at connection (2) if necessary with suitable pliers.

Unscrew bolt (3).

Tightening torque 11 53 9AZ .

Release coolant return pipe at connection (4) if necessary with suitable pliers.

Unfasten coolant return pipe.

Fig 4: Identifying Screw, Connection And Bolt

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

Release bolts (1).

Tightening torque 11 65 2AZ .

Remove retaining plate (2).

Release screws (3).

Tightening torque 11 65 2AZ .

Fig 5: Identifying Retaining Plate, Bolts And Screws

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Remove heat shield (1) in direction of arrow.

NOTE: Carefully swing out heat shield (1) in direction of arrow.

Risk of damage!

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

Fig 6: Swinging Out Heat Shield

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Release bolts (1).

Tightening torque 11 65 3AZ .

Set holder (2) down on cylinder head cover.

Fig 7: Identifying Holder And Bolts

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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 screw (1).

Tightening torque 11 42 5AZ .

Release oil pressure line (2) if necessary with suitable pliers.

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

Installation note:

Replace O-rings.

Fig 9: Identifying Oil Pressure Line And Screw

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Detach vacuum hose from vacuum unit (wastegate valve).

Unscrew nuts (1).

Tightening torque 11 65 1AZ .

Remove turbocharger towards top.

IMPORTANT:

Risk of damage!

Do not misuse linkage of vacuum unit (wastegate valve) for transportation.

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).

NOTE:

Picture shows turbocharger for cylinders 4 to 6.

Fig 11: Identifying Turbocharger Graphite Rings

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Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.