11 65 022 Removing and installing/replace exhaust turbocharger for cylinders 1-3 (N54, N54T)

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 converters. See 18 32 050 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 1-3 (N54, N54T) and 18 32 060 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 4-6 (N54, N54T) .
Release TRACK ROD on steering box
Remove CHARGE AIR COOLER .
Drain coolant. See 17 00 008 DRAINING AND ADDING COOLANT (N54, N54T) .
Remove COOLANT EXPANSION TANK .
Remove COOLANT THERMOSTAT .
Remove COOLANT PUMP .
Remove both vacuum reservoirs.
Remove right CHARGE-AIR DUCT .

Release screws (1).

Tightening torque: 11 42 7AZ .

Installation note:

Replace gasket.

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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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 Coolant Feed Lines And Screws

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Release screws (1).

Tightening torque: 11 53 3AZ .

Remove feed line (2).

Installation note:

Replace O-ring.

Fig 3: Identifying Feed Line, Screws And O-Ring

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Release screw (1).

Tightening torque: 11 53 8AZ .

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

Release screw (3).

Tightening torque: 11 53 9AZ .

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

Unfasten coolant return pipe.

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

Fig 4: Identifying Coolant Return Pipe Connection And Screw

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Release screws (1).

Tightening torque: 11 65 2AZ .

Remove retaining plate (2).

Release screws (3).

Tightening torque: 11 65 2AZ .

Fig 5: Identifying Retaining Plate 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: Removing Heat Shield

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Release screws (1).

Tightening torque: 11 65 3AZ .

Set holder (2) down on cylinder head cover.

Fig 7: Identifying Holder And Screws

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

Fig 10: Identifying Nuts Of Turbocharger

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Release screw (2).

Tightening torque: 11 42 5AZ .

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 note:

Replace O-rings.

Fig 11: Identifying Oil Feed Line, Sealing Rings And Screw

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Installation note:

Replace graphite sealing rings (1).

NOTE: Picture shows turbocharger for cylinders 4 to 6.

Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.