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 AIR INTAKE SILENCER HOUSING .
Remove TRAILING LINK ON SPRING STRUT DOME

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: 13 62 9AZ .

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

Fig 1: Identifying Exhaust Manifold Banjo Bolt

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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 Connector

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Release screws (1) on vacuum reservoir.

Tightening torque: 11 00 2AZ .

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

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

Tightening torque: 13 62 7AZ .

Unlock and detach all connectors.

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

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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: Feeding Out Vacuum Reservoir Upwards

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

Tightening torque:11 00 2AZ .

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: Unlocking 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 .

Lift out heat shield.

Fig 10: Identifying Heat Shield Screws

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Release screw (1).

Tightening torque:11 00 2AZ .

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

Fig 11: Identifying Low-Pressure Turbocharger Air Pipe And Screw

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Slacken nut (1).

Pull line clip from stud bolt.

Tightening torque:11 00 2AZ .

Fig 12: Identifying Nut

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Detach engine oil pipe (1).

Tightening torque 11 42 5AZ .

Detach engine oil pipe (2).

Tightening torque 11 42 5AZ .

Unfasten hose clamp (3).

Tightening torque: 11 00 7AZ .

Release screw (4).

Tightening torque:11 00 2AZ .

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

Tightening torque:11 00 2AZ .

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

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(E70 only)

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

Fig 14: Identifying Oil Return Line O-Rings

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Release bolts (1) through 180°.

Tightening torque:11 00 2AZ .

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 .

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 11 65 1AZ .

Unfasten screws (2).

Tightening torque: 11 65 2AZ .

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:11 00 2AZ .

Installation note:

Replace beaded metal gasket.

Fig 18: Identifying Oil Return Pipe Screws

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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 To Assembly With 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