11 65 040 Removing and installing or replacing high-pressure exhaust turbocharger (small turbocharger)

WARNING: Scalding hazard!
Only perform these tasks on an engine that has cooled down.

Recycling:

Catch escaping engine oil in a suitable container.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks:

Remove acoustic cover at front.
Remove acoustic cover at rear
Remove AIR INTAKE FILTER HOUSING .
Remove TENSION STRUT ON SPRING STRUT DOME

IMPORTANT: In event of turbocharger damage:

Pressure pipes
Intercooler
Intake air manifold

check the above for foreign bodies, damage and correct operation, replacing if necessary.

Release screws (1).

Fig 1: Identifying Turbocharger Screws

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Release screws (1) and mounting screws at top.

Fig 2: Identifying Screws And Mounting Screws

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Remove retaining plate (1) and set down in upward direction of valve hood.

Fig 3: Removing Retaining Plate

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Release screws on heat shield (1).

Fig 4: Identifying Heat Shield Screws

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Release hose clamp (1) from air duct (2).

Remove air duct (2) towards top.

Fig 5: Identifying Low-Pressure Turbocharger Air Pipe And Screw

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Release nut (1) and pull bracket off stud.

Fig 6: Identifying Nut

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Detach oil line (1).

Tightening torque 11 42 5AZ .

Detach oil line (2).

Tightening torque 11 42 5AZ .

Unfasten hose clip (3).

Release screw (4).

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

NOTE: Replace all O-rings and seals.

Fig 7: Identifying Engine Oil Pipe, Hose Clamp And Connecting Pipe Screws

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Release screws (1).

Tightening torque 11 65 1AZ

Unfasten screws (2).

Tightening torque 11 65 2AZ .

Remove exhaust turbocharger.

Installation:

Clean sealing surfaces and replace seal.

Apply a thin coating of copper paste to bolt thread.

To avoid damaging the threads and prevent turbocharger leakage, insert retaining screws in 1/2 turns simultaneously.

Fig 8: Identifying Exhaust Turbocharger Screws

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Assemble engine.